MMSC5000 - SMARTCOMMAND USER · PDF fileMMSC5000 - SMARTCOMMAND USER MANUAL ... 2.4 Engine Start Interlock ... 5200 Low-Profile Control Head

INSTALLATION, OPERATIONAND TROUBLESHOOTING

MMSC5000 - SMARTCOMMAND USER MANUAL

MARINE PROPULSION SYSTEMS

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COPYRIGHT

Released by After Sales dept.

Data subject to change without notice. We decline all responsibility for the use of non-original components or accessories wich have not been tested and submitted for approval.

ZF reserves all rights regarding the shown technical information including the right to file industrial property right applica-tions and the industrial property rights resulting from these in Germany and abroad.© ZF Friedrichshafen AG, 2014.

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TABLE OF CONTENT

MMSC5000 Rev B 01/13 Page 3

MMSC5000 SmartCommand User ManualTable of Contents

Table of Contents

MMSC5000SW70327.0I

SmartCommand User Manual ........................................................1Table of Contents................................................................................. 3

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

List of Tables ........................................................................................ 9

Revision List ....................................................................................... 13

Preface ............................................................................................... 15

1 Introduction........................................................................................ 171.1 SmartCommand System..................................................................................................................17

2 Operation ........................................................................................... 192.1 DC Power On ...................................................................................................................................192.2 Take Control ....................................................................................................................................192.3 Basic Operation ...............................................................................................................................202.4 Engine Start Interlock ......................................................................................................................212.5 Proportional Pause ..........................................................................................................................212.6 Station Transfer at Neutral ..............................................................................................................222.7 Station Transfer on the Fly ..............................................................................................................222.8 Warm Up Mode (Throttle Only) .......................................................................................................232.9 High / Low Idle ................................................................................................................................242.10 Twin Screw Synchronization ...........................................................................................................242.11 One Lever Operation Mode .............................................................................................................252.12 Cruise Mode (Default) ....................................................................................................................292.13 Proportional Pause ..........................................................................................................................292.14 Dimming Control Head LEDs ...........................................................................................................302.15 AutoTroll Mode (Optional) ...............................................................................................................302.16 EasiDock Mode (Optional)...............................................................................................................322.17 Two Speed Operation (Optional).....................................................................................................352.18 Mode Stacking.................................................................................................................................36

3 Installation: Planning.......................................................................... 393.1 Processor.........................................................................................................................................393.2 Tools For Installation .......................................................................................................................403.3 Control Heads..................................................................................................................................40

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3.4 Engine Stop Switch .........................................................................................................................413.5 Control System Power ....................................................................................................................423.6 Tachometer Connection ..................................................................................................................423.7 Wire Harnesses ...............................................................................................................................433.8 System Planning ..............................................................................................................................45

4 Installation ......................................................................................... 494.1 Processor.........................................................................................................................................494.2 Power, Start Interlock, Clutch Pressure, and Alarm Circuit Harness ..............................................504.3 Control Heads..................................................................................................................................544.4 Synchronization ...............................................................................................................................574.5 Main Engine Speed Control - Throttle Harness...............................................................................584.6 Clutch and Troll Control...................................................................................................................584.7 Engine Stop Switch .........................................................................................................................59

5 Set Up Procedures ............................................................................. 615.1 Processor Components Used in Set Up ..........................................................................................615.2 Activating Set Up Mode...................................................................................................................635.3 Set Up Functions & Values ..............................................................................................................655.4 System Function Codes (Required) ................................................................................................655.5 Assigning Station IDs.......................................................................................................................665.6 One Lever Mode (System Function Code A2) ................................................................................675.7 JMS Station Pairing (System Function Code A7) ............................................................................675.8 Engine Function Codes....................................................................................................................685.9 Clutch Function Codes ...................................................................................................................705.10 Troll Functions (AutoTroll) ...............................................................................................................745.11 Troll Functions .................................................................................................................................755.12 Docking Functions (EasiDock) ........................................................................................................795.13 Diagnostic Functions .......................................................................................................................80

ENG-289 Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems ....... 81

6 Dock Trials: Adjustments and Tests Secured to Dock ....................... 936.1 Control Head (Engines Stopped) .....................................................................................................936.2 Start Interlock (Engines Stopped) ...................................................................................................936.3 Service Field Test Unit (Break-out Box) and Multimeter Use..........................................................936.4 E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped).................................956.5 Engine Stop Switches Test (Engines Running)................................................................................986.6 Lever Movement at Control Heads..................................................................................................986.7 Warm-Up Mode Test (Engines Running).........................................................................................986.8 E1 - Throttle in Neutral ....................................................................................................................996.9 E4 - Throttle Maximum Astern.........................................................................................................996.10 E6 - High Idle .................................................................................................................................1006.11 E5 - Throttle Pause Following Shift ...............................................................................................102

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7 Sea Trials: Adjustments and Tests Underway ................................. 1037.1 Engine RPM ...................................................................................................................................1037.2 Reversal Pause On Direction Change............................................................................................1037.3 Synchronization Test .....................................................................................................................1047.4 J1 - Idle Lockup RPM.....................................................................................................................1057.5 L1 and L2 AutoTroll Minimum and Maximum Adjustments ..........................................................1057.6 L3 - Troll Throttle Limit ..................................................................................................................1087.7 L4 - Troll Pulse Duration ................................................................................................................1097.8 L5 - Troll Pulse Percentage............................................................................................................1107.9 d1 — Docking Minimum Pressure ..................................................................................................1107.10 d2 — Docking Maximum Pressure..................................................................................................1117.11 d3 - Docking Throttle Limit ............................................................................................................1117.12 d5 - Docking (EasiDock) Pulse Percentage ...................................................................................113

F-259 SmartCommand Sea Trial Report .......................................................................... 115

8 Control Options................................................................................ 1198.1 Alarm Capability ............................................................................................................................1198.2 Clutch Oil Pressure Interlock .........................................................................................................121

9 Periodic Checks and Maintenance .................................................. 1239.1 Control Processor ..........................................................................................................................1239.2 Control Head..................................................................................................................................1239.3 Battery ...........................................................................................................................................123

10 Troubleshooting ............................................................................... 12510.1 General ..........................................................................................................................................12510.2 Troubleshooting Questions............................................................................................................12910.3 System Inspection and Component Identification ........................................................................13210.4 LED Detailed Information...............................................................................................................13310.5 Diagnostic Menu............................................................................................................................13510.6 Audible Tones Detailed Information ..............................................................................................14210.7 Troubleshooting Station Transfer ..................................................................................................14510.8 Error Codes....................................................................................................................................14510.9 Problem Scenarios.........................................................................................................................14910.10 SmartCommand Control Head Replacement ................................................................................15310.11 SmartCommand Processor Replacement......................................................................................15610.12 Harnesses and Plug Pin-Outs ........................................................................................................159

11 Appendix A - System Components and Specifications.................... 179MMC-341 5000 Series Control Head Variations.............................................................. 181

MMC-337 4000 Series Control Head Variations.............................................................. 185

MMC-329 MC2000 Series Standard Control Head Variations......................................... 197

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MMC-280 400 Series Control Head Variations................................................................ 201

S-214 Automatic Power Selector Model: 13505 ............................................................. 207

Drawing 11488 DC Power Source Kit .............................................................................. 209

MMC-287 Grounding (Bonding) ...................................................................................... 219

MMC-288 References and Parts Source ......................................................................... 221

12 Appendix B - Sales and Service Information ................................... 223MMC-172 Factory Authorized Sales & Service Centers - International........................... 225

MMC-165 Warranty ......................................................................................................... 233

MMC-163 Warranty Registration..................................................................................... 235

13 Appendix C - System Drawings ....................................................... 237Drawing 13170 SmartCommand Twin Screw System Drawing........................................ 239

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LIST OF FIGURES


MMSC5000 SmartCommand User ManualList of Figures

List of FiguresFigure 2-1: Take Control at a Station................................................................................................................. 20Figure 2-2: Control Head Detents ..................................................................................................................... 21Figure 2-3: Warm Up LED ................................................................................................................................ 23Figure 2-4: One Lever LED................................................................................................................................ 25Figure 2-5: One Lever Mode: Inactive Lever Ahead........................................................................................... 26Figure 2-6: One Lever Operation: Inactive Lever in Neutral ............................................................................... 27Figure 2-7: Cruise Mode Response Function..................................................................................................... 29Figure 2-8: AutoTroll Lever Response Function ................................................................................................. 32Figure 2-9: EasiDock Response Function .......................................................................................................... 33Figure 3-1: Processor ....................................................................................................................................... 39Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation .................. 41Figure 3-3: Processor Harness Connector Locations ......................................................................................... 43Figure 3-4: Wire Harness Deutsch Pluggable Connectors ................................................................................. 44Figure 3-5: System Installation Diagram............................................................................................................ 45Figure 4-1: Processor Dimensions for Installation.............................................................................................. 49Figure 4-2: Wiring DC Power Using the APS..................................................................................................... 50Figure 4-3: Alternative Wiring for APS Power ................................................................................................... 51Figure 4-4: Connections for Start Interlock Circuit............................................................................................. 53Figure 4-5: Control Head Assembly .................................................................................................................. 54Figure 4-6: Deutsch Connector on 70269 Wire Harness ................................................................................... 55Figure 4-7: Turck Connector on 70269 Wire Harness........................................................................................ 55Figure 4-8: Daisy Chaining Control Heads......................................................................................................... 56Figure 5-1: Processor Display and Arrow Push Buttons..................................................................................... 61Figure 5-2: Processor Display and Push Buttons ............................................................................................... 62Figure 5-3: Control Head ID’s Not Set............................................................................................................... 63Figure 5-4: Display Normal Operating Condition ............................................................................................... 63Figure 5-5: Display Set Up Activated ................................................................................................................ 64Figure 5-6: Enter PIN ........................................................................................................................................ 64Figure 5-7: Change the Value of the Function Code.......................................................................................... 65Figure 6-1: Service Field Test Unit and Multimeter............................................................................................ 93Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections........................... 94Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections............................................. 94Figure 7-1: Multimeter and Test Unit Connections ......................................................................................... 106Figure 8-1: Alarm Circuit Requirements .......................................................................................................... 119Figure 8-2: Alarm Circuit Example .................................................................................................................. 120Figure 8-3: Clutch Pressure Switch Showing Processor Wire Harness and Shuttle Valve................................. 121Figure 10-1: Basic Control System.................................................................................................................. 125Figure 10-2: System Diagram ......................................................................................................................... 126Figure 10-3: Three Power Sources.................................................................................................................. 128Figure 10-4: Control Head LEDs ..................................................................................................................... 133

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LIST OF FIGURES


MMSC5000 SmartCommand User ManualList of Figures

Figure 10-5: Processor Display in Run Mode................................................................................................... 135Figure 10-6: Display With Active Error ............................................................................................................ 135Figure 10-7: Display When No Control Heads Assigned.................................................................................. 136Figure 10-8: Display with A000 ...................................................................................................................... 136Figure 10-9: Display with H000 ...................................................................................................................... 136Figure 10-10: Display changing from H000 to voltage reading........................................................................ 136Figure 10-11: Output shaft frequency value display ........................................................................................ 137Figure 10-12: Input shaft frequency value display ........................................................................................... 138Figure 10-13: Absent decimal points indicating station number...................................................................... 139Figure 10-14: Expected A/D counts and processor response .......................................................................... 139Figure 10-15: Control/Set button closure displays........................................................................................... 141Figure 10-16: Software revision level display .................................................................................................. 141Figure 10-17: Control head mounting hardware ............................................................................................. 153Figure 10-18: Connections between control heads ......................................................................................... 154Figure 10-19: Control head bottom view......................................................................................................... 154Figure 10-20: Socket key................................................................................................................................ 155Figure 10-21: SmartCommand processor ....................................................................................................... 156MMC-341 Figure-1: 5200 Standard Control Head........................................................................................... 181MMC-341 Figure-2: 5200 Low-Profile Control Head ....................................................................................... 181MMC-341 Figure-3: 5100 Standard Control Head........................................................................................... 182MMC-341 Figure-4: 5100 Low-Profile Control Head ....................................................................................... 182Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1............................................ 187Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2 ................................................................................ 188Figure MMC-337-3: Port Processor - Hard wiring Drawing 13932A - 15B....................................................... 189Figure MMC-337-4: Starboard Processor - Hard wiring Drawing 13932A - 15A.............................................. 189Figure MMC-337-5: 4200 Control Head - Front View Dwg #14132................................................................. 190Figure MMC-337-6: 4200 Control Head - Side View Dwg #14133.................................................................. 191Figure MMC-337-7: 4100LP Control Head – Front View Dwg #13932ART-8................................................... 192Figure MMC-337-8: 4100LP Control Head – Side View Dwg 13932ART-9...................................................... 193Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293............................................... 194Figure MMC-337-10: Control Head Mounting Holes and Cutout – Dwg #14649............................................. 195Figure MMC-329-1: Part Numbering Configurations Detents Available ........................................................... 197Figure MMC-329-2: Dimensions ..................................................................................................................... 198Figure MMC-329-3: Terminal Connections ..................................................................................................... 199Figure MMC-329-4: AFT Facing Control Head ................................................................................................ 199Figure MMC-280-1: Part Numbering Configurations ...................................................................................... 201Figure MMC-280-2: Detents Available ............................................................................................................ 201Figure MMC-280-3: Dimensions ..................................................................................................................... 202Figure MMC-280-4: Terminal Connections ..................................................................................................... 203Figure MMC-280-5: AFT Facing Control Head ................................................................................................ 203

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LIST OF TABLES


MMSC5000 SmartCommand User ManualList of Tables

List of TablesTable 2-1: Steps to Take Control....................................................................................................................... 20Table 2-2: Warm Up Mode LED........................................................................................................................ 23Table 2-3: L0 Function Code Values.................................................................................................................. 30Table 2-4: d0 Function Code Values ................................................................................................................. 33Table 3-1: Maximum Cable Lengths for Control Heads ..................................................................................... 41Table 3-2: Key to Wire Harness Connections .................................................................................................... 44Table 3-3: Key for Figure 5: System Installation Diagram .................................................................................. 46Table 3-4: Control Stations ............................................................................................................................... 46Table 3-5: Control Head to Control Head Cables............................................................................................... 46Table 3-6: Control Head to Processor Cables .................................................................................................... 46Table 3-7: Wire Harnesses and Other Parts ...................................................................................................... 47Table 4-1: Wire Gauges for Cables at Flag 1..................................................................................................... 51Table 4-2: Wire Gauges for Cables at Flag 2..................................................................................................... 51Table 4-3: Identifiers for Figure 4-2: Wiring DC Power Using the APS............................................................... 51Table 4-4: Alternative Wiring for APS Power..................................................................................................... 52Table 4-5: Connections for Start Interlock Circuit .............................................................................................. 53Table 4-6: Connections Between Control Heads ............................................................................................... 56Table 5-1: Push Button Keys in Normal Operating Mode................................................................................... 62Table 5-2: Push Buttons in Function Menu (Function Code LED’s are illuminated steadily)................................ 62Table 5-3: Push Buttons in Set Up Mode (Function Code LED’s are blinking) .................................................... 62Table 5-4: Push Buttons at Password Prompt (PIn? Appears on display) ........................................................... 63Table 5-5: Push Buttons for PIN Entry ............................................................................................................... 63Table 5-6: Push Buttons In Error Code Display (’Er’ shows in Function Code).................................................... 63Table 5-7: Engine Throttle Profile Definitions .................................................................................................... 68Table 5-8: L0 Function Code Values.................................................................................................................. 74Table 5-9: Trolling Valve Type Selection............................................................................................................ 75Table 5-10: J6 and J7 Values as Related to J0.................................................................................................. 78Table 5-11: d0 Function Code Values ............................................................................................................... 79Table ENG-289-1: Revision List......................................................................................................................... 81Table ENG-289-2: System Definition Functions (SmartCommand) .................................................................... 82Table ENG-289-3: Engine Functions and Values (SmartCommand)................................................................... 83Table ENG-289-4: Dual Throttle Engine Functions and Values (SmartCommand).............................................. 84Table ENG-289-5: Clutch Functions and Values (SmartCommand) ................................................................... 84Table ENG-289-6: Troll Functions and Values (SmartCommand)....................................................................... 85Table ENG-289-7: Docking Functions and Values (SmartCommand)................................................................. 85Table ENG-289-8: Governed Electric Troll Functions and Values (SmartCommand)........................................... 86Table ENG-289-9: Troubleshooting Functions (SmartCommand) ...................................................................... 87Table ENG-289-10: Steering and Helm Functions (POD)................................................................................... 87Table ENG-289-11: Low Speed Configuration Functions (POD) ........................................................................ 87Table ENG-289-12: High Speed Configuration Functions (POD) ....................................................................... 88

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LIST OF TABLES



Table ENG-289-13: Sport Fish Mode Functions (Sport Fish) ............................................................................. 89Table ENG-289-14: Steering and Helm Functions (SteerCommand) ................................................................. 89Table ENG-289-15: Low Speed Configuration Functions (SteerCommand) ....................................................... 90Table ENG-289-16: High Speed Configuration Functions (SteerCommand) ...................................................... 90Table ENG-289-17: Two Speed Functions ........................................................................................................ 91Table ENG-289-18: Speed Boost Functions ...................................................................................................... 91Table ENG-289-19: System Definition Functions (MCU/JMS)............................................................................ 91Table ENG-289-20: Troubleshooting Functions (MCU/JMS).............................................................................. 92Table 6-1: Functions Requiring Service Field Test Unit and Multimeter ............................................................. 94Table 7-1: Output Shaft Idle Lockup RPM ....................................................................................................... 105Table 7-2: Troll Minimum and Maximum Values ............................................................................................. 107Table F-259-1: Processor Information ............................................................................................................. 116Table F-259-2: Power Supply.......................................................................................................................... 116Table F-259-3: Dock Trials .............................................................................................................................. 117Table F-259-4: Record at Dock ....................................................................................................................... 117Table F-259-5: Sea Trials ................................................................................................................................ 117Table F-259-6: Record During Sea Trial .......................................................................................................... 117Table F-259-7: Follow Up ............................................................................................................................... 118Table 10-1: System Components .................................................................................................................... 126Table 10-2: LED Indications ............................................................................................................................ 134Table 10-3: Diagnostic Values ........................................................................................................................ 137Table 10-4: Error Codes.................................................................................................................................. 145Table 10-5: Problem Scenarios with Error Codes and Possible Solutions......................................................... 149Table 10-6: Function Code Values .................................................................................................................. 157Table 10-7: Wire Harness - Processor to Processor (p/n 70261-XX)................................................................ 159Table 10-8: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX)............................................ 160Table 10-9: Voltage Throttle Harness Pin-Out (p/n 14148-XX) ........................................................................ 160Table 10-10: Wire Harness - Throttle (Pulse Width Modulation [PWM]), (p/n 13533-XX)................................ 161Table 10-11: Wire Harness - Cable, Throttle, MAN EDC (p/n 14421-XX)......................................................... 161Table 10-12: Wire Harness- Throttle & Clutch Ahead/Astern w/Neutral Interlock, MAN- Sc (p/n 70588-XX) ... 162Table 10-13: Wire Harness- Throttle, Yanmar CAN Interface, SC (p/n 70766-XX) .......................................... 163Table 10-14: Wire Harness- Throttle, MTU Smartline- SmartCommand (p/n 70747-XX)................................ 163Table 10-15: Wire Harness- Throttle/Neutral Interlock, MAN (p/n 70263-XX) ................................................. 164Table 10-16: Voltage Throttle Harness Pin-Out (p/n 71262-XX) ...................................................................... 164Table 10-17: Wire Harness- Throttle, Dual Voltage- SmartCommand And MiniCommand (p/n 71589-XX) ...... 165Table 10-18: Wire Harness- Tach (Input And Output Shafts) SmartCommand (p/n 70494-XX) ....................... 165Table 10-19: Wire Harness- Clutch Ahead/Astern (p/n 15719-XX).................................................................. 166Table 10-20: Subassembly, Wire Harness Clutches with Troll (p/n 15725-XX) ................................................ 166Table 10-21: Wire Harness - Clutch/Troll Command (p/n 15732-XX) ............................................................. 167Table 10-22: Wire Harness - Clutch/Ahead/Astern/Troll Command/Troll On-Off (p/n 70390-XX)..................... 168Table 10-23: Wire Harness - Clutch/Ahead/Astern- ZFF Transmission (p/n 70673-XX) ................................... 169Table 10-24: Wire Harness - Clutch ZF Gear, MTU Smartline- SmartCommand (p/n 70901-XX) ..................... 170

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LIST OF TABLES



Table 10-25: Wire Harness - Clutch/Shaft Tach, SmartCommand (p/n 70259-XX) .......................................... 171Table 10-26: Power, Start Interlock Harness Pin-Out (p/n 13756-XX) ............................................................. 172Table 10-27: Wire Harness - Power, SI & Clutch Pressure Switch (p/n 13552-XX) .......................................... 172Table 10-28: Wire Harness - Power, SI, Clutch Pressure Switch & Alarm (p/n 13631-XX) ............................... 173Table 10-29: Wire Harness- Power Use w/ existing Start Interlock Only (p/n 15023-XX)................................. 173Table 10-30: Wire Harness- Power/Backup Input For MTU Start Interlock w/ SC (p/n 71021-XX) .................. 174Table 10-31: Wire Harness - Power, Start Interlock, Pressure SW, Alarm & Backup (p/n 71476-XX) ............... 175Table 10-32: Wire Harness- Control Head To OBOF Panel, Port and Stbd (p/n 71495-XX).............................. 176Table 10-33: Wire Harness - Control Head to Control Head (p/n 70268-XX) ................................................... 177Table 10-34: Wire Harness - Control Head to Processor (p/n 70269-XX) ........................................................ 177Table 10-35: Wire Harness - Iso CAN (p/n 70559-XX) .................................................................................... 178Table 10-36: CANtrak termination resistor (p/n 70540-XX) ............................................................................. 178

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REVISIONS LIST


MMSC5000 SmartCommand User ManualRevision List

Revision List

Rev Date Description

- 12/05

Cross Reference in Copyright Notices correctedFuse Value in Figure 14 in Section 3 correctedError codes included in Troubleshooting SectionSystem drawing in Appendix C updated to Rev. APassword instructions changed in Section 5

- 11/06

Some changes made in all Sections.Extensive changes and/or rewrites made to Section 2 - Operations; Section 5 - Set Up; Section 7 - Sea Trials; Appendix A (Section 11) and Appendix C (Section 13). Contact information updated for international sales and service centers in Appendix B (Section 12).

