ZF Marine ClearCommand User manual

Page 1
MM13050 Rev.B 11/01
ClearCommand MS565-13050
SW13447.3
Table of Contents
MM13050 Rev.B 11/01................................................................................................................................................ 1
ClearCommand MS565-13050
Table of Contents ........................................................................................................................................................ 1
Revisions List ............................................................................................................................................................... 1
1.0 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.1 This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 ClearCommand System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Features:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
2.1 DC Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 1: Control Head Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Engine Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2: Station Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3: Warm-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Synchronization (Multi Screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Control Head Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Speed Boost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0 REQUIRED PARTS AND TOOLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4: Control Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Electric Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Tools Required For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Push-Pull Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5: Wire Harness Connection Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Engine Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Control System Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.0 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
4.1 Processor(s) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 6: Control Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Control Head Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 400 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.2 MC2000 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.3 700 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
5.1 Eight-Conductor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 7: Plug Removal and Cable Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Processor Connections and Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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5.3.1 Processor Station Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 8: Terminal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.2 Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3.3 Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 9: Start Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.4.2 Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4.3 Aft Facing Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 10: Aft Facing Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.4 700 Series Control Head Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5 Engine Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5.1 Synchronization (Multi-Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.6 Push-Pull Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 11: Universal Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.6.1 Push-Pull Connection at Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 12: Push-Pull Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Main Engine Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7.1 Throttle Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7.2 Auxiliary Circuit Board Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7.3 Engine Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.0 SET-UP PROCEDURES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
6.1 Set-up Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.1 Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 13: Main Circuit Board SW1 Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 14: Processor Circuit Board Set-up Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.2 Order of Set-up Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.3 Selecting Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 15: Dip Switch SW1 Setting Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.4 Run State (Normal Operating Mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 16: Dip Switch Run State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 17: Jumper 2 Closed & Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.5 Enabling Set-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.6 Storing Set-up Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Number of Screws Selection [Single/Twin, etc]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 18: Dip Switch Setting Number of Screw5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 System ID # Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 19: Dip Switch Setting System ID # 0-1-2-3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4 Clutch Pressure Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 20: Dip Switch Setting Clutch Pressure Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.5 Clutch Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 21: Dip Switch Setting 0 - 16 Seconds Clutch Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.6 Throttle Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 22: Dip Switch Setting Throttle Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.7 Engine Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 23: Dip Switch Setting Engine Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.8 In Gear/Neutral Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 24: Dip Switch Setting In Gear/Neutral Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.0 ADJUSTMENTS AND TESTS (SECURED TO DOCK) - - - - - - - - - - - - - - - - - - - - - - 34
7.1 Control Head (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Start Interlock (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 Clutch Travel (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Page 3
7.3.1 Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.2 Ahead Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 25: Dip Switch Setting Clutch Cable Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.3 Verify Neutral, Ahead, and Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Engine Stop Switches Test (Engines Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.5 Warm-Up Mode Test (Engines Running). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.6 Electric Throttle Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.6.1 Throttle Minimum Signal (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 26: Dip Switch Setting Throttle Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 27: Throttle Connector at Processor Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 1: Throttle Minimum Output Adjustments ...........................................................................................................39
7.6.2 Throttle Maximum Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 28: Dip Switch Throttle Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 29: Throttle Connector at Processor Pigtail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 2: Throttle Maximum Output Adjustments...........................................................................................................41
8.0 ADJUSTMENT UNDERWAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44
8.1 Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2 Speed Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2.1 Speed Boost Percentage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 30: Dip Switch Setting Speed Boost Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.2.2 Speed Boost Timeout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 31: Dip Switch Setting Speed Boost Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2.3 Speed Boost Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 32: Dip Switch Setting Speed Boost Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.0 CONTROL OPTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
9.1 Alarm Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.2 Clutch Oil Pressure Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.1 Serial Communication Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.2 Control Head Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.3 Processor Control Head Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.4 Control Head Test (Secured to Dock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.3.5 Synchronization Operation Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.0 MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
10.1 Control Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix A.1
PARTS LIST ............................................................................................................................................................... 1
MMC-280 Rev.G 6/01 ................................................................................................................................................. 3
400 & MC2000 Control Head Variations
MMC-307 Rev.C 6-01 .................................................................................................................................................. 7
700 Series Control Head Sheet
MMC-310 Rev.D 6-01 .................................................................................................................................................. 9
464-4 Control Head Sheet
MMC-326 Rev.- 7/01.................................................................................................................................................. 11
CH14450 Control Head Sheet
MMC-279 Rev.A 11/00 ............................................................................................................................................. 13
400 Series Watertight Enclosure

