ZF CruiseCommand 785CE Programming manual

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

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3.4 Clutch Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 13: Processor Harness Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 14: Harness Plug Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Tools For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6.1 Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6.2 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7 Engine Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.0 PLAN THE INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
4.1 Processor(s) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 15: Processor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Control Head Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.1 400 & MC2000 Series Control Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.2 700 Series Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.3 512 Series Control Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.4 Control Head Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 DC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.0 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
5.1 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 16: Processor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Power/Start Interlock/(optional) Clutch Pressure/(optional) Alarm Circuit Harnesses . . . . . . . . . . . . . . . . . . . . . . . 18
5.2.1 Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 17: DC Power with Automatic Power Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 18: DC Power with Automatic Power Selector Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.2 Start Interlock Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 19: Start Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.3 Control Head Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.4 Alarm Circuit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.5 Clutch Pressure (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.2 Cable Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 20: Control Head Wiring Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3.3 Aft Facing Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 21: Aft Facing Control Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Synchronization (Multi Screw Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4.1 Tachometer Sensor Wire Harness (Active Synchronization Only) (Multi Screw) . . . . . . . . . . . . . . . . . . . . . 25
5.5 Main Engine Speed Control - Throttle Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6 Clutch and Troll [optional] Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.1 Clutch Control Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.2 Clutch and Troll Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.7 Engine Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.0 SET-UP PROCEDURES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
6.1 Processor Components used in Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 22: Processor Display and Arrow Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.1 Processor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 23: Display 7-Segment Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 24: Display Pad Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.2 Processor Arrow Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 25: Processor Arrow Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.3 Up and Down Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 26: Up and Down Arrow Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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6.1.4 Left and Right Arrow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 27: Left and Right Arrow Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.5 Left Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 28: Left Arrow Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.6 Right Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 29: Right Arrow Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 30: Display with Value more than Two Digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2 Activating Set-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 31: Display Normal Operating Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 32: Display Function Menu Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 33: Display with Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3 Set-up Functions & Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 1: Functions List....................................................................................................................................................32
6.3.1 A0 - Processor Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 34: Display with A0 - Processor Identification Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.2 A1 - Number of Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 35: A1 - Number of Engines Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.3 A2 - One Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 36: A2 One Lever Operation Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.4 E0 - Select Engine Throttle Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 37: E0 - Select Engine Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.5 E1 - Throttle in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.6 E2 - Throttle Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.7 E3 - Throttle Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.8 E4 - Throttle Maximum Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3.9 E5 - Throttle Pause Following Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 38: E5 - Throttle Pause Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.10 E6 - High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.11 E7 - Active Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 39: E7 - Active Synchronization Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.12 C0 - Clutch Oil Interlock Enabled/Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 40: C0 Clutch Oil Interlock Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3.13 C1 - Clutch Oil Interlock Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 41: C1 - Clutch Oil Interlock Delay Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.14 C2 - Reversal Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 42: C2 - Reversal Pause Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.15 C3 Reversal Pause Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 43: C3 - Reversal Pause Time Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.16 C4 - Reversal Pause Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 44: C4 - Reversal Pause Ratio Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.17 L0 - Troll Lever Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 45: L0 - Troll Lever Range Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.18 L1 - Troll Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 2: Trolling Valve Type Selection..........................................................................................................................41
Figure 46: L1 Troll Valve Function Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3.19 L2 - Troll Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.20 L3 - Troll Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.21 L4 - Troll Throttle Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.22 L5 - Troll Pulse Duration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.23 L6 - Troll Pulse Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.24 H0 - Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.25 H1 - Erase EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.3.26 H2 - High Side Driver Fault Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 47: H2 High Side Driver Fault Function Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Page 4
Table 3: Solenoid Error Status Enable ............................................................................................................................43
7.0 ADJUSTMENTS AND TESTS (SECURED TO DOCK) - - - - - - - - - - - - - - - - - - - - - - 44
7.1 Control Head (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Start Interlock (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Service Field Test Unit (Break-out Box) and Multi Meter Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 48: Service Field Test Unit and Multi Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 4: Functions Requiring Service Field Test Unit and Multi Meter ........................................................................45
Figure 49: E1, E2, E3, E4, and E6 Processor, Test Unit, and Multi Meter connections. . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 50: L2, L3, and L4 Processor, Test Unit, and Multi Meter connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 5: Throttle PWM, Voltage, Current Output Adjustments.....................................................................................46
Figure 51: E2 - Throttle Minimum and E3 - Throttle Maximum Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 Engine Stop Switches Test (Engines Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.6 Warm-Up Mode Test (Engines Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.7 E1 - Throttle in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 52: E1 - Throttle in Neutral Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.8 E4 - Throttle Maximum Astern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 53: E4 - Throttle Maximum Astern Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.9 E6 - High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 54: E6 - High Idle Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.0 ADJUSTMENT UNDERWAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -53
8.1 Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Reversal Pause On Direction Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 L2 & L3 Trolling Minimum and Maximum Adjustments (Engines Running). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 6: Propeller Shaft RPM .........................................................................................................................................54
Figure 55: Multi Meter and Test Unit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 56: L2 - Troll Minimum Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 7: Minimum Trolling Pressure..............................................................................................................................56
Figure 57: L3 - Troll Maximum Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 8: Maximum Trolling Pressure .............................................................................................................................57
8.4 L4 - Troll Throttle Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 58: L4 - Troll Throttle Limit Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.5 L5 - Troll Pulse Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 59: L5 - Troll Pulse Duration Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.6 L6 - Troll Pulse Percentage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 60: L6 - Troll Pulse Percentage Set-up Activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.0 CONTROL OPTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
9.1 Alarm Capability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2 Clutch Oil Pressure Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.0 MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
10.1 Control Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.2 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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