- 1/07 Text of Section 10, “Troubleshooting,” has been substantially updated and enhanced. Illustrations of pinouts for all major SmartCommand wiring situations were added.

- 9/07

Added Start Interlock to Section 2, Operation.Added Engine Stop Switch warning to Section 2, Operation.Added Mode Stacking to Section 2, OperationAdded E7 Values to Table 8, Section 5, Set Up Procedures

A 4/08 Replaced MMC-165 - Electronic Propulsion Limited Warranty

A.1 1/09 Replaced MMC-165 - Electronic Propulsion Limited WarrantyReplaced MMC-123, MMC-151, MMC-172 - Factory Authorized Sales & Service Centers Lists

A.2 11/11 Reformatted to FrameMaker, Restructured manual contents, Updated SW number, Various revisions per ELR00055, ELR00113, ELR00118 and ELR00130, updated all external documents

B 01/13 Revised per ELR00084, ELR00104, ELR00105, ELR00113, ELR00150, ELR00158, ELR00159, ELR00186 and ELR00202.

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PREFACE


MMSC5000 SmartCommand User ManualPreface

Preface

Conventional Symbols Used in the ManualThroughout this manual special attention should be paid to the following symbols

Important Information

IMPORTANT: Keep this manual in a safe place for future reference. It contains essential information about the installation and operation of the ZF Marine Propulsion Systems Miramar control system for your vessel.

WARNING: Personal Injury may result if this message is disregarded.

CAUTION: Damage to equipment may occur if this message is disregarded.

IMPORTANT: Contains essential information about a topic.

NOTE: Contains noteworthy information that may help to clarify a topic.

WARNING: Personal Injury could occur if the following steps are not followed exactly.

CAUTION: On Control Systems with more than one Processor, ZF Marine Propulsion Systems Miramar highly recommends that ALL UNITS utilize the same software revision for each Processor.

CAUTION: Electro-static discharge can damage this equipment. Personnel working on this equipment must be grounded to the chassis with an anti-static wrist strap.

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PREFACE


MMSC5000 SmartCommand User ManualPreface

How to Use the ManualThis manual is written describing all possible options available for this processor. Your vessel may not require all of these options. Refer only to the sections that apply to your vessel. If you wish to use one of the available options listed, please contact a technician from ZF Marine Propulsion Systems Miramar Sales & Service Organization (SSO). For more information on an SSO in your area, please see Section 12: Appendix B - Sales and Service Information.

CAUTION: Disconnect the power from the processor whenever welding is being done on the vessel. Failure to do so can cause permanent damage to the processor.

CAUTION: This equipment is designed to work with other ZF Marine Propulsion Systems Miramar designed equipment. DO NOT operate this equipment with any other manufacturer's equipment unless approved so in writing by ZF Marine Propulsion Systems Miramar Engineering Department.

NOTE: ZF Marine Propulsion Systems Miramar is not liable for any damage incurred if these notices are not followed exactly.

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INTRODUCTION


MMSC5000 SmartCommand User ManualIntroduction

1 Introduction

1.1 SmartCommand SystemThe SmartCommand System is designed for:

• Engines that require voltage, current (mA), PWM, or frequency speed command signals. SmartCommand systems work with all major electronic engine brands.

• Transmissions equipped with electric solenoid valves (on/off or proportional) and Controller Area Network (CAN) bus J1939 for connecting to ZF Marine Transmission Control Unit (MTCU).

1.1.1 Features

SmartCommand has the following performance features:

a Clutch and Engine Speed Sequencingb Start Interlockc High/Low Idled Multi Screw Engine Synchronizatione Electric Trolling Valve Controlf Emergency Reversal Protectiong Clutch Oil Pressure Interlock (optional)

Features that make the control head easy to use are:

a Indicator for Station-in-Commandb Six bi-color LEDs for indicating control system mode and statusc One to six Remote Stations, and up to three control heads on each of two independent CAN

bus lines, for commanding and controlling the vessel.d Sound transducer for system status indication.

The processor includes the following features:

a Four digit LED and key pad at main processor to simplify set up, configuration, and troubleshooting.

b Plug-in cable connectionsc SmartCommand failure alarm contact (optional)d Built-in diagnostics

Vessels that have more than one power source, which is recommended, should use an automatic power selector (APS). The APS (part number 13505, available from ZF Marine), compatible with 12 VDC or 24 VDC systems, increases the reliability of power delivery.

Cruise mode is the default mode of SmartCommand. This mode uses a single lever for clutch and throttle control, with one control lever for each screw. Automatic engine synchronization is enabled in Cruise mode.

Important: This manual contains information about all of the options available with the SmartCommand system. Your application might not use all of the options, so you can disregard those sections of the manual that do not apply to your configuration.

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INTRODUCTION


MMSC5000 SmartCommand User ManualIntroduction

1.1.2 Advanced Control Modes

SmartCommand has several advanced control modes:

mode gives you positive clutch response while ensuring easy and precise maneuvering ability in tight docking situations

mode maintains a constant propeller RPM while you have a full range of shaft speed control.

Warm up mode increases the engine RPM when the transmission is locked in neutral.

One lever mode allows you to have full shift and throttle control while operating multiple screws with a single lever.

Mode Stacking - allows use of One Lever and AutoTroll simultaneously.

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OPERATION


MMSC5000 SmartCommand User ManualOperation

2 OperationThis Section is intended for vessel operators. Generally speaking, most other Sections of this manual, while informative for users, contain information that is primarily useful for installers.

2.1 DC Power OnWhen DC power is turned ON, the SmartCommand control system:

• Commands neutral and idle from the processor.• Sounds an intermittent tone pattern at all stations indicating that no station has control. (Refer to

explanations of audible tones in section 10: Troubleshooting.)• Starts the transmission in the low speed gear. (If the vessel uses the Two Speed feature, the two

speed solenoid is de-energized.)

2.2 Take ControlThe system initializes with no control at any station. To take control at a station:

• Put control head levers in the neutral detent. The station cannot take control with the levers in any other position. The initialization tone pattern sounds.

• Press Control/Set at the station. The Control LEDs light steady green, indicating the station has control and the operator is commanding neutral. The tone pattern stops at all stations.

• Start the engine while commanding Neutral. If the control head levers are out of Neutral, the start interlock switch prevents the engines from starting.

• Move levers into the Ahead or Astern detent. The transmission shifts into gear and the Control LEDs light steady red, indicating the station is in control and the operator is commanding ahead or astern.

Warning: An Engine Stop Switch MUST be installed at every remote operating station. Refer to the Code of Federal Regulations (CFR) 46, 62.35-5 and the American Boat and Yacht Council (ABYC) standards on electric and electronic propulsion control systems (P-24.5.8). Personal Injury may result if this message is disregarded.

Important: The next control head lever movement shifts the transmission.

Note: Only one station has control at any time.

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OPERATION



Figure 2-1: Take Control at a Station

2.3 Basic OperationThe control head has three detents; Astern, Neutral, and Ahead, as shown in Figure 2-2: Control Head Detents. The system commands neutral/idle RPM with the control head levers positioned in the neutral detent. When you move the levers 15 degrees to the Ahead or Astern detent, the clutch(es) engage while the engine remains at idle RPM. In the throttle range, beyond the detents, engine RPM is incremented or decremented depending on the lever position.

Table 2-1: Steps to Take Control

Step Indicator Action Lever Position Response

1 A Move levers to Neutral Neutral Control head can take control

2 B Press Control/Set until CONTROL LEDs light Neutral Station takes control

3 C Move levers to ahead detent Ahead detent Vessel moves in response to lever position

Note: The Engine Start Interlock feature prevents the engines from starting if the DC power is not on, if a station is not in command, and if the control head levers are not in neutral. An exception to this rule is when the system is in Warm Up mode, when Start Interlock allows the engines to start with the levers in the throttle range.


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Figure 2-2: Control Head Detents

2.4 Engine Start InterlockEngine Start Interlock requires three steps to start the engine:

1. Turn ON DC power to the control system. The system must have power.2. Set the levers at the neutral detent.3. Take command at a station. One station must be in control.

2.5 Proportional PauseProportional pause provides a means of safely reversing vessel direction. Any time the levers are beyond the ahead or astern detent and you reverse direction, the clutch command signal is paused between ahead and astern. The pause allows time for the engine RPM to drop to idle and for the vessel to slow as it moves through the water. The pause interval depends on vessel speed, lever position, and the length of time the levers have been in that position. The proportional pause is configurable through proportional pause time and proportional pause ratio Function Codes C3 and C4, which are explained in section 5: Set Up Procedures.

Note: The neutral detent (the center of control head movement) is 10 degrees in the ahead direction. The degrees of lever movement are measured from this point, not from the vertical.

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2.6 Station Transfer at Neutral

To transfer control from one station to another with the levers in neutral:

1. Verify that both control head levers at the station in command are in the neutral detent.2. Verify that both control head levers at the station taking control are in the neutral detent.3. At the station taking control, press Control/Set.4. The Control LEDs on both sides illuminate steady green, indicating that this station has control.5. AutoTroll, EasiDock, and Warm Up modes, as well as the high idle function (see explanation of Function Code

E6 in section 5: Set Up Procedures), transfer to this station, and LEDs illuminate appropriately.6. The Control LEDs on the original station go out.7. Move the control levers into gear. The Control LEDs on both sides illuminate steady red. The LEDs stay red as

long as the vessel is in gear.

2.7 Station Transfer on the Fly

To transfer control from one station to another:

1. Leave the control head levers of the station in control in any position.2. Place the control head levers of the receiving station in the neutral detent position.3. At the station taking control, press Control/Set. The Control LEDs on both sides illuminate steady green. This

station now has control and AutoTroll, EasiDock, and Warm Up modes, as well as high idle (Function Code E6), are transferred to this station. LEDs illuminate to match the setting. One Lever mode does not transfer.

4. The Control LEDs on the control head at the original station go out.5. Throttle and clutch positions that had been commanded by the station from which control was taken remain

unchanged for one second after the Control LEDs on this station illuminate. This allows time for moving the control head levers at this station to approximate the same speed and direction.

6. Move the control levers into the position you want to command. The Control LEDs on both sides illuminate steady red.

Warning: Follow the steps in this section exactly. Personal Injury may result if this message is disregarded.



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2.8 Warm Up Mode (Throttle Only)Warm Up mode (throttle only) increases engine RPM while the clutch remains in neutral, when levers are in the ahead position. If you move the levers into the astern range, the engine remains at idle and the clutch remains in neutral. If the high idle function has been set (refer to Function Code E6 in section 5: Set Up Procedures), the engines idle at the high idle setting in Warm Up mode. The Warm Up LED shows steady red when you are in Warm Up mode.

Figure 2-3: Warm Up LED

2.8.1 Entering Warm Up Mode

You can start and warm up engines by moving the control head levers through the ahead throttle ranges, without the clutch engaging.

To put the system in Warm Up mode:

1. At the station in control, put the control head levers in the neutral detent position. Make sure the levers are definitely in neutral (i.e., the AutoTroll, EasiDock, or One Lever LEDs are not illuminated).

2. Press the Mode button and hold it down until the Warm Up LED blinks. Within 10 seconds, press the Control/Set button. (If Control/Set is not pressed with this amount of time, the Warm Up LED stops blinking and the mode does not change.)

3. The Warm Up LED changes from blinking to steady red.

Table 2-2: Warm Up Mode LED

LED State Meaning

Off Warm Up mode not selected or not available

Blinking Select Warm Up mode using Control/Set

Steady RED Warm Up mode is selected: transmission is in neutral


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4. At the station in control, position the control head levers in the ahead range. The percentage of throttle increases, while the transmission remains in Neutral. The Control LEDs blink green. If you move the levers into the astern range, the engine speed returns to idle and the clutch remains in neutral.

5. Warm Up mode is active (signified by the lighted Warm Up LED) until you deselect it by going to neutral as described below.

2.8.2 Exiting Warm-up mode

When the SmartCommand system is in Warm Up mode (Warm Up LED shows steady red), to exit:

1. At the station in control, place the control head levers in the neutral detent.2. The Warm Up LED illuminates steady red and the Control LEDs blink green.3. Press Mode and hold until the Warm Up LED extinguishes (approximately one second) and the Control

LEDs illuminate steady green.

4. Move the control head levers into the position you want to command in Cruise mode (Control LEDs illuminate steady red) or select another mode.

2.9 High / Low IdleThe SmartCommand system offers two engine idle RPM options:

• Low Idle — the normal engine idle RPM, the default setting, and the idle at power up.• High Idle — set with Function Code E6, which can be programmed during set-up. (See section 5: Set

Up Procedures.) High idle can be set to a maximum of 20% of full throttle. The default setting is the same as low idle.

To switch from low to high idle, move the control head levers to any of the detents. Press Control/Set on the control head and hold it down for one-half second. To switch back to low idle, move the control head levers to any of the detents and press and hold Control/Set for one-half second.

2.10 Twin Screw SynchronizationBy default, the SmartCommand System uses active synchronization if a tachometer signal is available and equal throttle synchronization if there is no tachometer signal. SmartCommand powers up with synchronization enabled. Synchronization is automatic, can be left on all the time, and is operable in One Lever mode.

In order for synchronization to activate and begin synchronizing the engines, the control head levers must be in the synchronization range. Engine speeds will match when both control head levers are in the Ahead throttle range (at least 5% forward of the detent) and throttles positioned within 10% of each other.

2.10.1 Setting Up Synchronization on the Processor

Choose Equal Throttle Synchronization, Active Synchronization, or no synchronization at processor set up (refer to the E7 Function Code in section 5: Set Up Procedures). When either Equal Throttle or Active Synchronization is set up, synchronization is enabled by default.

• Equal Throttle Synchronization — processor throttle signals are compared and matched, and the processors send the same signal to all engines. Once the signals match, the engines are considered to be synchronized. This type of synchronization is very effective in most cases.


Caution: Do not shift in High Idle, if the engine RPM at High Idle is higher than the maximum RPM recommended for your gears. For gear specifications and other information, refer to documentation provided with your transmission.

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• Active Synchronization — requires a tachometer signal representing the RPM of each engine, in addition to the throttle command signal. The function provides for the tachometer frequency to be measured and the throttle command signal outputs to be changed until both engines are running at the same RPM, as measured by the tachometer signals.

2.10.2 Disabling and Enabling Synchronization from the Control Head

To disable synchronization from a control head, while the levers are within the synchronization range, press the Control/Set button and hold for five seconds. The engines will now operate independently, regardless of the lever position.

If synchronization has been disabled, to enable it again from the control head, position the levers in the synchronization range, press the Control/Set button and hold for five seconds. The engines will now synchronize whenever the levers are in the synchronization range.

2.11 One Lever Operation ModeOne Lever mode allows you to control all vessel engines and gears with a single lever. This is useful for open water operation, but not for close quarter maneuvering. Either lever can be the active lever.

One Lever mode can be operated in two different ways — either with the inactive lever in neutral or with the inactive lever remaining stationary in the Ahead throttle range — selected through the A2 function at the time you set up the processors (see section 5: Set Up Procedures). Normal control sequencing and timing continue to operate on all engines when One Lever mode is in use. Engine synchronization and Two Speed operation work the same in One Lever mode as they do in Cruise mode.

Figure 2-4: One Lever LED

Warning: Whichever way you choose to use it, follow the steps to enable and disable One Lever Mode exactly. Personal Injury may result if this message is disregarded.

Note: One Lever mode can only be employed when you are in Cruise mode. The One Lever LED is always lit while in One Lever mode. The position of the active control head lever does not affect this LED.

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2.11.1 One Lever Operation: Option One (Inactive Lever Ahead)

The inactive lever ahead option of One Lever mode is set at the processor when a value of 01 is assigned to the Function Code A2 at the time set up procedures are performed (see section 5: Set Up Procedures). This option may be the best choice for sport fishers and other applications where it makes sense to leave the inactive lever stationary in the full forward position.

Figure 2-5: One Lever Mode: Inactive Lever Ahead1. At the active station, move both the control head levers to the Ahead Detent. AutoTroll, EasiDock, and

Warm Up LEDs cannot be illuminated. Press Mode once, twice, or three times until the One Lever LED blinks. (The number of button presses depends on the features installed on your vessel and the lever position.

2. Press Control/Set once to select One Lever mode.3. When the One Lever LED blinks green and red, choose a lever to control the system, by moving it

forward. This is the active lever.4. Move the active lever to the throttle position you want to command. The One Lever LED illuminates red

if the active lever is the port lever and green if the active lever is the starboard lever.

5. You can leave the inactive lever in the Ahead detent or move it further forward.• Disable One Lever Operation: (Inactive Lever Ahead)

The easiest way to break out of One Lever mode is to move both levers to the neutral detent for at least a half second. Alternatively, you can move the inactive lever to the neutral detent. Or you can put both levers at the Ahead detent, and press the mode button until the One

Note: Keep the inactive lever at the Ahead detent or further forward. If the inactive lever is moved to neutral (or through neutral to astern) One Lever mode is deactivated.

Note: Processor IDs determine which lever is considered port or starboard. The colors stated assume that the port processor has Processor ID 1 and the starboard processor has Processor ID 2.

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Lever LED goes out. You know you are out of One Lever mode, and that both levers are active again, when the One Lever LED is off. Both levers are now active.