Page 4
S-214 Rev.A 6/01 ....................................................................................................................................................... 15
Automatic Power Selector (APS) Model: 13505
Figure 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MM13821 Rev.- 7/00 ................................................................................................................................................. 17
43C Cable Conversion Kit
Revisions List ............................................................................................................................................................. 17
1.0 Parts Required: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.0 Tools Required: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
3.0 Actuator/Processor Preparation [Refer to Figure 1] - - - - - - - - - - - - - - - - - - - - - - - - 17
Figure 1: Actuator/Processor Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.0 Cable Installation [Refer To Figure 2] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Figure 2: Actuator/Processor Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MMC-287 Rev.B 7-01 ................................................................................................................................................ 19
Bonding - A.B.Y.C. E-9 46 CFR 111.05
MMC-288 Rev.C 7/01 ............................................................................................................................................... 21
References and Parts Source
MMC-165 Rev.C 10/00 .............................................................................................................................................. 23
Electronic Propulsion Control Systems Three Year Limited Warranty
F-226 Rev.A 11/00 ...................................................................................................................................................... 25
Sea Trial Report
Appendix B.1
1.0 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.1 SYMPTOM - When DC Power is turned On, operator cannot take command at one Station (both Port and Starboard
for twin screw). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 SYMPTOM - One side will not take command when DC Power is first turned ON. . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 SYMPTOM - The engine RPM varies, without moving the Control Head Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 SYMPTOM - The engine RPM reduces to Idle, the Control Head indicator light turns OFF, and a slow repetitive tone
emitted at all Stations after repositioning the Control Head lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 SYMPTOM - No audible tone at a Control Head when system is first turned ON, but otherwise works perfectly. . . 4
1.6 SYMPTOM - Audible steady tone from all Stations. Cannot gain command at any Station.. . . . . . . . . . . . . . . . . . . 4
1.7 SYMPTOM - The Control Head red indicator light does not light when in command, but everything else works per-
fectly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 SYMPTOM - No tones or lighted indicator lights at the Control Head, and no lighted indicator lights on the Processor
circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.9 SYMPTOM - The engine starts to turn over while starting and then stops. A slow repetitive audible tone from all Con-
trol Head Stations.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.10 The engine will not start.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.11 SYMPTOM - One long - One short tones from all Control Head Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.12 SYMPTOM - Three Short - One Long Tone from all Stations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.13 SYMPTOM - Cannot get any speed above IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.14 SYMPTOM - Cannot get any speed above IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.15 SYMPTOM - A slow repetitive tone is heard from all Stations when power is applied to the system. The slow repet-
itive tone ceases when the transfer button is depressed. Subsequently, a steady tone is heard whenever the transfer
button is depressed. The Control Head LED does not light. The transmission and engine remain at the Neutral/Idle
position regardless of Control Head lever position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Page 5
1.16 SYMPTOM - A slow repetitive tone is heard from all Stations when power is applied to the system. When the transfer
button is depressed, the tone ceases but the red LED does not light. Further depressing of the transfer button has no effect.
The transmission and engine remain at the Neutral/Idle position regardless of the Control Head lever position.. . . . . 8
1.17 SYMPTOM - Set-up Mode is entered and the normal 3 second steady tone is heard. The motor control relay “clicks”
continuously when the Dip Switches are turned On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.18 SYMPTOM - The motor relay does not click once, indicating values have been stored, when PB1 on the Auxiliary
Circuit is depressed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.0 RESET ALL PARAMETERS TO FACTORY DEFAULT VALUES - - - - - - - - - - - - - - - - 10
Figure 1: Dip Switch Setting Reset All Parameters to Factory Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Appendix C.1
Drawing 11202F-1 ....................................................................................................................................................... 3
Drawing 11202F-2 ....................................................................................................................................................... 5
Drawing 11202F-3 Notes Page ................................................................................................................................... 7

Revisions List
Rev Date Revision Description
A 7/31/01 1. Drawing 11202D has been revised to E. Please refer to the Drawing in
Appendix C for revisions.
2. Added Speed Boost and In-Gear/Neutral Delay.
B 11/19/01 Complete manual revised to current ZF Mathers standards.
1. Drawing 11202E has been revised to F. Please refer to the Drawing in
Appendix C for revisions.
2. Section 1.2.1 Features revised from 4 Stations to 5 Stations.
3. Section 3.7 Engine Stop WARNING updated with current references.
4. Section 5.5 Engine Stop WARNING updated with current references.