Page 5
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
Deutsch Connector Assembly .................................................................................................................................. 15
S-214 Rev.A 6/01 ....................................................................................................................................................... 19
Automatic Power Selector (APS) Model: 13505
Figure 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MMC-287 Rev.B 7-01 ................................................................................................................................................ 21
Bonding - A.B.Y.C. E-9 46 CFR 111.05
MMC-288 Rev.C 7/01 ............................................................................................................................................... 23
References and Parts Source
Appendix B.1
1.0 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1: Basic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.2 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.3 Electrical Wiring (Harnesses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1.4 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Troubleshooting Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Problem Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2: Automatic Power Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3: Control Head Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4: Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 5: Display Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6: Display Function A0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7: Display Function H0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 8: Display Applied Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 9: Display Tachometer Sender Frequency in Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 10: Display Stations Current Control Head Lever Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11: Display Stations Control Head Transfer Button Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 12: Display Software Revision Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Audible Tones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.1 Slow Repetitive Tone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5.2 One Long - Three Short. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 13: Display Stations Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 14: Display Stations A/D Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5.3 Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5.4 One Long - One Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5.5 Three Second Steady Tone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 Station Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6.1 Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6.2 Remote Station Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 15: Display Station A/D’s no decimal points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Page 6
Figure 16: Display with Station Transfer Button pushed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6.3 Stuck Transfer Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.7 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 1: Error Messages..................................................................................................................................................21
1.8 Problem Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 2: Problem Scenarios ............................................................................................................................................23
1.9 Cable Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.9.1 Power, Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 17: Power, Start Interlock Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.9.2 Power, Start Interlock & Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 18: Power, Start Interlock, Clutch Oil Pressure Switch Harness Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.9.3 Power, Start Interlock, Pressure Switch & Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 19: Power, Start Interlock, Clutch Oil Pressure Switch, and Alarm Harness Pin Out . . . . . . . . . . . . . . . . . . . 30
1.9.4 Throttle, PWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 20: PWM Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.9.5 Throttle, Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 21: Voltage Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.9.6 Throttle, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 22: Current Throttle Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.9.7 Clutch Power, Ahead & Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 23: Clutch Power, Ahead, and Astern Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.9.8 Clutch Power, Ahead, Neutral & Astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 24: Clutch, Ahead, Astern, and Neutral Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.9.9 Clutch Power, Ahead, Astern, Troll On/Off & Troll Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 25: Clutch and Clutch/Troll Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9.10 Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 26: Serial Communication Harness Pin Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.9.11 Tachometer Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 27: Tachometer Sensor Harness Processor End Pin Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.9.12 Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 28: Control Head Harness Pin Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.0 THROTTLE SIGNAL TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35
Figure 29: Dwg 11653-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 30: Dwg 11653-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Current (mA.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 31: Dwg 11653-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 32: Dwg 11653-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 PWM (Pulse Width Modulation) with Duty Cycle Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 33: Dwg 11653-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 34: Dwg 11653-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 PWM (Pulse Width Modulation) with DC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 35: Dwg 11653-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 36: Dwg 11653-I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 37: Dwg 11653-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.0 CLUTCH AND/OR TROLL TESTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
3.1 Ahead Clutch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 38: Dwg 11653-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Astern Clutch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 39: Dwg 11653-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 Neutral Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 40: Dwg 11653-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Page 7
3.4 Troll On/Off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 41: Dwg 11654-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5 Troll Command (Proportional Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 42: Dwg 11653-N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.6 Erase EEPROM (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix C.1
Drawing 11748, Single Screw, Two Stations ............................................................................................................. 3
Drawing 11746, Single Screw, Two Pluggable Stations ........................................................................................... 5
Drawing 11747, Twin Screw, Two Stations .............................................................................................................. 7
Drawing 11745, Twin Screw, Two Pluggable Stations ............................................................................................ 9