2.11.2 One Lever Operation: Option Two (Inactive Lever in Neutral): Default Mode

In the default mode of operation, the inactive lever remains in the neutral detent when it is unused. Function Code A2 is set to a value of 02 at the processors for this mode of operation.

2.11.3 Enable One Lever Operation: Inactive Lever in Neutral.

Figure 2-6: One Lever Operation: Inactive Lever in Neutral1. At the active station, move both the control head levers to the Ahead Detent or more fully forward,

remaining within 15% of each other. AutoTroll, EasiDock, and Warm Up LEDs cannot be illuminated. Press Mode once, twice, or three times until the One Lever LED blinks. The number of button presses depends on the features installed on your vessel and the lever position.

2. Press Control/Set once to select One Lever mode. If no button is pressed within approximately 3 seconds, the LED stops blinking and the mode does not change.

3. The One Lever LED blinks green and red for a maximum of two seconds. Choose the lever you want to inactivate.

4. Move this lever to the neutral position within the two second time frame. The One Lever LED illuminates red if the active lever is the port lever and green if the active lever is the starboard lever.

Important: If you are in One Lever mode at one station and you transfer vessel command to another station, One Lever mode does not transfer. To use One Lever mode at the new station in command, set it at that station.

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The processor ID’s control which lever is considered port or starboard: the colors stated assuming the Port Control Processor has Processor ID 1 and the Starboard Control Processor has Processor ID 2.

Move the active lever to the throttle position you want to command. Do not move the inactive lever.

2.11.4 Disable One Lever Operation: Inactive Lever in Neutral

Use the control head buttons to exit One Lever mode:

1. Press Mode for approximately one second to deselect One Lever mode.2. The One Lever LED extinguishes. One Lever mode is disabled.

Alternatively, move the inactive lever out of the neutral detent. One Lever mode is disabled. The One Lever LED turns off. Both levers are active.

Note: Best Practice: To break out of One Lever mode, move both levers to neutral and press the Mode button until the One Lever LED extinguishes.

Warning: If you attempt to disable One Lever mode with one lever in Neutral and the other lever in ahead results in different engine speeds on the port and starboard sides. The vessel turns until the levers are brought closer together. Personal Injury may result if this message is disregarded.

Note: The One Lever function is only operational in Cruise mode.

Important: One Lever mode does not transfer when SmartCommand transfers stations. To use One Lever mode at the new station, set it at that station.

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2.12 Cruise Mode (Default) Cruise mode is the default mode. The clutch engages at the 15 degree (ahead or astern) detent position. As the lever rotates through the 60 degree throttle range, engine speed increases from Idle to Full and shaft RPM increases from minimum to maximum.

The example shown in Figure 2-7: Cruise Mode Response Function assumes a 2:1 gear ratio, and an engine with an idle speed of 600 RPM and full throttle at 2300 RPM. In this situation, shaft RPM increases from 300 to 1150 RPM. (In real life situations, values may be different.)

Figure 2-7: Cruise Mode Response Function

2.13 Proportional PauseThe Proportional Pause provides a means of safely and efficiently reversing the vessel’s direction in the shortest time possible. When commanding a change in direction:

• The throttle command signal drops to Idle.• The clutch remains engaged or, if a shaft brake is installed, the clutch is commanded to Neutral.• The propeller dragging through the water helps slow the vessel's progress.

The clutch command signal is paused in this position for a sufficient duration to allow the engine's RPM to reach Idle and the vessel's speed through the water to slow enough that a clutch reversal does not damage the gear box or stall the engine.

The opposite clutch engagement command is given. When sufficient clutch oil pressure is reached, a throttle signal above Idle provides thrust in the opposite direction.

The amount of time the clutch command pauses depends on the amount of speed commanded and how long that speed has been commanded. Maneuvering from Idle Ahead to Idle Astern has no delay.

The vessel must travel at full throttle for a period of six times the programmed pause in order to reach the maximum programmed pause time. For example, if the maximum proportional pause is set to five seconds, the vessel must travel at full throttle for 30 seconds (6 x 5) in order to reach the full five second pause. If full throttle is commanded for 15 seconds, the pause is 2.5 seconds. If 50% throttle is commanded for 15 seconds, the pause is just 1.25 seconds. See section 5.9.3: C2 — Reversal Pause through section 5.9.4: C3 — Reversal Pause Time.

Note: If your vessel uses ZF Friedrichshafen gears with an MTCU, there is a short pause at clutch engagement, and the throttle increases slowly for the first two seconds the clutch is engaged.

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The default pause from Astern to Ahead is one half the Reversal Pause value, since most vessels do not reach the same throttle in Astern as they do in Ahead. Use the C4 Function Code to change the Astern to Ahead relationship.

2.14 Dimming Control Head LEDsControl head LEDs are bi-color red/green daylight bright. If the LEDs are too bright, press the MODE button for at least 10 seconds and they will dim incrementally. Hold the button down until the desired brightness is reached, and then release. Continual pressing of the MODE button causes the LEDs to recede to minimum brightness and then revert to full bright, then cycle back, etc. At power-up, the LEDs are set to their maximum brightness.

Changing the LED brightness on one control head will not affect the brightness level of LEDs on other control heads.

2.15 AutoTroll Mode (Optional)

AutoTroll mode controls electric Trolling Valves using single solenoids or dual solenoids for Troll On/Off and Proportional. Set up AutoTroll and its Function Codes at the processor. After Function Codes have been set up, AutoTroll is enabled and disabled from the control heads. AutoTroll gives your vessel specific, repeatable shaft RPM for trolling. The gears installed in the vessel determine whether troll can operate with or without feedback. Gears with feedback have additional wire harness connections, either a tachometer signal or an MTCU. AutoTroll with feedback requires an output shaft sender to close the loop.

This system has three modes of operation when a troll valve is present and has been configured: AutoTroll, Cruise mode, and EasiDock. When the control system initially powers up, Cruise mode is selected by default. If the vessel uses the tachometer signal to provide shaft RPM feedback, and the tachometer signal is lost, AutoTroll operates in open loop troll. Slip is commanded without feedback and can vary.

In Cruise mode, the trolling valve is at the maximum gear oil pressure position (locked up). The trolling valve is not used in Cruise mode.

AutoTroll must be selected and deselected at the control head.

2.15.1 Adjustable AutoTroll Lever Range

The troll lever range can be adjusted to one of five values at processor set up, through the L0 Function Code. The values for L0 are:

Table 2-3: L0 Function Code Values

L0 ValueAutoTroll Range (in Degrees)

Control Head Lever at Ahead and Astern Detents

Movement through AutoTroll Range Movement Beyond Troll Range

00Default No Troll Clutch Fully Engaged,

throttle at idle NA Clutch Fully Engaged, Neutral to Full Throttle

01 15 degrees Minimum Troll Clutch pressure, throttle at idle

Minimum to Maximum troll Clutch pressure, throttle from idle to maximum troll throttle

Clutch fully engaged, throttle from minimum to full






Clutch fully engaged, throttle limited to 75% of full




05 Detents OnlyOnly at detents, Minimum Troll clutch pressure, throttle at idle

No Movement Clutch fully engaged, throttle from minimum to full

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2.15.2 Enabling AutoTroll

1. Place both control head levers in the Neutral, Ahead, or Astern Detent. Both levers must be in the same detent. The EasiDock, One Lever, and Warm Up LEDs cannot be illuminated.

2. Press Mode until the AutoTroll LED blinks. If no button is pressed in ten seconds, the LED stops blinking and the mode does not change.

3. Press Control/Set once to illuminate the AutoTroll LED. AutoTroll mode is enabled.

2.15.3 Lever Movement in AutoTroll

By default, when SmartCommand enables AutoTroll, the AutoTroll solenoid pulses momentarily when the levers are placed into the Ahead or Astern detent. This starts the propeller shaft moving at minimum troll. The commanded value drops to 30% to 50% of the idle lockup RPM for AutoTroll operation.

• The throttle remains at Idle;• The transmission commands Ahead or Astern;• Control head AutoTroll LED illuminates steady red.• The Control LEDs blink red.

Continued control head lever movement through the troll range:

• Increases the propeller RPM from 30% to 50% of idle output shaft RPM to approximately 70% maximum output shaft RPM.

• Throttle remains at Idle or can be adjusted to increase up to 20% of maximum throttle within the Troll Range.

• The control head AutoTroll LED remains illuminated.• The Control LEDs blink red.

Moving the control head lever beyond the troll range:

• Clutch locks up (no slip).• Engine speed increases, maximum is defined by the L0 value.• The control head AutoTroll LED remains illuminated.• The Control LEDs illuminate steady red.

For the example shown in the figure below, the L0 Function Code has been set to 02: 30 degrees of the lever rotation angle is dedicated to trolling. As the lever rotates, shaft speed gradually increases from 90 RPM at the detent to 210 RPM at 30 degrees; engine speed remains at idle. For the last 30 degrees of lever rotation, the clutch is fully engaged and the engine speed increases linearly, up to the maximum throttle setting.


Note: If your vessel uses ZF Friedrichshafen gears with an MTCU, the throttle increases slowly for the first two seconds the clutch is fully engaged.

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Figure 2-8: AutoTroll Lever Response Function

The upper limit for the troll throttle percentage is 20% of full throttle. The default value for maximum troll throttle percentage is 0%: the engine always remains at idle. Only change the default value after completing the checks and calculations in section 7.6.2: Set the Troll Throttle Limit, and Throttle in Docking Range.

2.15.4 Disabling AutoTroll

Place the active control head levers in the Neutral, Ahead, or Astern detent.

Press Mode for approximately one second until the AutoTroll LED extinguishes. The clutch is locked up: it does not slip as it does in AutoTroll.

2.16 EasiDock Mode (Optional)

EasiDock mode gives you positive clutch response and appropriate thrust allowing you to modulate the clutches and control the engine speed for easy maneuverability in confined waters. It provides a rapid, smooth change from ahead to astern while docking the vessel.

SmartCommand commands a higher clutch pressure when SmartCommand enters EasiDock mode. The propeller shaft starts to move; the thrust is noticeable. After a short time, the pressure drops to a lower lockup percentage. Clutch pressures in EasiDock can be optionally configured at setup, either at a specific value or through a range. If the tachometer feedback used by EasiDock is lost, the vessel drops out of EasiDock mode.

EasiDock mode commands decreased clutch pressure at the Ahead or Astern detents, and in the EasiDock range. The clutch engages fully if the levers move past the EasiDock range; there is no slip.

Caution: To prevent damage to the clutch pack, the maximum throttle percentage in AutoTroll mode is limited. Most transmissions require that throttle be limited to less than 1000 RPM. If the throttle limit is set with the L3 Function Code, the upper limit must be chosen carefully. Detailed information about choosing the upper limit can be found in section 7.6.1: Calculating the highest throttle percentage allowed.

Caution: If the vessel is underway in AutoTroll with the control head levers in the Ahead or Astern detent and AutoTroll is disabled, the vessel enters Cruise mode. The vessel accelerates to normal idle in gear speed.

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In the example graph, docking mode is active the first 40 degrees from the detent position and allows a smooth but quick prop response (from 150 to 330 RPM) due to the combined action of clutch slip and engine speed increasing from 600 to 940 RPM. For the remaining 20 degrees, the clutch is fully engaged and engine speed increases to 75% of the full engine speed, to 1875 RPM.

Figure 2-9: EasiDock Response Function

The upper limit for the EasiDock throttle percentage is 20% of full throttle. The default value for the EasiDock throttle percentage is 0%: the engine always remains at idle. Only change the default value after completing the checks and calculations in section 7.6.1: Calculating the highest throttle percentage allowed.

2.16.1 Adjustable EasiDock Lever Range

The lever range in EasiDock mode can be adjusted to one of five values at set up, through the d0 (“lowercase d”) Function Code. The values for d0 are:

Caution: The maximum throttle percentage in EasiDock mode is limited to prevent damage to the clutch pack. Most transmissions require that the throttle is limited to less than 1000 RPM. Detailed information about choosing the upper limit is found in section 7.6.1: Calculating the highest throttle percentage allowed.

Table 2-4: d0 Function Code Values

d0 Value Docking Range

Control Head Levers at Ahead and Astern Detents Movement through Docking Range Movement Beyond Docking

Range

00Default No docking Clutch Fully engaged,

throttle at idle NA Clutch fully engaged, throttle from minimum to full

01 15 degrees Minimum Docking Clutch pressure, throttle at idle

Minimum to maximum docking clutch pressure, throttle from idle to maximum docking throttle


02 30 degrees Minimum docking clutch pressure, throttle at idle



03 40 degrees Minimum docking clutch pressure, throttle at idle



04 50 degrees Minimum Docking Clutch pressure, throttle at idle

Minimum to Maximum docking Clutch pressure, throttle from idle to maximum docking throttle


05 Detent Only Minimum Docking Clutch pressure, throttle at idle No movement in docking. Clutch fully engaged, throttle

from minimum to full*

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* If the d0 Function Code is set to 05, you can exit EasiDock while the levers are in the ahead range.

2.16.2 Enabling EasiDock

1. Place both control head levers in the Neutral, Ahead, or Astern Detent. Both levers must be in the same detent. The AutoTroll, Warm Up, and One Lever LEDs cannot be illuminated.

2. Press Mode until the EasiDock LED blinks. If no button is pressed in ten seconds, the LED stops blinking and the mode does not change.

3. Press Control/Set once to light the EasiDock LED. The Control LEDs blink green. EasiDock mode is enabled.

The output shaft tachometer signal must be present for the vessel to enter EasiDock mode. If EasiDock is set up, and no tachometer signal can be detected, the system delays two to three seconds. If no tachometer signal is detected after the delay:

• The station in command generates an error tone.• A fault code appears on the processor:

- fault code 92 if the input shaft sensor faults,

or

- fault code 93 if the output shaft sensor faults.

• The EasiDock LED blinks rapidly.• The clutch remains fully engaged.

EasiDock mode does not enable until the processor receives the tachometer signal.

2.16.3 Lever Movement in EasiDock

When EasiDock is selected, clutch pressure is increased for a short time determined by the docking pulse duration Function Code. After this pulse has been applied, the clutch is allowed to slip again.

• The throttle remains at Idle.• The transmission commands Ahead or Astern.• Control head EasiDock LED is illuminated.• The Control LEDs blink red.

Continued control head lever movement through the docking range:

• Increases the propeller RPM from minimum shaft RPM to maximum shaft RPM.• Throttle remains at Idle or can be adjusted to increase within the docking range.• The control head EasiDock LED remains illuminated.• The Control LEDs blink red.

Moving the control head lever beyond the docking range:

• Clutch locks up (no slip).• Engine speed increases, maximum is defined by the d0 value.• The control head EasiDock LED remains illuminated.• The Control LEDs illuminate steady red.

2.16.4 Disabling EasiDock

In order for EasiDock mode to be disabled, the EasiDock LED must be illuminated. Place the active control head levers in the Neutral, Ahead, or Astern detent. If Function Code d0 is set to 05 - Docking in Detents Only, you can exit while the levers are in any detent or in the ahead range. Press Mode for


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approximately one second until the EasiDock LED extinguishes and the clutch is locked up; the clutch does not slip as it does in EasiDock.

There is no additional acceleration if you disable EasiDock in the ahead range when d0 is set to 05. The clutch is already fully engaged and you are traveling at the normal in-gear speed.

2.17 Two Speed Operation (Optional)SmartCommand two-speed reverse reduction gears are controlled by a solenoid choosing the gear. You can manually or automatically control the up-shift and down-shift RPM, depending on the installation.

For Two Speed operation to be functional, two-speed gears must be installed and two-speed Function Codes must be set. Additional switches and wiring are required to switch gears manually.

2.17.1 Automatic Shift Operation

The up-shift and down-shift RPM for automatic shift are set through software. The vessel begins in the first (low) gear when ahead is commanded. When engine speed for both engines increases to the up-shift RPM, SmartCommand commands the transmission to shift to second gear on both engines simultaneously.

If the engines are running at different speeds, the gears shift when the slower engine reaches the up-shift speed.

As the engines decelerate, the shift to first gear is controlled by the down-shift RPM. Both engines down shift automatically and simultaneously. SmartCommand down shifts the gears when the faster engine reaches the down-shift speed.

2.17.2 Manual Shift Operation

Manual shift operates with two installer-supplied switches. The first switch specifies whether the system is in Automatic Shift mode or in Manual Shift mode. The second switch determines whether the system commands first or second gear in manual shift operation.

You can shift to second gear at any time.

SmartCommand controls the maximum downshift RPM. The maximum downshift RPM prevents shifting into first gear when the engines and gears are operating at a higher speed than is safe for a downshift. The maximum downshift RPM is software selectable and can be different from the downshift RPM used for automatic shift.

Caution: Disabling Easidock if the vessel is underway with the control levers in the Ahead or Astern detent causes SmartCommand to enter Cruise mode. The vessel accelerates to normal idle in gear speed.

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2.18 Mode Stacking

Mode Stacking - allows use of One Lever and AutoTroll simultaneously.

2.18.1 Normal to Auto-Troll Mode1. Move both levers to one of the three detent positions2. Press the Mode button, 100 ms pushes, until the Auto-Troll LED begins to flash red3. Press and hold 500 ms the Control/Set button until the Auto-Troll LED turns solid and the Control LEDs

begin to flash

2.18.2 Auto-Troll to Normal Mode

• Press and hold the Mode button 1000 ms and the Auto-Troll LED will turn off and the control LEDs will stop flashing

2.18.3 Normal to One Lever Mode1. Move both levers to the Ahead detent position 2. Press the Mode button, 100 ms pushes, until the One Lever LED begins to flash red3. Press and hold the Control/Set button 500 ms and the One Lever LED will begin flashing red and green4. Once the One Lever LED begins to flash red and green, there will be a 5000 ms time-out for selection

of the Active Lever5. Select the Master/Inactive Levers

a For Option 1 (A2 = 1): Move the Active Lever forward out of the ahead detent, then the Inactive Lever can be stowed at full ahead if desired

b For Option 2 (A2 = 2): Move the Inactive Lever into the neutral detent6. If the Active Lever was successfully assigned then the One Lever LED will be solid red or green

indicating port (A0 = 01) or starboard (A0 = 02) lever as master respectively

2.18.4 One Lever to Normal Mode1. Activate the Inactive Lever

a For Option 1 (A2 = 1): Move the Inactive Lever into the neutral detent or press the Mode Button for 1000 ms

b For Option 2 (A2 = 2): Move the Inactive Lever out of the neutral detent or press the Mode Button for 1000 ms

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OPERATION



2. The One Lever LED should then turn off

2.18.5 Auto-Troll to One Lever & Auto-Troll Mode

• see 2.18.3 for procedure

2.18.6 One Lever & Auto-Troll to Auto-Troll Mode

• see 2.18.4 for procedure

2.18.7 One Lever & Auto-Troll to One Lever Mode1. Move the Active Lever to one of the three detent positions2. Press and hold the Mode button 1000 ms and the Auto-Troll LED will turn off

2.18.8 One Lever to One Lever & Auto-Troll Mode1. Move the Active Lever to one of three detent positions2. Press the Mode button, 100 ms pushes, until the Auto-Troll LED begins to flash red

Press and hold the Control/Set button 500 ms and the Control LEDs will begin to flash

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INSTALLATION: PLANNING


MMSC5000 SmartCommand User ManualInstallation: Planning

3 Installation: Planning

3.1 Processor

3.1.1 Requirements

Figure 3-1: Processor

The processor receives control head signals (CAN bus signals) and converts these inputs to appropriate electronic or electric outputs to the governor and gear box. Information regarding throttle type, throttle/gear sequencing, other system options, and Function Codes is stored in the processor’s memory.

Install one processor per engine; for example, a twin screw system needs two SC5000 processors.

Mounting hardware is installer supplied. The manual is included with the processor.

3.1.2 Location

The preferred location for the processor is the engine room. If the engine room is too small, locate the processor in any area where it is accessible for electrical connections. Bulkhead mounting is preferred for easy access to the processor for wiring and adjustments.