INTRODUCTION
Page 1
1.0 INTRODUCTION
1.1 THIS MANUAL
The purpose of the ClearCommand System manual is:
• Operation (Section 2.0)
• Installation (Section 5.0)
• Set-up Procedure (Section 6.0)
• Adjustments (Section 7.0 and 8.0)
• Trouble Shooting Reference (Appendix B)
Keep this Manual on the vessel for future reference.
Throughout the manual special attention should be paid to the fol-
lowing boxes:
Appendix A contains the Service Sheets created by ZF Mathers to
aid in servicing, set-up, warranty, and documenting of this vessels
parameters.
Appendix B contains a brief Trouble Shooting. If you cannot find a
solution within the Trouble Shooting, contact ZF Mathers Service
Department.
Appendix C contains the System Drawing and Bills of Material.
During Installation and Testing, take special care to verify all wiring
is to specifications, terminations are correct, and that all Notes in the
System Drawing are followed.
NOTE: Contains Helpful Information
CAUTION: Damage to equipment may result if the Caution is ignored.
WARNING: Injury may result if the Warning is ignored.

INTRODUCTION
Page 2
1.2 CLEARCOMMAND SYSTEM
The ClearCommand Control Processor (hereafter referred to as Pro-
cessor) is designed for:
• Engines that require either voltage, mA, or PWM speed com-
mand signal
• Transmissions equipped with mechanical selection
During Installation and Testing, take special care to verify all wiring
is to specifications, terminations are correct, and that all Notes in
Appendix C Drawing Notes are followed.
1.2.1 Features:
• Sequencing of Clutch and Engine Speed (Section 2.1)
• Start Interlock (Section 2.2)
• Station-in-Command Indication (Section 2.3)
• Warm-up Mode (Section 2.4)
• ClearCommand System Fault Indication (Section 2.5)
• Engine Synchronization (optional) (Section 2.7)
• Proportional Pause on through Neutral Shifts using a Clutch Delay (Sec-
tion 6.7 & 6.7)
• In-Gear/Neutral Delay (Section 6.10)
• Speed Boost (optional) (Section 8.2 )
• ClearCommand Failure Alarm Contact (optional) (Section 9.1)
• Clutch Oil Pressure Interlock (optional) (Section 9.2)
• One to Five Stations (Appendix C Drawing)
1.2.2 Requirements
Refer to Section 3.
• One Processor per engine
• One Control Head per Station
• One Engine Stop Switch per Station
• One 33C or 43C Push-Pull cable per transmission clutch connec-
tion
• One Eight-conductor electric cable per Processor for each Control
Head connection

INTRODUCTION
Page 3
• One Two-conductor electric cable for power connection
• One Two-conductor electric cable for Start Interlock connection
• One Throttle Wire Harness for Processor engine interface connec-
tion
• One Serial Communication Wire Harness for Processor to Proces-
sor interconnection (Multi Screw only)

OPERATION
Page 4
2.0 OPERATION
2.1 DC POWER ON
When control system DC power is turned ON:
• Processor will command Neutral/Idle.
• Intermittent tone will sound at all Stations indicating that no Station
has command. (refer to Section 2.6
2.2 ENGINE START INTERLOCK
Features related to main engine start:
Start Interlock to block the engine start signal if the DC power has
not been turned ON.
Start Interlock to block the engine start signal if no Station has
command.
Start Interlock to block the engine start signal if clutch is engaged.
Start Interlock will block the engine start signal if the Set-up Mode
Jumper is Closed on the Main Circuit Board. Refer to
Figure 14:, page 26, for location of the Jumper.
The Processor is interlocked to prevent engine Start until power is ON
and the transmission is in Neutral. The engine Start signal will be con-
nected through the Processor to the starter solenoid or relay.
To take command at a Station:
• Control Head lever(s) must be in the Neutral
(vertical) detent.
• Operator must depress the transfer button for
at least 1/2 second.
The tone will stop at all Stations and the red indi-
cator light will be lit at the Station-in-Command.
Figure 1: Control Head Detents
NOTE: Only one Station has command at a time.