Revisions List
Rev Date Revision Description
A 9/01 1. SER-165 was replaced with current form.
B 11/01 Complete Manual revised to current ZF Mathers, LLC. standards adding
Software Part Number to Table of Contents.
1. Section 3.7 and 5.7: WARNING added CFR reference.
2. Section 6.3 Table 1: Functions List E0 Cummins Quantum voltage,
revised 4.1 to 4.0.
3. Section 6.3.4 Cummins Quantum voltage revised 4.1 to 4.0.
4. Section 7.5: CAUTION added CFR reference.
5. Section 9.1 Removed paragraph 3. Revised per ELR 637
6. Appendix B.1 TRAIN-156 Section 1.9.3 revised to B. Revised per ELR
638.

INTRODUCTION
Page 1
1.0 INTRODUCTION
1.1 THIS MANUAL
The purpose of the CruiseCommand Installation/Troubleshooting is:
• Operation (Section 2.0)
• Required Parts & Tools (Section 3.0)
• Plan the Installation (Section 4.0)
• Installation (Section 5.0)
•Set-up(Section 6.0)
• Adjustments (Section 7.0 and 8.0)
• Control Options (Section 9.0)
• Maintenance (Section 10.0)
• ZF Mathers Service Sheets (Appendix A.1)
• Troubleshooting (Appendix B.1)
• General System Drawing (Appendix C.1)
Keep this Manual for future reference.
Throughout the manual special attention should be paid to the fol-
lowing boxes:
Appendix A.1 contains the Service Sheets created by ZF Mathers to
aid in servicing, set-up, and documenting of this vessels parameters.
Appendix B.1 contains Troubleshooting explanations.
If you cannot find a solution within the Trouble Shooting, contact one of
the companies listed on the ZF Mathers Contact list at the end of Appen-
dix B.1.
Appendix C.1 contains basic System Drawings.
The following manual is written with all options considered. Not all
options are used on all Systems. Read ONLY the Sections that relate to the
application being used on this vessel.
NOTE: Contains Helpful Information
CAUTION: Damage to equipment may occur if this message is disregarded.
WARNING: Personal Injury may result if this message is disregarded.

INTRODUCTION
Page 2
1.2 CRUISECOMMAND SYSTEM
The CruiseCommand System is designed for:
• Engines that require either voltage, current (mA), or PWM
speed command signal
• Transmissions equipped with solenoid clutch or solenoid
clutch/troll
1.2.1 Features
• Sequencing of Clutch and Engine Speed
• Start Interlock
• Station-in-Command Indication
• Warm-up Mode
• High/Low Idle
• Engine Synchronization (Multi Screw)
• One Lever Operation (Multi Screw)
• Audible and Visual Indicators
• Electric Trolling Valve Control
• Key-Pad Set-up
• Plug-in Cable Connections
• Emergency Reversal Protection
• CruiseCommand Failure Alarm Contact (optional)
• Clutch Oil Pressure Interlock (optional)
• Built-in Diagnostics
• One to Four Remote Stations