Processors are spray proof, but must not be immersed.

The processor can be mounted in any attitude as long as the LEDs on the front cover are readable. Do not mount the processor on the engine, on the transmission, or in any location that will subject it to excessive vibration.

Locate processors away from heat sources, such as engine exhaust manifolds or turbochargers. Allow four feet (1.2m) or more clearance between processors and heat sources.

Note: ZF Marine Propulsion Systems Miramar recommends installing the system in accordance with current ABYC E-11 and P-24 standards.

Note: Read MMC-287 Grounding (Bonding) and MMC-165 Warranty at the end of this manual. Improper mounting location may cancel warranty.

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Do not mount close to gas engine ignition systems, alternators, or electric motors. Allow four feet (1.2m) clearance between the processor and alternators or electric motors.

A threaded hole and screw are provided to connect to the vessel’s grounding (bonding) system. See section 4: Installation for processor dimensions and MMC-287 Grounding (Bonding) for details on grounding electronics.

3.2 Tools For Installation

3.2.1 Required

• Screwdriver – medium Phillips #2• Drills -- 9/32 inch (7.2 mm) and 7/32 inch (5.6 mm)• Saw (appropriate type of saw for cutting the control head mounting hole)

3.2.2 Optional

• Wire cutter, stripper, and crimper (ZF Marine Propulsion Systems Miramar recommends Thomas & Betts WT-2000 if using single terminated harnesses)

• Service Field Test Unit (Break-out Box)• Calibrated Digital Multimeter (for CAT engines, the Multimeter must read PWM: ZF Marine

Propulsion Systems Miramar recommends Fluke 87 III or equivalent)

3.3 Control HeadsThere are several types of control heads available:

• 5000 Series SmartCommand Control Head• 4000 Series Twin Screw Analog Control Head• 522 Series Tournament style control heads used in conjunction with the OBOF panel (pn 71401)• 400 Series Control head used in conjunction with the OBOF panel (pn 71401)• MC2000 Series Control head used in conjunction with the OBOF panel (pn 71401)

See Appendix A - System Components and Specifications for physical dimensions for the type of control head used with the system. One control head is required per station. Control heads use one CAN bus from each processor (two CAN buses total) to provide power to the control head, and send and receive commands from the processors. See Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation to see how the CAN buses connect processors and control heads.

Clearance of 4.5 inches (114.3 mm) below the mounting surface of each control head is required.

Each control head is shipped with mounting hardware and the necessary gasket attached. One or two control heads must be directly connected to the processor or processors. If the system has more than two control heads, at least two are daisy-chained. Each chain has a maximum of three control heads.

Caution: Electromagnetic fields can influence SmartCommand’s electronic circuits and cause erratic operation. Heat can damage the SmartCommand system. Compasses should not be located near the processors.

Warning: Mount SmartCommand control heads at least 250 mm (9.84 in.) from compasses. If a safe mounting distance is not maintained, electromagnetic fields could influence SmartCommand Control Head electronic circuits, cause erratic operation, and possibly impair compass directions. Personal injury could result if this message is disregarded.

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Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation

3.4 Engine Stop SwitchThe installer must provide and install an Engine Stop Switch at each Remote Station.

Table 3-1: Maximum Cable Lengths for Control Heads

Number of Control Heads in Chain Processor to Control Head First Control Head to

Second Control HeadSecond Control Head to Third

Control Head

One control head 400 feet (228.7 m) NA NA

Two control Heads 300 feet (91.5 m) 150 Feet (45.7 m) NA

Three control Heads 150 feet (45.7 m) 100 feet (30.5 m) 100 feet (30.5 m)


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3.5 Control System Power The processor requires:

• A 12 VDC or 24 VDC battery source.• A 10 ampere trip free circuit breaker with manual reset.• Automatic Power Selector (refer to S-214 Automatic Power Selector Model: 13505)

The power for the control system should come from the same power distribution panel as the other engine functions. The processor’s return conductor must be connected to the common ground (refer to MMC-287 Grounding (Bonding)). Connect the return conductors of the processor together.

3.6 Tachometer ConnectionIf you want to utilize Active Synchronization or Two Speed operation, a signal representing the speed of the engines must be provided to the processors. In addition, the AutoTroll and EasiDock modes require that a tachometer signal representing propeller speed be provided to the processors.

ZF Padova and Friedrichshafen gear boxes can be delivered or retrofitted with these two sensors for supplying signals to the processor. The sensor provided to monitor an engine’s speed is an “AC coupled” type sensor, and the sensor for monitoring the output shaft (propeller) is an “open collector” style sensor.

Systems on vessels equipped with other gear boxes (not ZF Padova or Friedrichshafen) that do not have the sensors when initially installed can be adapted to provide the necessary signals.

Two types of tachometer sensors are available from ZF Marine Propulsion Systems Miramar which can provide the required engine speed:

• Mechanical sender (P/N 8902). This is a key-driven sensor which can be used on engines equipped for sensors. (Refer to documentation provided by the manufacturer of your engine.)

• Magnetic pick-up, available in an SAE size (P/N 8912) and a metric size (P/N 70341). This sensor counts the teeth on the flywheel ring gear to represent engine speed.

Both the mechanical and magnetic sensors provide one output for the control system and a second output for an optional customer-supplied tachometer.

If you install a sensor from a vendor other than ZF Marine Propulsion Systems Miramar, that sensor must meet specific criteria, depending on its type. These criteria are described in the following sub-sections.

3.6.1 Engine Speed Sensor Requirements1. Output signal of AC Coupled sensors must have:

• Minimum amplitude of +/- 1.5V (3.0 VDC peak to peak).• Maximum amplitude +/- 100V (200 VDC peak to peak). • Frequency no lower than 30 Hz at idle.• Frequency no higher than 8 kHz at full throttle.

2. Alternator• The pre-rectified stator AC terminal can be used as the signal source.• The signal may be connected to the AC Coupled sensor input.• The signal must meet the same criteria as any AC Coupled sensor signal.

3. Point side of the coil• The signal may be connected to the AC Coupled sensor input.• The signal must meet the same criteria as any AC Coupled sensor signal.

Caution: Voltage differences between the processors on power or ground can damage the processors.

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4. Electronically produced engine tachometer signal• The signal may be connected to the AC Coupled sensor input.• The signal must meet the same criteria as any AC Coupled sensor signal.

3.6.2 Propeller Shaft Speed Sensor Requirements — Active Sensor with Open Collector Input

The sensor must have:

• A source current capability not less than 2 mA.• A minimum frequency of 5 Hz at idle.• A maximum frequency of 8 kHz at full throttle. • An operational voltage of 9 - 10 VDC.

3.7 Wire HarnessesWire harnesses commonly used with SmartCommand are illustrated in section 10: Troubleshooting. The configuration of a vessel (type of system, number of stations, engines, and processors, etc.) will determine which harnesses are appropriate and necessary. There are numerous harnesses available from ZF Marine. For a complete wire harness list and part numbers contact ZF Marine Propulsion Systems Miramar, LLC sales department. Several different harnesses can be used for power, start interlock, clutch pressure, and the alarm circuit; the exact harness depends on the application. The Power and Start Interlock connections are required. Clutch Pressure and Alarm Circuit connections depend on the application.

Select the harnesses for the system from the catalog, or contact a ZF Marine Propulsion Systems Miramar salesperson. Measure the length required before deciding on a harness length.

Station 2, Pulse, and ZF CAN1 and CAN2 connectors on the processor are sealed with plugs at the factory. If the connectors are used, remove and discard the plugs. If a connectors is not used, make sure it is terminated with a blank plug.

Figure 3-3: Processor Harness Connector Locations

Note: Every connector should be plugged into either a wire harness or a plug. Do not leave a connector empty or with pins dangling.

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Figure 3-4: Wire Harness Deutsch Pluggable Connectors

Connect or disconnect the plugs using the release buttons by pressing the buttons and holding them. Continue to hold the buttons until the plug is fully connected or disconnected. Otherwise, you can damage the plug. Some harnesses also use Turck screw type connectors. Verify that screw type connectors are not cross-threaded when they are installed.

Table 3-2: Key to Wire Harness Connections

ID Connector Name Harness for Connector

1 Throttle Throttle Wire Harness, all types (Processor to Engine Interface)

2 Power Power/Start Interlock Wire Harnesses, all types (Processor to Power/Start Interlock connections, optionally Clutch Pressure and Alarm connections)

3 Clutch Clutch Wire Harnesses, all types (Processor to Ahead/Astern, optionally Troll Solenoids and Troll command, in some cases one plug on a two or three cable harness)

4 CAN 2 Used for CANtrak, Autopilot and Yanmar applications

5 Serial Serial Communication Wire Harness (Processor to Processor)

6 Tach Tachometer Sensor Wire Harness (Processor to Tachometer Sensor)

7 ZF CAN 1 CAN Bus for ZFF MTCU only: Used in conjunction with the clutch wire harness in position 3

8 Sta. A or Sta. B CAN Bus: Processor to control head

Large Plug side view

Small Plug end view

Connector Keying

[Cable

Depress & Hold

Depress & Hold

11230_ART

Depress

&

Hold

11232_ART

Processor Key

15137_ART

ConnectorKeying

ConnectorKeying

12

34

56

78

15138_ART

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3.8 System PlanningThe system installation diagram shown in the figure below shows a full system installation, including all options. Use this as a reference by crossing out the options not used on your vessel. On the three tables following the illustration and key figure, record cable lengths and other part numbers as necessary.

Figure 3-5: System Installation Diagram

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Table 3-3: Key for Figure 5: System Installation Diagram

Indicator Definition

A Port Processor

B Starboard Processor

C Port Engine

D Starboard Engine

E Circuit Breaker

F 10 Amp

G Fuse

H 30 Amp

J Power Source #1

K Power Source #2

L Common Ground

M Supplied by Shipyard

Table 3-4: Control Stations

Figure Reference Part Number Location Station Number

2A 5200 or 5200LP

2B 5200 or 5200LP

2C 5200 or 5200LP

2D 5200 or 5200LP

2E 5200 or 5200LP

2F 5200 or 5200LP

Warning: ZF Marine Propulsion Systems Miramar strongly recommends that the first control station be located on the Station A bus, and the second control station be located on the Station B bus, to provide for redundancy in case of failure. Personal Injury may result if this message is disregarded.

Table 3-5: Control Head to Control Head Cables

Figure Reference Part Number Length Port Length Starboard

4A 70268-XX x 2

4B 70268-XX x 2

4C 70268-XX x 2

4D 70268-XX x 2

Table 3-6: Control Head to Processor Cables


3A 70269-XX x 2

3B 70269-XX x 2

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Table 3-7: Wire Harnesses and Other Parts


5A and 5B (Throttle)

6A and 6B(Clutch)

6A and 6B (Tachometer)

7A and 7B (Power/Start Interlock with Optional Clutch Pressure and Alarm Circuit)

8 (Processor to Processor CAN) 70261-XX N/A

10A and 10B (ZFF Transmission Interface Option) Note 1: this cable is only present if ZFF gears with MTCU are used. 70260-XX

MTCU Power (ZFF gears only) 70260P-XX

Parts without Harness Lengths

1A and 1B – Processors SC5000 Quantity: 2

Terminating Resistor 70269 Quantity:

9 (APS Kit -see) All APS kit contents are within the dashed box 13984

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INSTALLATION


MMSC5000 SmartCommand User ManualInstallation

4 InstallationAs directed in section 3: Installation: Planning, collect all parts and tools before starting the actual system installation of SmartCommand. Determine locations and cable lengths for the processors, the APS, and the control heads. Read the instructions for each separate part before installing it.

4.1 Processor

Figure 4-1: Processor Dimensions for Installation

For installations using screws:

1. Place processor on mounting surface and mark screw holes. 2. Remove processor and drill screw holes.3. Secure processor using 1/4 inch or M6 fasteners. 4. Connect to the Grounding (Bonding) System. See MMC-287 Grounding (Bonding) for information on grounding

correctly. (Some installations use welded threaded pads for grounding.)

Note: When installing or removing a plug, always press release buttons down and continue to hold until the plug is fully connected or disconnected, to avoid damage.

Note: Place clamps or straps at least every 18 inches (~0.5 m) to support wire harnesses, unless the harness is contained in a conduit, and ensure that each cable is protected from physical damage. Refer to ABYC Standard E-11.16.4.1.10.

Warning: Do not open the processor enclosure -- this will void the warranty. The enclosure contains no user-serviceable parts and ZF Marine Propulsion Systems Miramar cannot guarantee that the unit will operate as designed if it is opened. Personal Injury may result if this message is disregarded.

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4.2 Power, Start Interlock, Clutch Pressure, and Alarm Circuit HarnessSeveral different harnesses can be used for the four functions in the title. The exact harness will depend on the application. Refer to section 10: Troubleshooting for harness information. The Power and Start Interlock connections are required. Clutch Pressure and Alarm Circuit connections are optional.

The harness has one plug on the processor end of the cable, and is supplied with two to four cables extending from the plug, depending on the requirement.)

Insert the Wire Harness plug in the POWER connector on the processor.

Continue with the sections that apply to the application. In all cases, make the Power and Start Interlock connections. Your application may have neither Alarm or Clutch Pressure, or it may have one or both.

4.2.1 Power Cable1. Install the power cable from the processor to the DC Power Source, using the wiring recommended in

this section. 2. Support the cable using clamps or straps 18 inches (0.5m) apart or closer, unless the cable is

contained in a conduit. Refer to the ABYC Standard E-11.3. Install each cable so it is protected from physical damage.4. Repeat for all processors.

Use an APS (Automatic Power Selector — see S-214 Automatic Power Selector Model: 13505) wired as shown in the following figure. An APS minimizes the chance of losing power to the control system by automatically selecting between two independent power sources. Wire two 12 VDC or 24 VDC power sources to the APS inputs using the wire gauges specified.

Figure 4-2: Wiring DC Power Using the APS

Caution: Turn Power OFF before connecting the Power Harness to the processor.

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APS output is strictly for ZF Marine Controls.

If the cable labeled with Flag Note 2 in Figure 4-2: Wiring DC Power Using the APS exceeds 40 feet, use the alternate wiring shown in Figure 4-3: Alternative Wiring for APS Power. Power installation kits containing all the components except the power cables are available from ZF Marine.

Figure 4-3: Alternative Wiring for APS Power

Table 4-1: Wire Gauges for Cables at Flag 1

Cable Length at Flag1 Wire Size (Reference ABYC E-11.16.1.2 10%)

0 - 15’ 12 AWG (#3 Metric Equivalent)

15’ - 30’ 10 AWG (#5 Metric Equivalent))

30’ - 60’ 8 AWG (#8 Metric Equivalent)

Table 4-2: Wire Gauges for Cables at Flag 2

Cable Length at Flag2 Wire Size (Reference ABYC E-11.16.1.2 10%)

0 - 20’ 14 AWG (#2Metric Equivalent)

20’ - 40’ 12 AWG (#3 Metric Equivalent))

Table 4-3: Identifiers for Figure 4-2: Wiring DC Power Using the APS

ID Description ID Description

A “OFF” position for Circuit Breaker G DC Common Return

B ’ON” Position for Circuit Breaker H PN 13505 Automatic Power Selector

C RED wire J PN: HFB Fuse HolderPN: AGC-30 Fuse

D Connection to processor K 30 Amp Fuse

E Black or Yellow Wire L Power Source 2

F PN 810: 10 Amp Circuit Breaker M Power Source 1

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INSTALLATION



Review section 13: Appendix C - System Drawings to confirm termination points for power connection. The power for the control system should come from the same power distribution panel as the other engine functions. The return conductor of the processor must be connected to the common ground. Connect the processor’s return conductors together.

4.2.2 Start Interlock Cable

Install the start interlock cable between the Starter Solenoid and the processor as follows (illustrated in Figure 4-4: Connections for Start Interlock Circuit):

1. Support the harness using clamps or straps 18 inches (0.5m) apart or closer, unless the harness is contained in a conduit.

2. Install each harness so it is protected from physical damage.3. Remove the remote key start switch lead from the Starter Solenoid. Strip and connect one start

interlock cable wire to this lead. 4. Strip and connect the second start interlock cable wire to the Starter Solenoid.

5. Repeat for all processors.

Table 4-4: Alternative Wiring for APS Power

ID Description

1 Remote Switch

2 Relay coil voltage must match power source

3 To processor

4 Off position of circuit breaker

5 On position of circuit breaker

6 10 Amp circuit breaker

7 Red wire

8 Alternate Wiring: to be used for long cable run for remote On/Off switch in excess of 40 feet

Caution: Voltage differences between the processors on power or ground can damage the processors.

Caution: The processor is designed for a start signal current with a maximum of 5 Amperes and 50 Volts. Current greater than 5 Amperes can damage the interlock circuit.

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INSTALLATION



Figure 4-4: Connections for Start Interlock Circuit

4.2.3 Alarm Circuit and Clutch Pressure (optional)

For information about these connections, refer to section 8: Control Options.

Table 4-5: Connections for Start Interlock Circuit

ID Item ID Item

A Start Switch G To DC Power Source

B Start Interlock Cable H Starter

C Power Harness J Ground (Bond)

D Power Pigtail K DC Common

E Start Interlock N.O. Contact: Maximum 5 Amperes L Battery

F ProcessorM Starter Solenoid

N Butt Splices

Caution: SmartCommand control heads should be mounted only in forward-facing stations, with the operating buttons facing aft. Mounting a control head in a manner other than this can result in reversed operational effects.

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4.3 Control HeadsSee MMC-341 5000 Series Control Head Variations for location of the cutout and mounting holes for the control heads used with this application.

4.3.1 Mounting the Control Head

Use the template supplied after the description of the control head variations in MMC-341 5000 Series Control Head Variations. Verify measurements for the centers of the threaded studs and the housing. Mark and drill the screw holes and corner cutout holes.

• Saw between the corner cutout holes.• Remove the four nuts and washers from the threaded studs on the control head.• Insert the control head into the cutout and screw holes. Make sure the gasket on the bottom of

the control head rests on the console outside the cutout and that the LED panel faces the operator.

• Install washers and nuts. Nuts are a nonstandard size.

Figure 4-5: Control Head Assembly

Caution: The most common source of trouble is loose wiring connections. Verify that wiring connectors are properly crimped and cannot be pulled out. Crimps and connections must be made to the wire, not to the wire insulation. Verify that all screwed wire connections are secure. Damage to equipment may occur if this message is disregarded.

Important: Before drilling or cutting, make sure there is a clearance space of at least 3.5 inches (88.9 mm) below the mounting surface (for control head cables and connections).

Warning: Mount SmartCommand control heads at least 250 mm (9.84 in.) from compasses. If a safe mounting distance is not maintained, electromagnetic fields could influence SmartCommand electronic circuits, cause erratic operation, and possibly impair compass directions. Personal injury could result if this message is disregarded.

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• Tighten washers and nuts enough that they will not come loose during normal vibration. Since mounting surfaces vary, the exact torque depends on the application. When tightening, be careful not to damage the mounting surface or control head.

• See the following sections for connecting the cables and terminating resistors at the control head.

4.3.2 Control Head Wire Harnesses

Control Head wire harnesses connect the processor to the control head. Install one control head on each CAN bus before daisy chaining additional control heads. For more than two stations, daisy chain additional control heads to one of the first two. For ease of troubleshooting, ZF Marine Propulsion Systems Miramar recommends that odd-numbered control heads be placed on one CAN bus, and even-numbered control heads on the other, although it is possible to assign any control head any number.

Install connections from the port and starboard processors to the same side on each of the control heads. For example, install the processor to control head cable from the starboard processor to the starboard side of the control head at Station 1. Do not install starboard processor connections on the port side of any control head.

4.3.3 Cable Connection

For the first two control heads installed, use the control head-to-processor wire harness (PN 70269-XX) between the processor and each control head. This wire harness has a Deutsch connector at the processor end and a Turck connector at the control head end.