OPERATION
Page 5
2.3 STATION TRANSFER
When transferring command from one Station to another (refer to Fig-
ure 2:)
A)Leave the Control Head lever(s) of the Station-in-Command in
any position.
B) Place the Control Head lever(s) of the Station taking command
in the Neutral (vertical) detent position.
C) At the Station taking command depress and hold for one second
the transfer button.
• The red indicator will light indicating the Station has taken
command.
• The Control System will remain unchanged for one second
after the red indicator lights to allow the operator time to
move the Control Head lever(s) to a position approximately
matching the last command setting.
2.4 WARM-UP MODE
At the Station-in-Command, ensure that the Control Head lever is in
the Neutral (vertical) position (refer to Figure 3:):
• The red indicator light will blink slowly indicating
Warm-up Mode and the clutch has stayed in Neu-
tral. The operator can now start and warm-up the
Figure 2: Station Transfer
Figure 3: Warm-up Mode
A) Depress and hold the transfer button.
B) After one second move the Control Head lever to the
Ahead detent position.
C) Now release the transfer button.

OPERATION
Page 6
engine while moving the Control Head lever
through the throttle ranges.
D)When the Control Head lever is returned to Neutral
(vertical) detent, ClearCommand will reset to Normal
Operating Mode after one second.
2.5 SYNCHRONIZATION (MULTI SCREW)
This ClearCommand System utilizes dual lever synchronization. The
advantage of this is that the Control Head levers are active at all times,
which eliminates the possibility of shifting when the engine RPM’s are
not at Idle.
The Control Head levers are in the synchronization range when the
Processors are commanding:
• At least 10 percent of the throttle range
• Commanded throttles are within 10 percent of equal RPM
The Processor’s throttle signals are compared and then matched. The
Processors then send the same signal to both engines. The engines are
now synchronized.
A green indicator light located on the Control Head of the Station-in-
Command indicates engine synchronization:
• When the green light is NOT LIT, no synchronization.
• When the green light is LIT, synchronization.
When in the Synchronization Mode:
• Both Control Head levers have full command of throttle
• Synchronization can be disabled while in the synchronization
range by depressing for one-second the transfer switch of the
Control Head at the Station-in-Command.
• Synchronization can be re-enabled by matching the Control
Head levers and then depressing the transfer switch for one-
second again.

OPERATION
Page 7
2.6 CONTROL HEAD TONES
Low Repetition Rate Tone is normal when DC power is first
applied to ClearCommand. This tone indicates the Proces-
sor is in Neutral and Idle, and the operator can take com-
mand at a Station.
If this tone occurs during operation, refer to Appendix B Trouble Shoot-
ing Section.
Low Repetition Rate Tone is also heard during Set-up Mode. Dur-
ing the Set-up procedure when the transfer switch is
depressed to gain command at a Station to aid in the adjust-
ment setting.
If this tone occurs during operation, refer to Appendix B Trouble Shoot-
ing Section.
Steady Tone signals a voltage problem or a component has failed.
Confirm the voltage is steady between 12 and 24 volts DC,
and that there is not a momentary voltage drop.
If tone continues, refer to the Appendix B Trouble Shooting.
High Repetition Rate Tone is used to signal a jam condition of the
clutch push-pull cable. The Processor has stopped when this
tone is heard. Moving the Control Head lever away from the
position that the tone was encountered should move the
push-pull cable out of the jam condition and stop this tone.
The cause of the excessive push-pull cable load MUST be found. Refer to
the Appendix B Trouble Shooting.
Repetitive Signal - One Long - One Short Tone is used to show a
clutch position feedback error.
Refer to Appendix B Trouble Shooting Section.
Repetitive Signal - Three Short - One Long is used to indicate a
Control Head is malfunctioning due to loose or unconnected
cable connections.
Refer to Appendix B Trouble Shooting Section.

OPERATION
Page 8
2.7 SPEED BOOST OPERATION
ClearCommand is capable of providing a transitory speed signal
(speed boost) to the governor during clutch engagement to decrease
the possibility of stalling the engine during a reversal. It is recom-
mended to only use Speed Boost if required to keep the engine from
stalling on a through shift, such as a reversal.
After the Speed Boost Start timeout has expired, throttle will raise to
the Speed Boost Percentage. The throttle signal will remain there until
the Speed Boost Timeout has expired. If Speed Boost is active, Speed
Boost will be applied on every shift from Neutral.
When adjusting Speed Boost, begin by leaving the Speed Boost Start
Timeout at the default value of 0 seconds, and work with the other two
Speed Boost parameters to acquire the required Speed Boost to keep
the engine from stalling. Refer to Section 8.2 for further explanation
on adjusting.