OPERATION
Page 3
2.0 OPERATION
2.1 DC POWER ON
When CruiseCommand 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 2.8)
2.2 TAKE COMMAND
To take command at a Station:
• Control Head lever(s) must be in the Neutral detent.
• Operator must depress the transfer button for 1/2 second.
The tone will stop at all Stations and the red LED indicator light on the
Control Head will light, indicating the Station is in Command.
2.3 BASIC OPERATION
The Control Head has three detents; Astern, Neutral, and Ahead.
(Refer to Figure 1:) With the Control Head lever(s) positioned in the
Neutral (vertical) detent, the System will command Neutral and Idle
RPM. Control Head lever movement of 15 degrees to the Ahead or
Astern detent will command Ahead or Astern clutch engagement
while the engine remains at Idle RPM. Further movement of the Con-
trol Head lever will increase the engine RPM in proportion to the Con-
trol Head lever position.
NOTE: Only one Station has command at a time.
Figure 1: Control Head Detents

OPERATION
Page 4
2.4 ENGINE START INTERLOCK
The engine start signal is blocked unless the following are true:
• DC power has been turned ON to the Control System.
• A Station has command.
• The Control System is commanding Neutral.
2.5 STATION TRANSFER
When transferring command from one Station to another:
C) At the Station taking command depress and hold the transfer
button for 1/2 second. (Refer to Figure 3:)
• The red LED indicator will light at the receiving Station’s
Control Head, indicating the Station has taken command.
D)The commanded positions of the Throttle and Clutch will
remain unchanged for one second after the red indicator lights.
This allows the operator time to move the Control Head
lever(s) to a position approximately matching the last Station’s,
which will allow the vessel to maintain the current speed and
direction.
A)Leave the Control Head lever(s) of
the Station-in-Command in any
position.
B)Place the Control Head lever(s) of
the receiving Station in the Neutral
detent position. (refer to Figure 2:)
Figure 2: Remote Stations before Transfer of Command
• The red LED indicator
light will go Off at the
transferring Station’s
Control Head, indicat-
ing the Station no longer
has command.
Figure 3: Remote Station Transfer after Transfer of Command

OPERATION
Page 5
2.6 WARM-UP MODE
This feature allows the operator to increase the engine’s RPM while
the Clutch remains in Neutral. Warm-up Mode is operational only in
Ahead. The system is placed into Warm-up Mode as follows:
C) After one second move the Control Head lever to the Ahead
detent position.
D)Now release the transfer button.
• The red indicator light will blink slowly indicating Warm-up
Mode and the clutch has stayed in Neutral.
E) The operator can now start and warm-up the engine while mov-
ing the Control Head lever through the Ahead throttle ranges.
F) When the Control Head lever is returned to the Neutral detent,
the red LED will discontinue blinking and the CruiseCommand
will automatically reset to Normal Operating Mode after one
second.
G)The next Control Head lever movement will shift the transmis-
sion.
A)At the Station-in-Command,
ensure that the Control Head lever
is in the Neutral detent position
(refer to Figure 4:):
B)Depress and hold the transfer but-
ton.
Figure 4: Control Head Warm-up Mode
Figure 5: Control Head Normal Operating Mode

OPERATION
Page 6
2.7 HIGH / LOW IDLE MODES
The CruiseCommand Control System offers two options of engine
IDLE RPM settings.
• Low Idle Mode (default setting)
• High Idle Mode. (an adjustable elevated Idle RPM)
2.7.1 Low Idle
Low Idle is the normal engine Idle RPM.
When the System is initially powered up, it will always command Low
Idle.
2.7.2 High Idle
A High Idle RPM may be programmed during Set-up. The High Idle
maximum setting is 20% of full throttle.
2.7.3 Selecting Between High / Low Idle
To select between Low and High Idle (or vice versa) at the Station-in-
Command: (refer to Figure 6:)
A) The Control Head levers may be in any position.
B) Depress and hold the transfer button for 1/2 second and then
release.
• If the System was in Low Idle it will toggle to High Idle and vice
versa.
C) To return to the previous Idle setting, depress and hold the transfer
button again for 1/2 second and then release.
Figure 6: High/Low Idle Mode Selections