In a typical installation, Station A on both processors connects to the control head at Station One. Station B on both processors connects to the control head at Station Two. See section 13: Appendix C - System Drawings for a detailed system drawing showing connections.

4.3.3.1 Connecting the First Two Control Heads to the Processor

All control head to processor wire harnesses have a Deutsch pluggable connector on the processor end and a screw type connector at the control head end. Install a separate wire harness between the processor and the first two control heads in each CAN bus receptacle.

Label each wire harness at both ends with the station it connects. Label Port and Starboard.

Support the wire harness using clamps or straps 18 inches (0.5m) apart or closer, unless it is contained in a conduit. Refer to ABYC Standard E-11.

Install each wire harness so it is protected from physical damage.

Warning: Do not open the control head. If you do, the warranty is voided. Control heads contain no user serviceable parts, and ZF Marine Propulsion Systems Miramar cannot guarantee the operation of a unit once it has been opened. Damage to the equipment may occur if this message is disregarded.

Figure 4-6: Deutsch Connector on 70269 Wire Harness

Figure 4-7: Turck Connector on 70269 Wire Harness

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See section 4.3.3: Cable Connection for cable connection at the control head.

4.3.3.2 Connecting Control Heads After the First Two

All control head to control head cables have screw type connectors at both ends. Install a Control Head to Control Head Wire Harness (P/N 70268-XX) between the control heads on each CAN bus.

Label each wire harness at both ends with the station it connects. Label Port and Starboard.

Support the wire harness using clamps or straps 18 inches (0.5m) apart or closer, unless it is contained in a conduit. Refer to ABYC Standard E-11.

Install each wire harness so it is protected from physical damage.

See section 13: Appendix C - System Drawings for wire harness connections at the control head. Figure 4-8: Daisy Chaining Control Heads shows an example chain for control heads One and Three. Connections to the port processor are always on the port side of the control head. Connections to the starboard processor are always on the starboard side.

Figure 4-8: Daisy Chaining Control Heads

Table 4-6: Connections Between Control Heads

ID Description ID Description

A Port Processor (Connection to Sta. A) E Port Connections to Control Head 3 (Sta. A)

B Port Processor (Connection to Sta. B) F Starboard Connections to Control Head 3 (Sta. B)

C Starboard Processor (Connection to Sta. A) G Terminating Resistors

D Starboard Processor (Connection to Sta. B) H Serial (CAN bus) Connection Between Processors

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Use Control Head-to-Control Head wire harnesses (PN 70268-XX) for a system with more than two control heads. Install termination resistors at the last station in the daisy chain.

4.3.4 Termination Resistor

There are four connectors on each control head. Two are used to communicate to the processor or to other control heads closer to the processor, and two are used to communicate with higher numbered control heads in a chain. Install a termination resistors (PN 70389) on the open screw type terminal on the control head at the end of a chain. For installations with one or two control heads, install termination resistors on the open terminals. For installations with one control head and two processors, install two termination resistors, one for the port side and the other for the starboard side. For installations with two processors and two or more control heads, install four termination resistors, two at the control head at the end of the Station A bus, and two at the control head at the end of the Station B bus.

4.4 SynchronizationSmartCommand uses Equal Throttle Synchronization by default. The processors send equal throttle command signals to both governors when the levers are in the synchronization range. (See section 2.10: Twin Screw Synchronization) In most cases, Equal Throttle Synchronization is very effective. For engine RPM synchronization, select Active Synchronization at processor at set-up time (refer to the E7 Function Code in section 5: Set Up Procedures). Active Synchronization requires a tachometer signal representing the RPM of each engine, in addition to the throttle command signal. The function provides for the tachometer frequency to be measured and the throttle command signal outputs to be changed until both engines are running at the same RPM, as measured by the tachometer signals.

4.4.1 Serial Communication Wire Harness (Required)

The processors must be connected with a serial communication wire harness (P/N 70261). Refer to information and drawings in section 10: Troubleshooting. A serial communication harness has on both ends of the cable.

Remove the SERIAL plug-in cap from all processors and discard.

Insert the serial wire harness plug into the SERIAL connector on one of the processors.

Run the harness cable to the next processor and plug into the SERIAL connector there.

4.4.2 Tachometer Sensors (Active Synchronization Only)

Tachometer sensors must meet specifications described in section 3.6: Tachometer Connection.

4.4.3 Tachometer Sensor Wire Harness (Active Synchronization Only)

This harness has plugs on both ends of the cable. The plug on the sensor side is designed to mate with tachometer assemblies supplied by ZF Marine Propulsion Systems Miramar.

Remove the TACH connector cap from the processor and discard.

Insert the Tachometer Sensor Wire Harness plug in the TACH connector on the processor.

Run the Port Tachometer Sensor Cable to the Port engine tachometer source.

Run the Starboard Tachometer Sensor Cable to the Starboard engine tachometer source.

Make tachometer cable connections as instructed by the engine manufacturer’s documentation.

NOTE: Connect the wire harness with care, making certain that the two eight-pin connectors are correct — it is possible to install them with the keyways reversed. For example, the connectors on the ZF CAN 1 and serial wire harness with a green C-key connector (PN DT06-8SC-CE01), and a gray A-key connector (PN DT06-8SA-CE01) could be installed backwards if close attention is not paid.

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INSTALLATION



4.5 Main Engine Speed Control - Throttle Harness

The processors connect directly to the engine interface using a Throttle Wire Harness. Refer to section 10: Troubleshooting to select the correct Throttle Wire Harness for the engine signal required.

Connect the plug end of the Throttle Wire Harness into the THROTTLE connector at the processor.

Run the cable to the engine interface.

Refer to the engine documentation for termination points at the engine interface.

4.6 Clutch and Troll ControlThe Clutch and Troll Harnesses have single plugs on the processor end of the cable.

The Clutch Harness has two cables extending from the plug:

One for Ahead Clutch solenoid

One for the Astern Clutch solenoid

Insert the harness plug into the CLUTCH plug-in on the processor cover.

Run the two cables labeled Ahead and Astern Clutch to the transmission.

Refer to the transmission documentation for termination points at the clutch solenoids.

4.6.1 Tachometer Sensors (Required for AutoTroll and EasiDock)

Tachometer sensors must meet specifications in section 3.6: Tachometer Connection.

4.6.2 Tachometer Sensor Wire Harness (Required for AutoTroll and EasiDock)

This harness has plugs on both ends of the cable. The plug on the sensor side is designed to mate with tachometer assemblies supplied by ZF Marine Propulsion Systems Miramar.

Remove the TACH connector cap from the processor and discard.

Insert the Tachometer Sensor Wire Harness plug in the TACH connector on the processor.

Run the Port Tachometer Sensor Cable to the Port engine tachometer source.

Run the Starboard Tachometer Sensor Cable to the Starboard engine tachometer source.

Make tachometer cable connections as instructed by the engine manufacturer’s documentation.

NOTE: Set up all processors with the same Wire Harness and Engine Set Up selections

CAUTION: For ZF Hurth Gears with Two Proportional Solenoids Only: The maximum current to ZF Hurth solenoids must be limited by the control system. Set up the processor values before connecting the cable from the processor to the gear box. If the processor is connected to the gear box before values are assigned, the solenoids can be permanently damaged.

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4.6.3 Clutch and AutoTroll and EasiDock Control

The Clutch/Troll Harness has three or more of the following cables extending from the plug:

One for the Troll Command solenoid

One for the Troll ON/OFF solenoid

One for Neutral Clutch solenoid

One for Ahead Clutch solenoid

One for the Astern Clutch solenoid

Insert the harness plug into the CLUTCH connector on the processor.

Run the two cables labeled Troll Command and Troll ON/OFF to the transmission.

Refer to the transmission documentation for termination points at the troll solenoids.

Run the three cables labeled Ahead, Neutral, and Astern Clutch to the transmission.

4.7 Engine Stop SwitchThe installer must supply the stop switches. Refer to the information supplied with the stop switches and engine for installation.

NOTE: Some transmissions do not use an On/Off standard.

WARNING: It is important that each control station have a method, independent of SmartCommand, for stopping the engines. Refer to the Code of Federal Regulations (CFR) 46, 62.35-5 and the American Boat and Yacht Council (ABYC) standards on electric and electronic propulsion control systems (P-24.5.8). Personal Injury may result if this message is disregarded.

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MMSC5000 SmartCommand User ManualSet Up Procedures

5 Set Up ProceduresSet up procedures apply to all combinations of required and optional features. The vessel may have all, some, or none of the optional features. For each vessel, refer to sections that apply to options installed.

Each SmartCommand processor has several functions that must be prepared for an application. Assign Function Code values only after reading each function set up thoroughly.

5.1 Processor Components Used in Set UpEach SmartCommand Processor has an LED display and four arrow push buttons. (Figure 5-1: Processor Display and Arrow Push Buttons)

The LED display has four seven-segment LEDs for showing Function Codes and Values.

Use the arrow push buttons to scroll displays and select Function Codes.

Figure 5-1: Processor Display and Arrow Push Buttons

At first power-up the processor displays four dashes, blinking concurrently, indicating that no control heads have assigned station IDs. (If any control heads do have assigned IDs, the display is in normal operating condition, with the digits 5000 flashing sequentially.)

The two left pads are used for the Function Code in set-up or function displays. The two right pads are used for entering or displaying the numeric value of the Function Code. A decimal indicator is located on the bottom right corner of each pad. (See Figure 5-2: Processor Display and Push Buttons) Use the arrow push buttons on the processor(s) to scroll through and select Function Codes. Once you have selected a Function Code, use the arrow keys to scroll through, modify, and select values.

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Figure 5-2: Processor Display and Push Buttons

Table 5-1: Push Button Keys in Normal Operating Mode

Key Action Result

UP ARROW or DOWN ARROW

Press UP ARROW or DOWN ARROW once. Activate Function Menu.

Table 5-2: Push Buttons in Function Menu (Function Code LED’s are illuminated steadily)

Key Action Result


Press UP ARROW or DOWN ARROW. Scroll the Function displayed.

LEFT ARROW and RIGHT ARROW

Press LEFT ARROW and RIGHT ARROW simultaneously and hold for two seconds.

For H0, first two pads blink. Use DOWN ARROW to view diagnostic values.All functions except H0: Function Code LEDs blink if the PIN was entered earlier. Enter Set Up mode.PIn? prompt appears if PIN not entered yet.

Left Arrow Press LEFT ARROW and hold for one second. Stored Error Codes Display.

Right Arrow Press and hold.For Function Codes with values to the right of the decimal point, displays the complete Function Code value so you can see all the digits.

Table 5-3: Push Buttons in Set Up Mode (Function Code LED’s are blinking)

Key Action Result


Press UP ARROW or DOWN ARROW. Scroll through Function Codes.

LEFT ARROW and RIGHT ARROW

Press LEFT ARROW and RIGHT ARROW simultaneously and hold for two seconds.

Save Value: Function Code LEDs stop blinking. Exit Set Up mode.

Left Arrow Press LEFT ARROW and hold for one second. Escape: Exit set up mode without changes. Function Code LEDs stop blinking.

Right Arrow Press and hold.For Function Codes with values to the right of the decimal point, displays the complete Function Code value so you can see all the digits.

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The part number (the digits 5000, flashing sequentially) does not appear immediately after set up exits. It reappears five minutes after the last key press. The part number also appears when power is cycled.

5.2 Activating Set Up Mode

At first power up, the processor displays four dashes, blinking concurrently:

Figure 5-3: Control Head ID’s Not Set

The blinking dash display indicates that no control heads are assigned station IDs. If any control heads are assigned station IDs, the display is in Normal Operating Condition (digits 5000, flashing sequentially).

Figure 5-4: Display Normal Operating Condition

Table 5-4: Push Buttons at Password Prompt (PIn? Appears on display)

Key Action Result

N/A No Key presses, just wait. A single blinking dash displays on the left most LED pad.

Table 5-5: Push Buttons for PIN Entry

Key Action Result

Left Arrow Press and hold LEFT ARROW. Escape PIN entry.

Up Arrow Press UP ARROW. Digit on display increments.

Right Arrow Press RIGHT ARROW. Next digit to the right can be programmed.

Table 5-6: Push Buttons In Error Code Display (’Er’ shows in Function Code)

Key Action Result


Press either UP ARROW or DOWN ARROW. Scroll through the error messages.

Right Arrow Press and Hold for one second. Clears error if it has been resolved. If there is more than one error, press and hold for each error. Only resolved errors clear.

NOTE: To exit set-up mode, press and hold the right and left arrows simultaneously for one second, always making sure to press the right arrow first. If you press the left arrow first, it is possible that the newly-entered values will not be saved.

NOTE: To escape from the set up procedure, press the LEFT ARROW Push Button and hold it for approximately one second. The Function Code stops flashing and the Function value is the original, saved value. You can escape at any time.

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To start setting the vessel’s functions:

1. Press the up arrow or down arrow. The Function Menu activates.2. Press the up arrow or down arrow. The Function Menu scrolls through the Function Codes one at a time. 3. When the Function Code you want to change is visible on the display, press the right arrow and left arrow Push

Buttons simultaneously and hold them for approximately two seconds.

Figure 5-5: Display Set Up Activated4. The PIn? prompt appears.5. A second or two later, the PIn? prompt changes to a blinking dash in the left most LED pad.

Figure 5-6: Enter PIN6. To set each digit of the password:

• Press the “Up” arrow once. The number “1” will appear on the first LED.• Press the “Right” arrow once. A dash will appear at the second LED.• Press the “Down” arrow once. The number “9” will appear on the second LED• Press the “Right” arrow once. A dash will appear on the third LED.• Press the “Down” arrow twice. The number “8” will appear on the third LED.• Press the “Right” arrow once. A dash will appear on the fourth LED.• Press the “Down” arrow three times. The number “7” will appear on the fourth LED.

This is the PIN for all processors at the first release. After you enter the last digit, press the right arrow.

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1. The Function Code appears. The left two pads blink. Setup mode is activated

Figure 5-7: Change the Value of the Function Code2. Press the up arrow or down arrow push buttons to change the value of the function. (Keep pressing to scroll

through the values quickly.)3. Press the up arrow or down arrow while holding the right arrow down at the same time to move through the

values more slowly. 4. When the value you want displays, store it. Press the right arrow and left arrow simultaneously and hold until

the Display Function Code stops blinking. The value is stored in memory.5. You can continue to change values without re-entering the PIN. After five minutes with no button presses, re-

enter the PIN to change a Function Code value.6. Press the up arrow or down arrow push buttons to scroll through the Function Codes.

5.3 Set Up Functions & ValuesSee ENG-289 Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems for a list of Function Codes, each defined by application, function name, default value, and range.

5.4 System Function Codes (Required) Set the A1, A0, and A2 Function Codes first. A3 is set when you identify the control heads. You can set the value for the A4 - Neutral Indication Tone Function Code at setup, but it is not necessary.

5.4.1 A0 — Processor Identification

SmartCommand must identify which processor controls which screw, so processors must have a unique identifying number. Two processors can never have the same Processor Identification Number. The values of this Function are 01 (Default Value), and 02. Set this Function Code value and the value of A1 before any other Function Code values are set. Set the values to 01 for Port and 02 for Starboard. To change the value of the function, press LEFT ARROW and RIGHT ARROW simultaneously and hold for two seconds to enter set up mode. The PIn? prompt appears: enter the PIN as shown in section 5.2: Activating Set Up Mode. Set the value of the function depending on the processor you are programming.

5.4.2 A1 — Number of Engines

The total number of screws must be entered into the memory of every processor. The same value must be entered in every processor on a vessel. The default value for this function is 02 Twin Screw (Default Value). Confirm that this value is correct. To change the value of the function the processor, press Left Arrow and Right Arrow simultaneously and hold for two seconds to enter set up mode. Press Up Arrow or Down Arrow to increment or

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decrement the value as required. Press Right Arrow and Left Arrow simultaneously and hold for two seconds to save the new value.

5.5 Assigning Station IDsPowering the processors also powers all the control heads. Do not take control at any control head until station IDs are assigned. Control stations cannot accept control before A0 and A1 are assigned.

At the first power up, all control heads sound a one-second tone and all six LED’s flash. After you set the values for the A0 and A1 Function Codes, confirm that A3 shows that zero stations are assigned. Go to any station. Press Control/Set until the Control LEDs are the only LEDs illuminated. Station One is assigned. Go to each of the other control heads in the order you want to assign the station IDs. (See your notes from Figure 3-5: System Installation Diagram and Table 3-4: Control Stations. Press Control/Set at each station until the AutoTroll, EasiDock, Warm Up, and One Lever LEDs extinguish. At both processors, the value of A3 increments when each station ID is defined.

After all station IDs are assigned, the display at power up changes to the digits shown below, flashing sequentially from left to right.

When you are in the Function Menu (Function Code illuminated steadily), the A3 (Number of Control Stations) Function Code displays the number of stations that are set up.

5.5.1 Renumbering Station IDs

There is usually no need to renumber the station IDs. However, if you have replaced a processor, control head, or otherwise changed the hardware setup, it may be necessary. Power down the system and repower it. It is not possible to change station IDs after any station has taken control.At both processors, verify that A0 and A1 are set correctly. Scroll to the A3 Function Code and press the left and right arrows simultaneously; hold for two seconds to enter set up mode. The Function Code blinks or the PIn? prompt appears. Enter the PIN if necessary; the first station ID appears.

IMPORTANT: The A0 and A1 values must be set before any other Function Code values are set.

CAUTION: If ZF Hurth gears with two proportional solenoids are installed, set the value for the J0 Function Code immediately after setting the A0 Function Code. (See section 5.11: Troll Functions) The clutch solenoids can be damaged by over current if this value is not set.

WARNING: Follow the complete procedure in this section if you replace or add processors or control heads. One or both control head levers on some or all stations could become nonresponsive.

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Press the left and right arrows and hold until the station ID disappears and you exit set up mode for the A3 function. This deletes the station ID and the number of stations decrements automatically. Release the buttons. Repeat for each station ID. The PIn? prompt stops appearing after the first time.

Once all the station IDs are removed, take control at each control head in the order you want to renumber the stations.

5.5.2 Deleting a Station

Power down the system and disconnect the control head. Reconnect the remaining control heads, adding or moving terminating resistors as necessary. Power up the system. Do not take control at any control head. At both processors, scroll through the Function Codes to A3. Press Left Arrow and Right Arrow simultaneously and hold for two seconds to enter set up mode. The Function Code blinks or the PIn? prompt appears. If required, enter the PIN, and the first station ID appears. When the processor is in setup mode (Function Code blinking), A3 shows the assigned station IDs.Press Left Arrow and Right Arrow and hold until the station ID disappears and you exit set up mode for the A3 function. This station ID is deleted. Repeat for all station IDs on both processors.

After you have removed all the station IDs, take control at each control head in the order you want.

5.5.3 Adding a Station

To add a station later, remove power, install the control head, add all the cables and terminating resistors, and power up the processors. The new station sounds a tone and all six LEDs flash. Press Control/Set at the new control head until the Control LEDs illuminate and the tone stops. The control head is assigned the first unused station number.

5.6 One Lever Mode (System Function Code A2)

One Lever Mode allows a single control head lever to command all engines and gears at the same speed and direction. The values of this function are 00 Disable and 01 Option 1, and 02 Option 2 (Default Value). After one lever mode is set at the processor, you can select it at the active control head. Option 1 and Option 2 enter and exit One Lever Mode in different ways; vessel operation is the same in both modes. See section 2.11: One Lever Operation Mode for operations information.

5.7 JMS Station Pairing (System Function Code A7)

JMS Station Pairing, A7, serves two purposes. The first is to enable communication between the JMS Maneuvering Control Unit (MCU) and the SmartCommand system. The second is to establish the pairing method that will be used between the JMS operation and the SmartCommand control head. The values of

IMPORTANT: Verify that you have deleted all the station IDs on both processors. If a control head is assigned two different station IDs, it will not operate correctly.

IMPORTANT: Make certain that you delete all the station IDs on both processors. If a control head is assigned two different station IDs, it will not operate correctly.