REQUIRED PARTS AND TOOLS
Page 9
3.0 REQUIRED PARTS AND TOOLS
3.1 PROCESSOR
One Processor required per engine (refer to the System Drawing in
Appendix C)
Mounting Hardware is installer supplied.
Included with the Processor:
•WagoTool
• Anti-Static Wrist Strap
•SpareFuse
3.2 CONTROL HEAD
Refer to Appendix A for Control Head Variations and Dimensions
Sheets.
One Control Head required per Station.
Included with the Control Head:
• Gasket (400 Series Control Head only)
•Terminals
• Mounting screws
Figure 4: Control Processor
11336-

REQUIRED PARTS AND TOOLS
Page 10
• Watertight cable grip for the cable entrance on the Processor
• Control Head Dimensions Variations & Installation Sheets
3.3 ELECTRIC CABLE
Eight-Conductor Cable (Control Head to Control Processor)
Shielded 20 AWG, 300V, PVC Insulated: -20 degrees C to +80 degrees C.
UL VW-1 PVC Jacket. Color Coded.
Two Conductor Power Cable (Processor to DC Power Supply)
14 AWG, 300V, PVC Insulated: -20 degrees C to +105 degrees C
UL VW-1 PVC Jacket. Red with purple stripe and black.
Two Conductor Start Interlock Cable (Starter Switch to Processor to Starter Sole-
noid)
16 AWG, 300 V, PVC Insulated: -20 degrees C to +105 degrees C
UL VW-1 PVC Jacket. Yellow with red stripe.
3.4 TOOLS REQUIRED FOR INSTALLATION
• Wago Tool (provided)
• Anti-static Wrist Strap (provided)
• Wire cutter, stripper, and crimper (Recommend Thomas & Betts WT-2000)
• Screwdriver – med. Phillips #2
• Screwdriver – med. straight slot
• Screwdriver -- small straight slot
• Hole saw -- 1 inch (25,4mm)
• Drills -- 9/32 inch (7,2mm) and 7/32 inch (5,6mm)
•Saw(appropriate type of saw for cutting material Control Head will be mounted on)
• Multi meter
NOTE: Retrofit applications may require planning for an adapter pad to cover the old Control
Head cutout. A variety of adapter and cover pads are available from ZF Mathers, LLC.

REQUIRED PARTS AND TOOLS
Page 11
3.5 PUSH-PULL CABLE
Use Type 33C push-pull cable to the transmission clutch selector lever.
When measuring cable length, measure cable from end of thread to
end of thread.
Many transmissions are delivered with factory push-pull cable mount-
ing kits. If mounting kit is not included, contact the transmission
dealer for a Factory Cable Connection Kit or refer to the Universal
Mounting Figure in the Push-Pull Cable Installation Section of this
manual.
3.6 WIRE HARNESS
NOTE: If 43C cable is required for this application, a 43C Cable Conversion Kit is required.
These Kits are available from ZF Mathers, LLC. Refer to Appendix A - 43C Cable Con-
version Kit Manual for more information.
Harnesses are Available from ZF Mathers, LLC.
Select from Appendix A – Parts List the correct Har-
ness for your System.
Throttle Wire Harness (Processor to Engine Interface)
Serial Communication Wire Harness (Twin Screw) (Proces-
sor to Processor)
The above Cable Harnesses use one or both of the
plug connector types detailed in Figure 5:.
When connecting the plugs, ensure that the release
button or buttons are depressed and held until plug is
fully connected or disconnected.
Connecting or disconnecting plugs without depressing
and holding the release button or buttons will damage
the plug.
Figure 5: Wire Harness Connection Plug
Cable
Depress & Hold
Depress & Hold
11230-
Detail I
Large Plug Side View
Depress
&
Hold
11232
Detail II
Small Plug End View

REQUIRED PARTS AND TOOLS
Page 12
3.7 ENGINE STOP SWITCH
It is mandatory for an Engine Stop Switch to be located at each Sta-
tion.
3.8 CONTROL SYSTEM POWER
The Processor requires:
• A battery source of 12 or 24 volts DC
• A 10 ampere circuit breaker with manual reset
• Automatic Power Selector (refer to Appendix A - S-214 APS Ser-
vice Sheet)
The power for the Control System should come from the same power
distribution panel as the other required engine functions. (Refer to
Appendix C Drawing Notes)
WARNING: An Engine Stop Switch at each Station is an absolute requirement. Refer to CFR46,
SEC. 62.35-5 and ABYC P-24.5.8.