OPERATION
Page 7
2.8 SYNCHRONIZATION (MULTI SCREW)
The CruiseCommand System utilizes dual lever synchronization. Dual
lever synchronization provides the security of both of the Control
Head levers always being active.
Synchronization is automatic and only operates in Ahead; conse-
quently it can be left ON full time. Cruise-Command will always
power-up with synchronization Enabled.
In order for synchronization to become active and work toward syn-
chronizing the engine’s RPM’s, the Control Head levers must be in the
synchronization range.
Synchronization Range is:
• Both Control Head levers are in an Ahead position
• Greater than 5% percent of the throttle range is commanded
• Commanded throttles must be within 10% of one another.
The Processor’s throttle signals are compared and then matched. The
Processors then send the same signal to all engines. The engines are
now synchronized.
A green LED indicator light located on the Control Head of the Sta-
tion-in-Command indicates engine synchronization:
• When the green LED is NOT LIT, no synchronization.
• When the green LED is LIT, synchronization.
Synchronization can be turned OFF and ON:
To turn synchronization OFF:
1. Place the Control Head levers in the synchronization range.
2. Push the Transfer Button until the green LED blinks and goes out (approxi-
mately 2 seconds). Synchronization is now OFF.
To turn synchronization ON:
1. Place the Control Head levers in the synchronization range.
2. Push the Transfer Button until the green LED lights (approximately 2 seconds)
• The green LED light will blink as the system is working to synchronize.
• The green LED will become solid green when the engines are synchronized.

OPERATION
Page 8
2.9 ONE LEVER OPERATION MODE (MULTI SCREW)
This System utilizes One Lever Operation Mode to allow one Control
Head lever (Master) to command all engines and gears. The "Master"
lever can be any lever. The advantage of this is that only one Control
Head lever operates all engines and gears. Normal control sequenc-
ing and timing applies to all engines.
To turn OFF One Lever Operation:
A)Place the Master Control Head lever into the Neutral Detent.
B) Place the in-active Control Head lever(s) into the Neutral
Detent.
C) The green LED will turn Off, indicating control system is now
in Normal Operating Mode.
NOTE: The green LED will always be lit while in One Lever Operation, no matter what position
the Master Control Head lever is in.
NOTE: The Control Head lever(s) that are in-active can now be placed out of the way in any posi-
tion forward of the Ahead detent.
Figure 7: Step A One Lever Operation Mode
One Lever Operation Mode must be
enabled.
To turn ON One Lever Operation:
A)At the Station-in-Command,
move all of the Control Head
levers to the Ahead Detent
Figure 8: Step B One Lever Operation Mode
B) Push and Hold the transfer but-
ton while moving the Master
Control Head lever out of the
Ahead detent. DO NOT
RELEASE TRANSFER BUT-
TON until the green light turns
On, indicating One Lever Oper-
ation Mode is now Active.
CAUTION: It is strongly recommended that the Master Lever is returned to the Neutral/Idle posi-
tion prior to disabling One Lever Operation. Failure to do so may result in a sudden
change in vessel direction.
NOTE: One Lever Operation may be used in Troll Mode or in Non-Troll Mode.