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this function are: 00 - No JMS (Default Value), 01 – JMS Split Pairing, and 02 - JMS Full Pairing. See MMMCU5000 Joystick Maneuvering System Installation, Operation & Troubleshooting Manual for further information regarding the JMS control system.

5.8 Engine Function CodesSet values for Function Codes E0 and E7 at set up.

Set values for the following functions at dock trials and sea trials.

For standard throttle signal applications:

• E1 - Throttle in Neutral• E2 - Throttle Minimum• E3 - Throttle Maximum• E4 - Throttle Maximum Astern• E5 - Throttle Pause Following Shift• E6 - High Idle

For Dual Throttle voltage applications:

• e1 Dual Voltage (V2) throttle in Neutral• e2 Dual Throttle (V2) Minimum• e3 Dual Throttle (V2) Maximum

5.8.1 E0 — Select Engine Throttle Profile

Engine manufacturers use different electronic interfaces to command engine speed. Enter the engine type so the correct signals are sent to the specific type of engine in the vessel. The Engine Throttle Profile, in combination with the Throttle Harness type, configures the throttle output profile to meet the specifications of engines from different manufacturers in specific configurations. The values of this function are:

IMPORTANT: For JMS MCU software versions 71333.0E and earlier, A7 should be set to the type of pairing that is desired to be used when the JMS system is operational.

For JMS MCU software versions 71333.1A and later the type of pairing is set by the JMS AutoCommissioning tool; therefore, A0 must always be set to 02 – JMS Full Pairing.

Table 5-7: Engine Throttle Profile Definitions

E0 Value Engine Type

01 Caterpillar (PWM) (8 to 92%)

02 Cummins Centry (Voltage) (0.9 to 4.5VDC)

03 Cummins Quantum (Voltage) (0.9 to 1.2- 4.0VDC)

04 Detroit Diesel (Voltage) (0.64 to 4.65 VDC)

05 MTU or MAN (Current) (4.0 to 20 mA)

06 Scania (Voltage) (0.4 to 2.95 VDC)

07 John Deere (Voltage) (0.5 to 4.5 VDC) EDC Only

08 Volvo EDC Engines (Voltage) (0.6 to 3.6 VDC) Volvo EVC Engines use a different voltage.

09 Detroit Diesel (Frequency) (120.64 to 360.9 Hz)

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5.8.2 E7 — Active Synchronization

SmartCommand uses Active Synchronization by default. If the tachometer signal is not available, the system automatically uses Equal Throttle Synchronization.Equal Throttle Synchronization is very effective in most cases. The processors send equal throttle command signals to both governors when synchronization criteria are met but the RPM rates of the engines do not necessarily match. For additional information about synchronization, see section 2.10: Twin Screw Synchronization.If you want the RPM of the engines to match, select Active Synchronization at the processor. In addition to the throttle command signal, Active Synchronization requires a tachometer signal representing the RPM of each engine. The tachometer frequency is measured and the throttle command signal outputs are changed until the frequencies of the tachometer signals are the same (in other words, both engines are running at the same RPM). The values of this function are 00 (equal throttle synchronization enabled - this is the default), 01 (Active Synchronization enabled with equal throttle if tach signal fails), 02 (disabled), and 03 (Active Synchronization enabled with no synchronization if the tach signal fails).

5.8.3 E8 Initialization Type

The Function Code E8 allows the SmartCommand control system to be automatically activated in the “Warm Up” mode upon initially energizing and taking command at a control station. The values of this Function Code are: 00 – Cruise Mode at power up (Default) and 01 – Warm up mode at power up.

10 Detroit Diesel (Frequency) (120.64 to 463.5 Hz)

11 J1939 Throttle output on J6 Yanmar Engine (CAN Eng)

12 CANBus Output (VW Electronic Engines Only)

13 Fiat 450 (CAN Eng)

14 Fiat 560 (CAN Eng)

30CMD (Voltage) Output V1(0.75 to 3.8 VDC)

CMD (Voltage) Output V2 (0.38 to 1.9 VDC)

40Inmar (Voltage) Output V1(0.8 to 4.2 VDC)

Inmar (Voltage) Output V2 (4.2 to 0.8 VDC)

41Crusader (Voltage) Output V1 (0.48 to 4.65 VDC)

Crusader (Voltage) Output V2 (0.2 to 2.33 VDC)

Table 5-7: Engine Throttle Profile Definitions

E0 Value Engine Type

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5.9 Clutch Function Codes

5.9.1 C0 — Clutch Oil Pressure Interlock

The C0 Function Code indicates to the processor whether or not a clutch oil pressure switch is in use and how it is being used. The primary function of a clutch oil pressure switch is to protect the clutch pack (damage to which could be very costly). The clutch oil pressure switch commands the throttle to idle if full pressure is not reached, or pressure is lost, when ahead or astern clutch engagement is commanded. The values of this function are:

• 00 -- Not Installed (Default)• 01 -- Installed• 02 -- Throttle Clutch Pressure Interlock Mode

When this Function Code is set, the value most likely to be used is 02. When C0 is set to 02, the throttle will remain in idle until it recognizes that the oil pressure switch has been closed.

5.9.2 C1 — Clutch Oil Pressure Interlock Delay

The clutch oil interlock delay prevents drops in throttle when gear oil pressure fluctuates. The system responds to the low pressure by reducing the throttle command signal to idle. Used in conjunction with the clutch oil interlock function (Function Code C0), the value entered for the C1 function determines how quickly the system responds to low gear oil pressure. If the C0 value is 01, the C1 Function Code setting indicates the period of time the system will wait until it actually looks at the status of the clutch oil pressure switch. (For example, if the value of C1 is 3.0 the system will wait 3 seconds before dropping the throttle command signal to idle.)If the value of C0 is 02, the C1 Function Code setting indicates the amount of time that must pass with the switch open before the throttle will be pulled back to idle. The C1 Function Code can be set from 0.5 to 10 seconds, in increments of 0.1 (one tenth) second. The default Value is set to 01.0 second delay.

IMPORTANT: Set the value of this function to 01 (INSTALLED) only if the optional clutch oil pressure switch is used with this application.

IMPORTANT: The clutch oil pressure interlock delay C1 Function Code is operable only if the optional clutch oil pressure switch, Function Code C0, is set to 01 or 02, as explained below. If C0 is set to the default of 00, a C1 Function Code setting will have no effect.

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5.9.3 C2 — Reversal Pause

If you reverse the direction of the vessel, there is a pause before the opposite clutch command signal takes effect. This pause allows time for the engine RPM to drop to idle and for the vessel to slow through the water. The C2 function determines when this pause occurs -- either while the clutch is engaged or in neutral. In general, you would use in-gear delay to allow the propeller to slow vessel progress through the water, but neutral delay if the vessel has shaft brakes. The three values the C2 Function Code can be set to are 00 (in gear -- this is the default), 01 (neutral), and 02 (fixed neutral). The sequence of events depends on the value set, as described below. In-Gear Delay (00):

• Throttle drops to idle.• Transmission remains engaged in ahead or astern.• Control system pauses for the duration of the pause.• Transmission shifts into the opposite gear.• Throttle changes to match the control head lever position.

.

Neutral Delay (01):• Throttle drops to idle.• Transmission shifts to Neutral.• Control system pauses for the duration of the pause.• Transmission shifts into the opposite gear.• Throttle changes to match the control head lever position.

Fixed Neutral (02): • Throttle drops to idle.• Transmission shifts to Neutral.• Control system pauses for the duration programmed in Function Code C3 Reversal Pause

Time. The delay is not proportional.• Transmission shifts into the opposite gear.• Throttle changes to match the control head lever position.

IMPORTANT: If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), full throttle is limited for the first two seconds the opposite gear is engaged.

CAUTION: Fixed Neutral Delay is used for Thruster Control installations. The drive train can be damaged if it is used in reverse reduction gear applications, or reversal time can be reduced unduly.

IMPORTANT: If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), full throttle is limited for the first two seconds the opposite gear is engaged.

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5.9.4 C3 — Reversal Pause Time

After you command a Full Speed Reversal, the Reversal Pause Time feature decelerates the engine and pauses before throttling to the commanded speed in the opposite direction when C2 is set to 00 or 01. The pause time is proportional to the percent throttle commanded and the length of time it has been commanded.For the system to pause for the full duration specified in the C3 Function Code, the vessel must be at full throttle and ahead, and have remained at this setting for at least six times the duration of the pause value. If the vessel is at a lower throttle setting or has been at speed for less than six times the duration of the pause value, the pause is shorter. The pause may be shorter for astern to ahead maneuvers, depending on the value of C4.The throttle position drops to Idle and the transmission remains engaged or shifts to neutral, depending on the value of the C2 function.The limits for this function are 00.0 to 16.0 seconds. Adjust this function during sea trials. You must have instruction to determine the correct setting.Default Value is set to 03.0 second pause.

5.9.5 C4 — Reversal Pause Ratio

00 - 2:1 Ratio

This is the default setting and determines how the value set in the Reversal Pause Time (C3) Function is applied for astern to ahead maneuvers. If the C4 Function Code is set to the 00 value, an astern to ahead maneuver is one half of the Reversal Pause Time. This is the typical selection, since most vessels do not reach the same throttle in astern as they do in ahead. The duration to slow to a sufficient water speed for a safe reversal is significantly faster.

01- 1:1 Ratio

A 01 value for the C4 function sets the same pause time for ahead to astern maneuvers and astern to ahead maneuvers. Choose this value for vessels that reach the same water speed in both directions, for example, a Double Ended Ferry or Bow or Stern Thruster control.

The values of this Function are 00 2:1 (Default Value) and 01 1:1.

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5.9.6 C5 — Shift Solenoid Type

This Function Code must be set to 00, unless a ZF Hurth gear with proportional ahead and astern solenoids is installed. The current is limited to the solenoids when the 01 or 02 values are selected.

00 - All shift solenoids except ZF Hurth (Default)

01 - ZF Hurth Gears with two proportional solenoids using 12 VDC power

02 - ZF Hurth Gears with two proportional solenoids using 24 VDC power

5.9.7 C6 — ZF Hurth Duty Cycle Ahead

This Function Code adjusts the maximum current available to the ahead proportional solenoid. Failure to limit the current may result in permanent damage to the solenoid. The values available are 0% to 100.0% duty cycle. The default value is 100%. Do not change the value of this function unless directed to do so by ZF Marine Propulsion Systems Miramar.

5.9.8 C7 — ZF Hurth Duty Cycle Astern

This Function Code adjusts the maximum current available to the Astern proportional solenoid. Failure to limit the current may result in permanent damage to the solenoid. The values available are 0% to 100.0% duty cycle. The default value is 100%. Do not change the value of this function unless directed to do so by ZF Marine Propulsion Systems Miramar.

5.9.9 C8 — Fixed Neutral Delay

Only use C8 when C2 is set to 00 or 01, that is, when the vessel uses a proportional delay. C8 programs in a delay time in addition to the proportional delay.

CAUTION: For ZF Hurth Gears with Two Proportional Solenoids Only: The maximum current to ZF Hurth proportional solenoids must be limited by the control system. Set up the processor values before connecting the cable from the processor to the gear box. If this value is not correct or the processor is connected to the gear box before the value is set up, the solenoids can be permanently damaged.

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5.10 Troll Functions (AutoTroll)At set up, set the L0 Function Code. At dock trials and sea trials, set the values for the Function Codes:

• L1 - Troll Minimum Pressure, • L2 - Troll Maximum Pressure, • L3 - Troll Throttle Limit, • L4 - Troll Pulse Duration, • L5 - Troll Pulse Percentage

5.10.1 L0 — Troll Lever Range

The troll lever range can be adjusted to one of five values at processor set up, through the L0 Function Code. The values for L0 are as shown below in Table 5-8: L0 Function Code Values

IMPORTANT: To configure a ZFF Transmission with MTCU, set J0 to a value of 08 first, then set L0 to the desired troll lever range. J1 through J7 are not accessible with this configuration.

Table 5-8: L0 Function Code Values

L0 Value Troll Range (in Degrees)

Movement between Ahead and Astern Detents

Movement through Troll Range Movement Beyond Troll Range

00 No Troll Clutch Fully Engaged, throttle at idle NA Clutch Fully Engaged, Neutral

to Full Throttle


Minimum to Maximum troll Clutch pressure, throttle at idle











05 Detents Only Minimum Troll Clutch pressure, throttle at idle

No Movement: Troll at Detents only.


NOTE: The default value for Function Code L0 is 00 (No Troll). If this function is set to 00, the other L Function Codes (meaning Troll) do not appear in the function menu.

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5.11 Troll FunctionsThe J Function Code values provide the processor the ability to control the trolling valve in a “closed loop” fashion, by allowing for the speed of the propeller (output shaft) to be continuously monitored. As information about the output shaft is fed to the processor, the signal to the valve can be altered as necessary so the vessel can maintain a constant propeller speed while the commanded mode is AUTOTROLL or EASIDOCK.

Generally speaking, the only two of the eight J Function Codes that require programming at system installation time are J0 and J1. The J2 through J7 values are automatically assigned as a result of the troll valve type entered into J0.

5.11.1 J0 — Trolling Valve Function

This function determines the behavior of the current signal to the proportional valve. The default value is 00.When the value of J0 is set to 08, no other J Function Codes can be displayed.Using definitions from Table 5-9: Trolling Valve Type Selection determine what value to choose for a particular application. After selecting the appropriate value, enter your selection for Function Code J0 on the processor.

NOTE: Set the J2 through J7 Function Codes only if you are instructed to do so by ZF Marine Propulsion Systems Miramar. If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), the J1 through J7 functions are not displayed.

Table 5-9: Trolling Valve Type Selection

Value Selection and Definition

00Normal - no current when off. The current to the proportional valve increases as clutch pressure increases. When full pressure (lockup) is reached, the current to the valve drops to zero. This is the default value. Preset for generic 10 - 25% duty cycle.

01Inverse - no current when off. The current to the proportional valve decreases as clutch pressure rises. When full pressure (lockup) is reached, the current increases to maximum. Preset for generic 10 - 25% duty cycle.

02

Normal - no current when off. The current to the proportional valve increases as clutch pressure rises. When full pressure (lockup) is reached, the current to the valve drops to zero. Preset for ZF Padova 220 - 665 12 VDC Systems. All values assume 12V/10 Ohm proportional solenoid. New or upgraded transmissions only.

03

Normal - no current when off. The current to the proportional valve increases as clutch pressure rises. When full pressure (lockup) is reached, the current to the valve drops to zero.Preset for ZF Padova 220 - 665 24 VDC Systems. All values assume 12V/10 Ohm proportional solenoid. New or upgraded transmissions only.

04Normal - no current when off. The current to the proportional valve increases as clutch pressure rises. When full pressure (lockup) is reached, the current to the valve drops to zero.Preset for ZF 2000, 24 VDC systems

05Inverse - no current when off. The current to the proportional valve decreases as clutch pressure rises. When full pressure (lockup) is reached, the current increases to maximum.Preset for ZF 1900 and 2500 24 VDC systems.

06 Preset for 12 VDC ZF Hurth transmissions with two (2) proportional solenoids only. ZF Hurth with one (1) proportional solenoid, use 00.

07 Preset for 24 VDC ZF Hurth transmissions with two (2) proportional solenoids only. ZF Hurth with one (1) proportional solenoid, use 00.

08 Preset for ZF Friedrichshafen transmissions with MTCU (Marine Transmission Control Unit).

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5.11.2 J1 — Idle Lockup RPM

The value for J1 is actually the frequency of the signal being generated by the output shaft sensor (Tach 2), when the engine is running at idle and the ahead clutch is engaged. Determine the value for J1 by using the H0 diagnostics function (refer to section 10: Troubleshooting for detailed diagnostic information), during a sea trial, or calculate the value using the following information:

1. Engine RPM @ idle = ________________________2. Reduction ratio = _______________________3. Number of pulses per revolution (PPR) = ________________________

Following is an example of the way to calculate the frequency of the Tach 2 signal:1. Engines RPM @ idle = 6002. Reduction ratio = 2:13. PPR = 604. Multiply engine RPM by the reduction ratio times the PPR:600 x .50 x 60 = 18000 pulses per minute

(PPM)5. To convert the PPM to pulses per second (Hz), divide by 60:18000 / 60 = 300 Hz.

Enter 300 as the value for the J1 Function Code. (Remember that you can see values greater than two digits by pressing and holding the right arrow key down, which dedicates all four LEDs to the value.) If the J0 Function Code has been set to 08, no entry for the value of the J1 Function Code is required.

5.11.3 J2 — Minimum Troll Lockup RPM

The default value for the J2 Function Code is 30. This value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar.The value entered for J2 determines the frequency of the output shaft when it is at minimum pressure during trolling. At the default 30 setting, the output shaft will rotate at 30% the value of the J1 Function Code setting. If J1 is set to 300 and J2 is set to 30, the processor will maintain an output frequency of 90 Hz (300 x .30) while at minimum pressure. This frequency represents a speed that is 30% of full clutch engagement.

IMPORTANT: If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), throttle is limited for the first two seconds after clutch engagement is commanded, to prevent clutch damage. In Cruise mode, the throttle pause following a shift (E5 Function Code value) is increased to 0.9 seconds and throttle in the subsequent 1.1 seconds is limited to a 15% increase. In AutoTroll or EasiDock, when lever command leaves the troll range, in the subsequent two seconds throttle is limited to a 15% increase.

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5.11.4 J3 — Maximum Troll Lockup RPM

The default value for the J3 Function Code is 70. This value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar.The value entered for J3 determines the frequency of the output shaft when it is at maximum pressure during trolling. At the default 70 setting, the output shaft will rotate at 70% the value of the J1 Function Code setting. If J1 is set to 300 and J3 is set to 70, the processor will maintain an output frequency of 210 Hz (300 x .70) while at maximum pressure. This frequency represents a speed that is 70% of full clutch engagement.

5.11.5 J4 — Troll Range

The default value for the J4 Function Code is 00.0. This value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar.The value entered for J4 determines how closely the processor should attempt to reach the frequencies set by the J2 and J3 Function Codes (tolerances). When J4 remains at the default value of 00.0, the processor will constantly adjust the output signal to the proportional valve until the frequency determined by J2 or J3 is matched.

5.11.6 J5 — Troll Time-out

The default value for the J5 Function Code is 00.3. This value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar.The value entered for J5 determines how often the processor measures the speed of the output shaft to compare the actual speed to the expected speed (refresh rate). If the expected and actual speeds don’t match, the signal to the proportional solenoid is increased or decreased as necessary.

5.11.7 J6 — Minimum Troll % PWM

The default value of the J6 Function Code varies, depending on the value set for the J0 Function Code. The J6 Function Code value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar. The J6 and J7 functions set the limitations for controlling a specific trolling valve, allowing the control system to lock quickly onto the required RPM. Table 5-10: J6 and J7 Values as Related to J0 below, lists the expected values for the J6 Function Code, as determined by the J0 setting.

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5.11.8 J7 — Maximum Troll % RPM

The default value of the J7 Function Code varies, depending on the value set for the J0 Function Code. The J7 Function Code value should not be changed, except at the direction of ZF Marine Propulsion Systems Miramar. Along with the J6 Function Code, J7 sets the limitations for controlling a specific trolling valve, allowing the control system to lock quickly onto the required RPM. The expected values for the J7 Function Code, as determined by the values set for J0, are shown in Table 5-10: J6 and J7 Values as Related to J0.

5.11.9 J8 — Automated Troll Setup Trigger and Monitor

The J8 Function Code initiates the process of the automated troll setup which will find the best minimum and maximum trolling settings (J6 & J7) by cycling the trolling valve throughout its range. During setup, the Function Code will sequence through several steps (00-07) while the automated troll process is occurring.

5.11.10 J9 — Automatic Troll Setup Maximum Time

Time for each step and sample to complete. This value is in seconds. The default value is set to 60 seconds, minimum 20 and Max 250 seconds.