PLAN THE INSTALLATION
Page 13
4.0 PLAN THE INSTALLATION
4.1 PROCESSOR(S) LOCATION
Processors are spray proof, but must
not be immersed.
An engine room location of the Pro-
cessor is preferred.
• If the engine room is too small,
locate in any area where it is
accessible for electrical and push-
pull cable connections.
Bulkhead mounting preferred for ease
of access for wiring and adjust-
ments, the Processor can be
mounted in any attitude.
• If the clutch cable is connected to
an I/O drive outside the hull, the
Processor must be two feet (0,6m) or
more above waterline.
Do not mount the Processor on the engine, to the transmission, or in
any location that will subject it to excessive vibration.
Refer to Figure 6: for Processor dimensions.
Locate Processor(s) away from heat sources, such as engine exhaust
manifolds. Allow 4 feet (1,2m) of clearance, or more, between the
Processor(s) and such heat sources.
Do not mount close to gas engine ignition systems, alternators, or
electric motors. Allow 4 feet (1,2m) of clearance between the Pro-
cessor and alternators or electric motors.
The Processor’s mounting feet must be connected to the vessel’s
bonding system.
NOTE: Read the Warranty in Appendix A. Improper mounting location may cancel warranty.
Figure 6: Control Processor Dimensions
10.71
(
272mm
)
2.69
(
68,3mm
)
6.70
(170,2mm)
2.70
(68,6mm)
3.20
(81,3mm)
10.40
(264,2mm)
4.75
(120,7mm)
10.25
(
260,4mm
)
11000-MS569
CAUTION: Electro-magnetic fields can influence ClearCommand’s electronic circuits.
CAUTION: It is mandatory that the Processor DC negative is bonded (connected) to the vessel
bonding system. See Appendix A Bonding Section.

PLAN THE INSTALLATION
Page 14
Locate each Processor such that the push-pull cables from it to the
engine governors have large radius bends, with the least total
degrees of bend and moderate length.
4.2 CONTROL HEAD LOCATION
Refer to Appendix A Control Head Dimensions and Variations for
dimensions and specific information on a Control Head.
4.2.1 400 Series Control Heads
When properly mounted on a console, the Control Head is watertight
from the top. An adhesive gasket must be used to seal the Control Head to
the mounting surface. However, below the mounting surface the Control
Head needs protection from water or spray.
4.2.2 MC2000 Series Control Heads
When properly mounted on a console, the Control Head is watertight
from the top. An adhesive gasket is mounted on the bottom of the Control
Head to seal it to the mounting surface. However, below the mounting
surface the Control Head needs protection from water or spray.
4.2.3 700 Series Control Heads
When properly mounted on a console, the Control Head is watertight.
4.3 DC POWER SOURCE
It is important to keep the length of power cable short to reduce volt-
age drop. The power cable should not exceed 20 feet (6m). If individual
wires are used for supply (+) and return (-) then the total wire length
should not exceed 40 feet (12m).
It is recommended by ZF Mathers that an Automatic Power Switch
(APS) and a second power source be used. Refer to Appendix A.1 -
APS Service Sheet and Appendix C.1 System Drawing.
NOTE:The minimum bend radius of 10 inches (254mm),for a total degree of bends of less than 270
degrees. Push-pull cable lengths should not exceed 20 feet (6m).
NOTE: If a Control Head is mounted weather exposed from the underside, consider using a Water-
tight Enclosure. Reference Appendix A Watertight Enclosure for specific information.
NOTE: If a Control Head is mounted weather exposed from the underside, consider using a Water-
tight Enclosure. Reference Appendix A Watertight Enclosure for specific information.
CAUTION: It is important that the wire size from the battery to the circuit breaker panel is large
enough to keep voltage drop due to current flow, to less than 3 percent. The DC
return to the battery must be large enough to supply all current requirements with a
voltage drop of less than 3 percent.