OPERATION
Page 9
2.10TROLLING VALVE CONTROL (OPTIONAL)
The CruiseCommand System is able to control electric Trolling Valves
that utilize single or dual solenoids.
The Troll Mode option is selected during Set-up.
2.10.1Trolling Valve Command Operating Modes
This system has two Modes of Operation when a Troll Valve Type of
command has been set up: Troll and Non-Troll. When the control sys-
tem is initially powered up, the default Mode Of Operation is the Non-
Troll Mode.
2.10.2Operation in Non-Troll Mode
During Non-Troll Mode the Trolling Valve will remain locked up or at
maximum oil pressure position and System will work in Normal Operat-
ing Mode.
2.10.3Operation in Troll Mode
Troll Mode is a feature that must be turned On and Off at the Control
Head.
A) Place the Control Head lever in the Neutral, Ahead, or Astern
Detent.
B) Depress and hold the transfer button for two seconds.
• The solid red indicator light on the Control Head will begin blink-
ing rapidly, indicating the system is now in Troll Mode.
C) Once the system has been placed in Troll Mode and in the Ahead or
Astern detent, the propeller will begin to rotate at approximately
30% of Idle lock-up RPM.
• The throttle remains at Idle;
• The transmission commands Ahead or Astern;
• Control Head red LED flashing.
D) Continued Control Head lever movement through the Troll Range:
NOTE: If system is set for multiple screw operation, ensure all Control Head levers are in the Neu-
tral/Idle (vertical) or Ahead detent.

OPERATION
Page 10
• Will increase the propeller RPM from 30 percent shaft RPM to
approximately 70 percent shaft RPM;
• The throttle remains at Idle or can be adjusted to increase up to
20% of maximum throttle within this Troll Range.
• The Control Head red LED will become a steady light when the
Control Head lever reaches the end of the Troll Range.
E) The remaining movement of the Control Head lever beyond the
Troll Range:
• Clutch locks up.
• Will increase engine speed up to maximum throttle.
2.10.4To turn Troll Mode On:
A) Place the Station-in-Command Control Head lever in the Neutral,
Ahead, or Astern detent.
B) Depress and hold the Transfer Button until the red indicator light on
the Control Head changes (approximately 2 seconds) then release
the button:
• When the red indicator light is blinking rapidly, the control system
has turned Troll Mode ON. The clutch is slipping.
2.10.5To turn Troll Mode Off:
A) Place the Station-in-Command Control Head lever in the Neutral,
Ahead, or Astern detent.
B) Depress and hold the Transfer Button until the red indicator light on
the Control Head changes (approximately 2 seconds) then release
the button:
• When the red indicator light is a steady red, the control system has
Troll Mode OFF. The clutch is locked-up.
2.10.6Types of Trolling Valve Command
•00=No Trolling Valve (Refer to Section 2.10.2 for operation)
•01=Type 1 Trolling Valve Command (20 degrees Troll Range) (Refer
to Section 2.10.3 for operation)
•02=Type 2 Trolling Valve Command (35 degrees Troll Range) (Refer
to Section 2.10.3 for operation)

OPERATION
Page 11
•03=Type 3 Trolling Valve Command (45 degrees Troll Range) (Refer
to Section 2.10.3 for operation)
To turn Troll Mode ON (Troll Mode)/OFF (Non-Troll Mode) is the same
for all Troll Types.
NOTE: When Troll Type 3 is being used, maximum throttle is limited to 75%.
Figure 9: Control Head 20 Degree Troll Range - Type
1
Figure 10: Control Head 35 Degree Troll Range -
Type 2
Figure 11: Control Head 45 Degree Troll Range - Type 3

REQUIRED PARTS AND TOOLS
Page 12
3.0 REQUIRED PARTS AND TOOLS
3.1 PROCESSOR
One Processor required per engine (refer to the Drawing in Appendix
C.1)
Mounting Hardware is installer supplied.
Operator Manual included with the Processor:
3.2 CONTROL HEADS
There are two types of Control Head connections available:
• Plug Connected
• Terminal Connected
Refer to Appendix A.1 for Control Head Variations and Dimensions
Sheets for the type of Control Head being used with this System.
One Control Head is required per Station.
Included with the Control Head:
•Gasket
•Terminals
• Mounting screws
• Control Head Dimensions Variations & Installation Sheets
Figure 12: Processor
The Processor receives the variable DC volt-
age from the Control Head(s) and converts
these inputs to the appropriate electronic or
electric outputs at the correct time and
sequence to the Governor and Gear Box. The
information regarding throttle type, throttle/
gear sequencing, etc. are all stored on mem-
ory within the Processor.
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.