5.11.11 JA — Automatic Troll Setup Samples Per Step

Number of samples per step. The default value is 3 samples per step, minimum 1 and Max 5 samples per step.

Table 5-10: J6 and J7 Values as Related to J0

J0 Value 00 01 02 03 04 05 06 07 08

J6 Value 10.0 30.0 17.0 08.0 10.0 30.0 05.0 10.0 --.--

J7 Value 25.0 10.0 24.0 11.5 30.0 10.0 10.0 20.0 --.--

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5.11.12 Jb — Automatic Troll Setup Deadband Window

Automatic Troll Setup Deadband Window, This parameter is used to increase or decrease the amount of deadband needed for the Automatic Troll Setup function to determine the correct Troll Frequency. The default is 2%, minimum 1% and maximum is 100%.

5.12 Docking Functions (EasiDock) The “d” Function Codes enable the use of EASIDOCK and provide for fine tuning of control system operations when EASIDOCK mode is being commanded. As evidenced by its name, EASIDOCK mode aids controlled maneuvering of a vessel in tightly constrained situations. Because the control system must know the actual speed of the propeller to perform the EASIDOCK operations, before the d Function Codes can be displayed and operable, the J0 (trolling valve function) and J1 (idle lockup RPM) Function Code values must first be entered.

Additional detailed information about EasiDock functions can be found in F-259 SmartCommand Sea Trial Report

5.12.1 d0 — Docking Lever Range

The d0 Function Code is used to enable EASIDOCK mode and to indicate the number of degrees past the ahead or astern detents that are dedicated for EASIDOCK adjustment. The default d0 Function Code value is 05, which allows for reduced thrust when control head levers are in the ahead or astern detents. Once a lever has been moved past the detent, full thrust and engine speed are available. The values for the d0 Function Code are shown in Table 5-11: d0 Function Code Values.

CAUTION: Although the EASIDOCK Function Codes provide similar versatility to the AUTOTROLL Function Codes, experience has shown that, in general, the EASIDOCK default values provide the best response. Use extreme caution when making any adjustments to the “d” Function Codes.

Table 5-11: d0 Function Code Values

d0 Docking Range (in Degrees)

Movement between Ahead and Astern Detents

Movement through Docking Range

Movement Beyond Docking Range

00 No Docking Clutch fully engaged, throttle at idle. N/A Clutch fully engaged, idle to full

throttle.

01 15 degrees Minimum docking clutch pressure, throttle at idle.

Minimum to maximum docking clutch pressure, throttle at idle.

Clutch fully engaged, idle to full throttle.



Clutch fully engaged, idle to full throttle.



Clutch fully engaged, idle to 75% of full throttle.



Clutch fully engaged, idle to 10% of full throttle.

05 Detent Only Minimum docking clutch pressure, throttle at idle. N/A Clutch fully engaged, idle to full

throttle.

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5.12.2 d1 — Docking Minimum Pressure

The d1 Function Code selects the percentage of the troll range, as specified by Function Codes J2 and J3, when a control head lever is in the ahead or astern detents. The default d1 Function Code value is 50.0. So, if normal propeller shaft RPM is 100, this setting will cause the propeller to rotate at 50 RPM when EASIDOCK mode is commanded.If too much thrust seems to be produced at this setting when the vessel is maneuvering in EASIDOCK mode, the d1 value should be decreased. (Conversely, if insufficient thrust is produced, increasing the d1 value will increase the thrust.)

5.12.3 d2 — Docking Maximum Pressure

The d2 Function Code determines the rotation of the propeller shaft when the control head lever is at the end of the EASIDOCK range. The default value for the d2 Function Code is 100.0. If Function Code d0 is set to the default of 05, the d2 Function Code value is irrelevant.

5.12.4 d3 — Docking Throttle Limit

The d3 Function Code allows the engine RPM to increase while the clutch pressure is increased from minimum to maximum. The default value of d3 is 00.0, which keeps the engine RPM at idle whenever EASIDOCK mode is commanded.The d3 Function Code has no effect when Function Code d0 is set to the default of 05.

5.12.5 d4 — Docking Pulse Duration

The default value of the d4 Function Code is 3.0 seconds. At this setting, when the control head lever is moved from neutral to ahead or astern, the processor sends a signal (determined by the d5 Function Code) to the proportional solenoid for three seconds. The signal is strong enough to cause clutch pressure to build to a high level before dropping to the lower pressure used during EASIDOCK. This initial pulse will be distinctly noticeable when you engage the ahead or astern clutch.

5.12.6 d5 — Docking Pulse Duration

The value of the d5 Function Code determines the strength of the signal that will be applied to the proportional solenoid when the control head lever is moved from neutral to ahead or astern.The default value of the d5 Function Code is 100% of the value set for Function Code J3. (See section 5.11.4: J3 — Maximum Troll Lockup RPM)

5.13 Diagnostic FunctionsUse Function Code H0, “Diagnostics,” at dock trials, sea trials, and during troubleshooting. Refer to section 10: Troubleshooting for detailed diagnostic information.

Function Code H1, “Reset Function Codes to Default Values,” is also for troubleshooting. Only authorized ZF personnel should use this Function Code.

IMPORTANT: Factory default Function Code settings are different from those supplied with customized kits. This means that if you reset Function Codes to their defaults, the kit presets will be overridden.

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ENG-289 Rev A 04/12 Page 81

ENG-289 Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems


Function Codes for SmartCommand, JMS, SBW, MCU and POD SystemsConfidentiality Protection Classification: Public

Integrity Protection Classification: NormalAvailability Protection Classification: Normal

Table of Contents

SmartCommand Function Codes .............................................................. page 82POD Function Codes................................................................................................. page 87Sport Fish Function Codes........................................................................................ page 89SteerCommand Function Codes ............................................................................... page 89Two Speed Function Codes ...................................................................................... page 91Speed Boost Function Codes.................................................................................... page 91

MCU Function Codes ................................................................................ page 91

Below is a list of Function Codes, each defined by application, function name, default value, and range. There is a place to enter data for Sea Trials, if you are not performing a Sea Trial please disregard these columns.

NOTE: The information contained within this document is ZF Proprietary and must NOT be duplicated and/or distributed, electronically or otherwise to any person or organization outside of ZF Marine without explicit permission from the ZF Marine Business Unit Manager or responsible department Manager.

Table ENG-289-1: Revision List


- 2/28/2012 Initial ReleaseA 04/09/12 Revised SteerCommand Table ENG-289-14

IMPORTANT: Factory default Function Code settings are different from settings supplied with customized kits. This means that if you reset Function Codes to their defaults, the kit presets will be overridden.

ZF Marine Propulsion Systems Miramar, LLC12125 Harbour Reach Dr Ste B

Mukilteo, WA 98275P - 425-583-1900F - 425-493-1569

www.zf.com

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SmartCommand Function CodesTable ENG-289-2: System Definition Functions (SmartCommand)

Function Code Function Name and Description Default

Value Value Range, or OptionsActual Setting

Port Starboard

A0 Processor Identification 00

01, 02 Each processor must have a unique ID number.This function must be the second function set.AUTOTROLL and WARM UP LEDs are illuminated RED before this value is set.

A1 Number of Engines 02 02 - Twin ScrewThis function must be the first function set.

A2 One Lever Operation 0200 - Disable01 - Option 102 - Option 2

A3 Number of Stations 00 00 - 06.

A4 Neutral Indication Tone 0100 - No Tone01 - Tone upon engaging neutral detent02 - Tone upon shifting to Neutral

A7 JMS Station Pairing 000 – No JMS01 – JMS, Split Pairing02 – JMS, Full Pairing

A8 Number of Joystick Stations (Open Loop Only) 00 00 - 03 (value is automatically set by SC5000)

CAUTION: If the vessel has ZF Hurth gears with two proportional solenoids installed, set the J0 Function Code immediately after setting the A0 Function Code. J0 sets Function Codes to limit current to a Hurth gear box: the solenoids can be permanently damaged if other Function Codes are set first.

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Table ENG-289-3: Engine Functions and Values (SmartCommand)



Port Starboard

E0 Select Engine Throttle Profile 06

01 - Caterpillar (PWM) (8% to 92%)02 - Cummins Centry (Voltage) (0.9 to 4.5 VDC)03 - Cummins Quantum (Voltage) (0.9 to 1.2 - 4.0 VDC)04 - Detroit Diesel (Voltage) (0.64 to 4.65 VDC)05 - MTU or MAN (Current) (4.0 to 20.0 mA)06 - Scania (Voltage (0.42 to 2.95 VDC)07 - John Deere (Voltage) (0.5 to 4.5 VDC)08 - Volvo (Voltage) (0.6 to 3.6 VDC)09 - Detroit Diesel (Frequency) (120.64 to 360.9 Hz)10 - Detroit Diesel (Frequency) (120.64 to 463.5 Hz)11 - J1939 Throttle output on J6 Yanmar Engine (CAN Eng)12 - CANBus Output (VW Electronic Engines Only)13 - Fiat 450 (CAN Eng)14 - Fiat 560 (CAN Eng)30 - CMD (Voltage) Output V1(0.75 to 3.8 VDC)CMD (Voltage) Output V2 (0.38 to 1.9 VDC)40 - Inmar (Voltage) Output V1(0.8 to 4.2 VDC)Inmar (Voltage) Output V2 (4.2 to 0.8 VDC) 41 - Crusader (Voltage) Output V1 (0.48 to 4.65 VDC)Crusader (Voltage) Output V2 (0.2 to 2.33 VDC)

E1 Throttle in Neutral (only available with type 03 - throttle profile) 00.0 00.0 to 25.0% of Throttle Range

E2 Throttle Minimum 08.2 00.1 to 97.0% Will always be 3% or more below Maximum.

E3 Throttle Maximum 59.2 04.0 to 100.0 % Will always be 3% or more above Minimum

E4 Throttle Maximum Astern 100.0 00.0 to 100.0% of Throttle MaximumE5 Throttle Pause Following Shift * 00.5 00.0 to 05.0 SecondsE6 High Idle 00.0 00.0 to 20.0% of Throttle Range

E7 Synchronization 01

00 – Equal Throttle (Open Loop) Synchronization01 - Active (Closed Loop) Synchronization (reverts to Equal if Tach Signal lost)02 - No Synchronization 03 - Active (Closed Loop) Synchronization (no synchronization if Tach Signal is lost)

E8 Initialization Type 0000 - Cruise mode at Power-up01 - Warm-up Mode at Power-up

E9 Throttle Rate Increase 0.8 00 - 25Ea Throttle Rate Decrease 0.8 00 - 25

Eb Throttle Command Incremental/De-incremental 0.0 0.0- 6.0

Ec Engine Minimum (Idle) RPM 550-800Ed Engine RPM Increment 00-100EE Engine Idle RPM 600 550 - 800EF Engine Full Throttle RPM 2300 2300 - 5000* If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), the value of the E5 Function Code is automatically reset to 0.9 seconds to prevent clutch damage.

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Table ENG-289-4: Dual Throttle Engine Functions and Values (SmartCommand)



Port Starboard

E1 Dual Throttle (V1) in Neutral 00 00.0 to 25.0% of Throttle Range

E2 Dual Throttle (V1) Minimum 8.2 00.1 to 97.0% Will always be 3% or more below Maximum.

E3 Dual Throttle (V1) Maximum 59.2 04.0 to 100.0 % Will always be 3% or more above Minimum

e1 Dual Throttle (V2) in Neutral 00 00.0 to 25.0% of Throttle Range

e2 Dual Throttle (V2) Minimum 7 00.1 to 97.0% Will always be 3% or more below Maximum

e3 Dual Throttle (V2) Maximum 59 04.0 to 100.0 % Will always be 3% or more above Minimum

Table ENG-289-5: Clutch Functions and Values (SmartCommand)



Port Starboard

C0 Clutch oil interlock 0000 - Not-installed01 - Installed02 - Throttle clutch pressure interlock mode.

C1 Clutch oil interlock delay 1.0 00.5 to 10.0 seconds.

C2 Reversal pause 00

00 -In gear01 - Neutral02 - Fixed neutral delay: if function C2 is set to a value of 02, then function C3 sets fixed neutral delay duration.

C3 Proportional pause time 03 00 to 99 seconds.

C4 Proportional pause ratio 0000 - 2:1 Ahead to astern: astern to ahead01 - 1:1 Ahead to astern: astern to ahead

C5 Shift solenoid type 00

00 - All shift solenoids except ZF Hurth with two proportional solenoids.01 - ZF Hurth with two proportional solenoids and 12 V power02 - ZF Hurth with two proportional solenoids and 24 V power

C6 ZF Hurth duty cycle ahead 100 00 to 100% ZF Hurth ahead lockup percentage PWM

C7 ZF Hurth duty cycle astern 100 00 to 100% ZF Hurth astern lockup percentage PWM

C8 Fixed neutral delay with proportional pause 0.0 0.0 to 4.0 seconds

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Table ENG-289-6: Troll Functions and Values (SmartCommand)



Port Starboard

L0 Troll Lever Range 00

00 - No Troll If this function is set to 00, the d Function Codes and the other L Function Codes do not appear in the function menu01 - 15 Degrees (100% throttle allowed)02 - 30 Degrees (100% throttle allowed)03 - 40 Degrees (75% throttle allowed)04 - 50 Degrees (10% throttle allowed)05 - Troll at detent only (only L1 must be set and operational)

L1 Troll Minimum Pressure 1.0

01- 99% of the AutoTroll range. Will always be less/more (normal/inverted) than Troll Maximum by at least 1%. If J1 is set to 00 (open loop troll), L1 is the percentage of open loop current available.

L2 Troll Maximum Pressure 100.0

02 - 100% of the AutoTroll range. Will always be more/less (inverted/normal) than Troll Minimum by at least 1%. If J1 is set to 00 (open loop troll), L2 is the percentage of open loop current available.

L3 Troll Throttle Limit 00 00 - 20% of Maximum Throttle

L4 Troll Pulse Duration 00.600.0- 09.9 Seconds. Time that the troll valve is commanded to Troll Pulse Percentage every time Troll is engaged.

L5 Troll Pulse Percentage 100% 00.1- 100.0% of available Troll Range.

Table ENG-289-7: Docking Functions and Values (SmartCommand)



Port Starboard

d0

Docking Lever Range No docking Function Codes are available until L0 is set to a value above zero and J1 is defined to a value above 00.

00

00 - No Docking If this function is set to 00, the other d Function Codes do not appear in the function menu01 - 15 Degrees (100% throttle allowed)02 - 30 Degrees (100% throttle allowed)03 - 40 Degrees (75% throttle allowed)04 - 50 Degrees (10% throttle allowed)05 - Docking at detent only (only d1 must be set and operational)

d1 Docking Minimum Pressure 50.001- 99% of the Troll (J2) Range. Will always be less/more (normal/inverted) than Docking Maximum by at least 1%.

d2 Docking Maximum Pressure 100.002- 100% of the Troll (j3) range. Will always be more/less (inverted/normal) than Docking Minimum by at least 1%.

d3 Docking Throttle Limit 00 00 - 20% of Maximum Throttle

d4 Docking Pulse Duration 3.000.0- 09.9 Seconds. Time that the troll valve is commanded to Docking Pulse Percentage every time Docking is engaged.

d5 Docking Pulse Percentage 100% 00.1- 100.0% of available Docking Range.

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Table ENG-289-8: Governed Electric Troll Functions and Values (SmartCommand)



Port Starboard

J0 Troll Valve Function 00

00 - Normal no current when at Lock up preset for generic 10 - 25% duty cycle01 - Inverse, no current when at Lock up preset for generic 10-25% duty cycle02 - Normal, no current at lock up preset for ZF 220 - 665 12 VDC Systems - ZF Padova Gears. Assumes 12V/10 Ohm Troll Valve, New or upgraded transmissions only.03 - Normal, no current when at lock up preset for ZF220 - 665 24 VDC Systems - ZF Padova Gears. Assumes 12V/10 Ohm Troll Valve. New or upgraded transmissions only.04 - Normal, no current when at lock up preset for ZF 2000 24VDC Systems05 - Inverse, no current when at lock up preset for ZF 1900 0r 2500 24 VDC Systems06 - Preset for 12 VDC ZF Hurth Systems07 - Preset for 24 VDC ZF Hurth Systems08 - Preset for ZF Friedrichshafen gears with MTCU

J1** Idle Lockup Hz 0 5 Hz to 3 kHz - taken from H0 Tach 2 reading

J2** Min. Troll LU RPM 30 Preset per J1: 30% of lockup shaft RPM (or 30% of J1 value in terms of shaft frequency feedback)

J3** Max Troll LU RPM 70** Preset per J1: 70% of lockup shaft RPMJ4** Troll Range 00** 0 - 20% Preset per J1J5** Troll Time out 0.3** 1.0 sec. in 0.1 second increments Preset per J1

J6** Min. Troll% PWM 10.0**01.0- 99.0%. Will always be less/more (normal/inverted) than Troll Maximum by at least 0.1%. Preset per J1

J7** Max Troll% PWM 25.0**1.1- 100.0%. Will always be more/less (inverted/normal) than Troll Minimum by at least 0.1%.Preset Per J1.

J8 Automatic Troll Setup Start & Monitor 0

00 – Auto Setup not Initiated/ Failed01 – Initiate Auto Setup02 – Auto Setup Initiated03 – Clutch Fill Time Detection04 – Minimum Troll Current Detection05 – Maximum Troll Current Detection06 – Recalculating Clutch Fill Time07 – Auto Setup Successful

J9 Automatic Troll Setup Maximum Time 60 20- 250 Sec.

JA Automatic Troll Setup Samples Per Step 3 1- 5 Samples

Jb Automatic Troll Setup Deadband Window 2 01- 100%

* If J0 is set to 08 (ZF Friedrichshafen gears with MTCU), to prevent clutch damage, throttle profile is changed to include a 0.9 throttle pause following a shift (see Function Code E5) and a two-second period with a maximum 15% throttle increase.** Not available if J0 is set to 08 (ZF Friedrichshafen gears with MTCU).

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POD Function Codes

Table ENG-289-9: Troubleshooting Functions (SmartCommand)



Port Starboard

H0 Diagnostic NA

Input Voltage (+/- 0.5VDC)Tachometer Frequency Output Shaft Sensor (Tach 2)Tachometer Frequency Input Shaft Sensor (Tach 1)Station 1 Lever A/DStation 2 Lever A/DStation 3 Lever A/DStation 4 Lever A/DStation 5 Lever A/DStation 6 Lever A/DControl/Set Button, Stations 1, 2, 3, 4, 5 and 6, Software Revision Level

H1 Return to Factory Defaults 00 Store to Return to Factory Defaults (For Authorized Personnel Only)

Table ENG-289-10: Steering and Helm Functions (POD)



Port Starboard

c0 Steering Actuator Configuration 04 04c1 Number of Helms 01 00 - 02c2 Number of Wheel Turns 2.0 00.5 – 9.9c3 Helm Station in Control 01 00 -01c4 Helm Force Feedback Minimum 00 0 – 59c5 Helm Force Feedback Maximum 00 0 – 50

c6 Auto Pilot Enable 0000 - Disable01 - Enable

c7 AutoPilot Direction 0000- Normal01- Reversed

c8 AutoPilot Speed 100 100 - 5000c9 Counts Per Degree 100 00 - 9999

cA Helm Feedback Type 00

00- No Feedback, No Resistance, No Zero01- Resistance, No Zero02- No resistance, with Zero03- Resistance and Zero

cc Throttle Limit with Faulted Steering 20 0- 100%

Table ENG-289-11: Low Speed Configuration Functions (POD)



Port Starboard

b0 Minimum adjustment of the port Pod 41 0 to +50°

b1 Center adjustment of the Pod on the port side 0.0 "b2" to "b0"

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b2 Maximum adjustment of the Pod on the port side -11 -20 to 0

b3 Minimum adjustment of the Pod on the starboard side 11 0 to +20°

b4 Center adjustment of the Pod on the starboard side 0.0 “b5” to “b3”

b5 Maximum adjustment of the Pod on the starboard side -41 -50 to 0

b6 Maximum Traveling Speed for the Port Pod 3000 100 - 3500

b7 Maximum Traveling Speed for the Starboard Pod 3000 100 - 3500

Table ENG-289-12: High Speed Configuration Functions (POD)



Port Starboard

r0 Minimum adjustment of the Pod on the port side 10 0 to +50°

r1 Center adjustment of the Pod on the port side 0.0 “r2” to “r0”

r2 Maximum adjustment of the Pod on the port side -10 -20 to 0

r3 Minimum adjustment of the Pod on the starboard side 10 0 to +20°

r4 Center adjustment of the Pod on the starboard side 0.0 “r5” to “r3”

r5 Maximum adjustment of the Pod on the starboard side -10 -50 to 0

r6 Start high speed mode calculation. 1190 10 - 3000r7 End high speed mode calculation. 1785 10 - 3000

r8Frequency of the throttle command Helm will start calculating the minimum zero and force feedback to the helms.

1190 10 - 3000

r9

Frequency of the throttle command at which the Helm will end calculating the maximum zero and force feedback to the helms.

1785 0 - 3000

rAFrequency of the throttle command at which the Helm will start calculating the minimum auto zero to the helms.

1000 0 - 3000

n0 Adjustment of the Joystick Direction to the Port. (c2) 0.0 -5.00 – 5.00 degrees

n1 Adjustment of the Joystick Direction to the Port. (c3) 0.0 -5.00 – 5.00 degrees

n2 Adjustment of the Joystick Direction to the Starboard. (c6) 0.0 -5.00 – 5.00 degrees

n3 Adjustment of the Joystick Direction to the Starboard. (c7) 0.0 -5.00 – 5.00 degrees

n9 Soft Engagements of the Gear when using the Joystick 0.0 00 - 150

Table ENG-289-11: Low Speed Configuration Functions (POD)



Port Starboard

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SETUP PROCEDURES



Sport Fish Function Codes

SteerCommand Function Codes

WARNING: Changing n9 Parameter will change the Engagement Time

nA Enable bits for Pod warnings FF Are for use by certified ZF technicians only.nb Enable bits for Pod faults FF Are for use by certified ZF technicians only.nc Pod Faults Enabled. 00 Are for use by certified ZF technicians only.

Table ENG-289-13: Sport Fish Mode Functions (Sport Fish)



Port Starboard

u0 Min Angle of pods when in Troll mode 00 0 to 20u1 Max Angle of pods when in Troll mode 00 0 to 20

u2

Max throttle used to deflect pods in Troll mode. When this throttle is being commanded then the pod angle should be the value found in 'u1'

00 0 to 99

u3 Min Angle of pods when in EasiDock mode 00 0 to 20

u4 Max Angle of pods when in EasiDock mode 00 0 to 20

u5

Max throttle used to deflect pods in EasiDock mode. When this throttle is being commanded then the pod angle should be the value found in 'u4'

00 0 to 99

u6 Min Angle of pods when in Cruise mode 00 0 to 20u7 Max Angle of pods when in Cruise mode 00 0 to 20

u8

Max throttle used to deflect pods in Cruise mode. When this throttle is being commanded then the pod angle should be the value found in 'u7'

00 0 to 99

Table ENG-289-14: Steering and Helm Functions (SteerCommand)



Port Starboard

c0 Steering Actuator Configuration 00

0 - No Actuators1 - Opposing Actuators Port Pushing, Stbd Pulling, for Port Turn.2 - Opposing Actuators Port Pulling, Stbd Pushing, for Port Turn.3 - Non-Opposing Actuators Port Pulling, Stbd Pulling, for Port Turn.4 - Non-Opposing Actuators Port Pushing, Stbd Pushing, for Port Turn.5 - Single Actuator Pulling, for Port Turn6 - Single Actuator Pushing, for Port Turn

c1 Number of Helms 01 00 - 02

Table ENG-289-12: High Speed Configuration Functions (POD)



Port Starboard

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SETUP PROCEDURES



c2 Number of Wheel Turns 2.0 00.5 – 9.9c3 Helm Station in Control 01 00 -01c4 Helm Feedback 00 0 – 50c5 Low Speed Helm Holding 10 0 – 50

c6 Auto Pilot Enable 00 00 - Disable01 - Enable

c7 AutoPilot Direction 00 00 - Normal01 - Reversed

c8 AutoPilot Speed 100 100-5000c9 Counts Per Degree 100 00 - 9999

cA Helm Feedback Type 00

00- No Feedback, No Resistance, No Zero01- Resistance, No Zero02- No resistance, with Zero03- Resistance and Zero

cb Hold Current 00 0-50cc Throttle Limit with Faulted Steering 00 0 to 100cd Auto - Zero Configuration 90 01 to 360

Table ENG-289-15: Low Speed Configuration Functions (SteerCommand)



Port Starboard

b0 Minimum adjustment of the port Actuator 1000 0 to 1600

b1 Center adjustment of the Actuator on the port side 0 -100 to +1000

b2 Maximum adjustment of the Actuator on the port side -100 -160 to 0

b3 Minimum adjustment of the Actuator on the starboard side 1000 00 to 1600

b4 Center adjustment of the Actuator on the starboard side 0 -100 to 0

b5 Maximum adjustment of the Actuator on the starboard side -100 -160 to 00

b6 Maximum Traveling Speed for the Port Actuator 30000 100 to 4000

b7 Maximum Traveling Speed for the Starboard Actuator 3000 100 to 4000

Table ENG-289-16: High Speed Configuration Functions (SteerCommand)



Port Starboard

r0 Minimum adjustment of the Actuator on the port side 800 0 to 1600

r1 Center adjustment of the Actuator on the port side 0 -80 to 800

r2 Maximum adjustment of the Actuator on the port side -80 -160 to 0

r3 Minimum adjustment of the Actuator on the starboard side 800 0 to 1600

Table ENG-289-14: Steering and Helm Functions (SteerCommand)



Port Starboard

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SETUP PROCEDURES



Two Speed Function Codes

Speed Boost Function Codes

MCU Function Codes

r4 Center adjustment of the Actuator on the starboard side 0 -80 to 0

r5 Maximum adjustment of the Actuator on the starboard side -80 -160 to 0

r6 Start high speed mode calculation. 1000 10 to 3000r7 End high speed mode calculation. 2263 10 to 3000

r8 Start Auto Zero & Force Feedback Calculation for Helm 1000 10 to 3000

r9 End Auto Zero & Force Feedback Calculation for Helm 2263 10 to 3000

rA Maximum Traveling Speed for Port Actuator 1000 0 to 3000

Table ENG-289-17: Two Speed Functions



Port Starboard

U1 Pulses Per Revolution 00 0 - 255U1 Down Shift RPM 00 0 - 9999U2 Up Shift RPM 00 0 - 9999U3 Maximum Down Shift RPM Docking 00 0 - 9999

Table ENG-289-18: Speed Boost Functions



Port Starboard

F0 Boost Percent 00 0.0 - 20.0F1 Boost Duration 00 0.0 - 20.0F2 Boost Start Delay 00 0.0 - 10.0F3 Boost Bypass Clutch Delay 00 0.0 - 99.0

Table ENG-289-19: System Definition Functions (MCU/JMS)



Port Starboard

A0 Hold Heading mode 01

01 – Hold Heading only when moving sideways02 – Hold Heading only when moving sideways, ahead or astern03 – Hold Heading only when moving sideways or astern

A1 Bow Thruster Enable Relay Output 0000 – Off01 – On, Relay for bow thruster is enabled

A2 Bow Thruster Enable Relay Time out 0300 1 to 9999 seconds

Table ENG-289-16: High Speed Configuration Functions (SteerCommand)



Port Starboard

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SETUP PROCEDURES



A3 Bow Thruster Active Relay Output 0000 – Off01 – On, Active Relay for bow thruster is enabled

A4 Low Side Driver for Bow Thruster on Relay Outputs 00

00 – off (uses high side driver)01 – On (uses low side driver)

CAUTION: If the vessel has ZF Hurth gears with two proportional solenoids installed, set the J0 Function Code immediately after setting the A0 Function Code. J0 sets Function Codes to limit current to a Hurth gear box: the solenoids can be permanently damaged if other Function Codes are set first.

Table ENG-289-20: Troubleshooting Functions (MCU/JMS)



Port Starboard

H0 Software Version -- SW71333.XX, where XX indicates the two-digit version of the JMS software installed.

H1 Reset Station List --Cancels pairing of joystick and control heads. Can only be done upon start-up or after power-cycling.

H2 Station Pairing -- Pairs joystick with control head

Table ENG-289-19: System Definition Functions (MCU/JMS)



Port Starboard

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DOCK TRIALS: ADJUSTMENTS AND TESTS SECURED TO DOCK


MMSC5000 SmartCommand User ManualDock Trials

6 Dock Trials: Adjustments and Tests Secured to Dock

6.1 Control Head (Engines Stopped)1. Apply power to the control system.2. The control head at each station sounds an intermittent tone pattern (the initialization tone pattern).3. Verify that all stations sound the initialization tone pattern. Stations that generate no tone or a five second

steady tone once per minute are not operating correctly. Refer to Section 10: Troubleshooting if the system does not emit the initialization tone or if no station can take command.

4. Take command at any station. There are additional control head tests after you start the engines.

6.2 Start Interlock (Engines Stopped)

1. Turn the SmartCommand DC power OFF.• Verify that the engines cannot start.

2. Turn the SmartCommand DC power ON. Do not take command at a station.• Verify engines cannot start.

3. Take command at a station. Place the control head levers to ten percent throttle.• Verify engines cannot start.

4. Place the control head levers in the Neutral/Idle position. Take command at a station.• Verify engines start in this position.

6.3 Service Field Test Unit (Break-out Box) and Multimeter UseZF Marine Propulsion Systems Miramar recommends the use of ZF Marine Service Field Test Unit (P/N 13927) (Break-out Box) and a calibrated Multimeter to adjust the functions listed in Table 6-1: Functions Requiring Service Field Test Unit and Multimeter.

Figure 6-1: Service Field Test Unit and Multimeter

NOTE: If any of the tests in this section fail, verify Start Interlock Installation and Start Interlock Connections.

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For Functions E1, E2, E3, E4, E6, L3, and d3 connect the eight pin connector of the Service Field Test Unit into the Processor Throttle connector and to the Throttle Wire Harness on the ECM (Reference “1” in Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections)

Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections

For Functions L1, L2, d1, and d2 connect the twelve pin connector of the Service Field Test Unit to the Processor Clutch connector and to the Clutch Wire Harness on the gear box (Reference “1” in Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections).

Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections

Table 6-1: Functions Requiring Service Field Test Unit and Multimeter

Function Section Showing Adjustments

E1 Section 6.8: E1 - Throttle in Neutral

E2 and E3 Section 6.4: E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped)

E4 Section 6.9: E4 - Throttle Maximum Astern

E6 Section 6.10: E6 - High Idle

L1 and L2 Section 7.5: L1 and L2 AutoTroll Minimum and Maximum Adjustments Do not use this setup procedure for L1 or L2 if MTCU-equipped ZF Friedrichshafen gears are installed.

L3 Section 7.6: L3 - Troll Throttle Limit

d1 and d2 Section 7.6: L3 - Troll Throttle Limit. Do not use this setup procedure for d1 or d2 if MTCU-equipped ZF Friedrichshafen gears are installed.

d3 Section 7.6: L3 - Troll Throttle Limit

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6.4 E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped)Adjustments may not be required. Verify the existing Throttle Minimum and Maximum values before adjusting them.

Throttle Minimum (E2)

The E2 Function Code adjusts the throttle signal at Idle. This adjustment modifies the value set by the Engine Throttle Profile (E0). Throttle Minimum can be set between 1% and 97% of the maximum throttle output capability of the driver. The value must be at least 3% less than Throttle Maximum setting.

Throttle Maximum (E3)

The E3 Function Code adjusts the throttle signal at full throttle. This adjustment modifies the value set in Select Engine Throttle Profile (E0). Throttle Maximum can be set between 4% and 100% of the maximum throttle output capability of the driver. The value must be at least 3% greater than the Throttle Minimum setting.

Use the Service Field Test Unit and a Multimeter:

A Disconnect the Throttle Wire Harness from the processor.B Connect the eight pin connectors from the Service Field Test Unit to the Processor Throttle connector

and to the Throttle Wire Harness. See Section 6.3: Service Field Test Unit (Break-out Box) and Multimeter Use.

• For PWM (Duty Cycle Measurements):1. Set the Multimeter to the Duty Cycle Setting:

a Attach the black lead to COM and the red lead to V on the Multimeter.b Attach the black lead from the Multimeter to the negative (-) connector on the

break out box, and attach the red lead from the Multimeter to the PWM connector on the break out box.

NOTE: For Equal Throttle Synchronization, the setting for throttle minimum must be the same on both processors and the setting for throttle maximum must be also be the same on both processors. Otherwise, the engines will synchronize at different RPM.

NOTE: Before beginning any adjustments, select the correct Engine Profile (described in Section 5.8.1: E0 — Select Engine Throttle Profile).

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• For Voltage (VDC) measurements:1. Set the Multimeter to the Voltage setting:

a Attach the black lead to COM and the red lead to V on the Multimeter.b Attach the black lead from the Multimeter to the negative (-) connector on the

break out box, and attach the red lead from the Multimeter to the VDC connector on the break out box.

• For Current (mA) measurements:1. Set the Multimeter up as an ammeter:

a Attach the black lead to COM and the red lead to mA on the Multimeter.b Attach the black lead to the negative (-) connector on the break out box.

Attach the red lead to the mA connector on the break out box. Press and hold the mA push button on the break out box.

2. In the diagram, a Shows the ECM with the throttle cable connected to the eight pin connector.b Shows the unused twelve pin connectors. c Identifies the break out boxd Is a reminder to press the MA button on the breakout box to take the

measurement. 3. Turn ON power to the engine’s throttle interface. Verify processor power is ON.

a At the processor, press UP ARROW or DOWN ARROW once to enter the Function Menu.

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b On the processor, use the UP ARROW or DOWN ARROW to scroll to the E2 Function Code for Throttle Minimum

c or E3 Function Code for Throttle Maximum.

d The Multimeter reads the output signal.

e On the processor, press LEFT ARROW and RIGHT ARROW simultaneously and hold for two seconds to enter set up mode. The Function Code blinks or the PIn? prompt appears if PIN not entered yet.

f Change the value of the function, or enter the PIN and change the value of the function.

g When the value you want displays or you reach the RPM that you want, store the value and exit Set Up mode.

h Shut down power to the engine and processor.i Remove the Service Field Test Unit. Reconnect the Throttle Wire Harness to

the processor.

WARNING: Never adjust Throttle Maximum while at dock. Personal Injury may result if this message is disregarded.

NOTE: To read current on the Service Field Test Unit, press the mA push button on the box.

NOTE:

• To show values that have more than two digits (for example, 010.5), press the RIGHT ARROW key and hold

it until the Function Code disappears and the display shows three or four digits: this is the full three- or

four-digit value. The decimal indicator lights if the number has a decimal value.

• To make small adjustments to the signal, press RIGHT ARROW simultaneously with UP ARROW or DOWN

ARROW.

• Release the RIGHT ARROW key to return to Set Up mode: the Function Code blinks in the two left pads and

the first two digits of the value display in the two right pads.

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6.5 Engine Stop Switches Test (Engines Running)1. Start engines.2. Verify all Engine Stop Switches function correctly at all stations.

Refer to information supplied by engine manufacturer or switch supplier for set up and adjustments.

6.6 Lever Movement at Control Heads

1. Turn on the engines. 2. Bump the ahead and astern gears. To “bump” a gear, quickly move to the ahead or astern detent, and quickly

move back to neutral. 3. Verify processor reacts to lever movement in the correct direction.

4. Place the control head levers in the neutral detent position to prepare for the next test.

6.7 Warm-Up Mode Test (Engines Running)

1. At the station in command, put the control head lever in the neutral detent position. 2. Press the MODE button until the WARM UP LED blinks. If no button is pressed in ten seconds, the LED stops

blinking and the mode does not change.3. Press CONTROL/SET once. The WARM UP LED illuminates steady red and the CONTROL LEDs blink green.4. Move the control head lever into the ahead range. The throttle increases and the transmission remains in

Neutral. Moving the lever in the astern direction does not increase throttle. 5. If the WARM UP LED is illuminated steady red and the CONTROL LEDs blink green, Warm Up mode has been

activated. Continue with adjustments and tests.6. If the WARM UP LED is not lit, blinking, or anything other than steady red, verify all connections are correct. Make

any necessary changes. Repeat the Warm Up mode Test.7. Move each control head lever to full throttle. Verify the engine reaches full throttle


WARNING: Do not attempt to continue tests until the Engine Stop Switches function correctly. Personal Injury may result if this message is disregarded.

CAUTION: Verify the vessel is secured to the dock. Step B engages the transmission briefly.

NOTE: Lever movement tests whether the control head is operating. Verify the Port Control Head lever operates the Port Processor and the Starboard Control Head lever operates the Starboard Processor.

NOTE: To confirm Speed Command operation, use Warm-Up mode on each engine from each station, one engine at a time.

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6.8 E1 - Throttle in Neutral

The Cummins-Quantum Engine requires different throttle command signals in Neutral than when In-Gear. These engines require a voltage throttle signal of 0.9 VDC when unloaded at Neutral. When a load is placed on the engine by engaging the clutch, the throttle command signal increases to 1.2 VDC.

The Throttle in Neutral Function adjusts the throttle signal level at Neutral/Idle. The Neutral value may be adjusted between 1% to 25% of the maximum throttle output capability of the voltage circuit. Throttle at Idle Ahead and Astern is adjusted with the E2 - Throttle Minimum Function Code.

For example, if the circuit has the ability to drive 0 to 5.00 VDC and the value entered is 10, the output at Neutral would be 0.50 VDC.

The limits for this function are 01.0% to 25.0%. Throttle defaults are based on the Throttle Profile selected.

• Disconnect the Throttle Wire Harness from the SmartCommand Processor.• Connect both eight pin connectors from the Service Field Test Unit to the Processor Throttle

connector and to the Throttle Wire Harness. See Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections for details.

• Power up the engine’s throttle interface. Verify processor power is ON.• Press UP ARROW or DOWN ARROW to activate the Function Menu. • Use UP ARROW or DOWN ARROW to scroll to the E1 Function Code

• The Multimeter reads the output signal for Throttle in Neutral. • Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the

Function Code LED pads blink or the PIn? prompt appears if PIN not entered yet. • Change the value of the function, or enter the PIN and change the value of the function using UP

ARROW or DOWN ARROW. • When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and

hold for one second.• Exit Set Up mode.• Shut down power to the engine and processor.• Remove the Service Field Test Unit and reconnect the Throttle Wire Harness to the processor.

6.9 E4 - Throttle Maximum AsternThis value determines the percentage of Throttle Range that is allowed in Astern. Throttle Maximum Astern can be set from 1% to 100% of the throttle range. The default value is 100% regardless of engine profile: maximum throttle astern matches maximum throttle ahead. To reduce the Maximum Throttle Astern, use a percentage of the throttle range.

Throttle Percentage Astern Throttle Maximum Throttle Minimum – ( )Throttle Maximum Astern × ( )Throttle Minimum

CAUTION: If any tests in Section 6.6: Lever Movement at Control Heads or Section 6.7: Warm-Up Mode Test (Engines Running) fail, correct the problem before taking the vessel out for sea trials.

NOTE: Only use this function when the E0 SELECT ENGINE THROTTLE PROFILE is set to: 03 - CUMMINS QUANTUM.

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For example, if Throttle Minimum (E2) is 10 and Throttle Maximum (E3) is 80, and E4 is 50%,

Throttle Percentage Astern 80 10 – ( ) 0.5 × ( ) 10

the final throttle percentage astern is 45% of full throttle.

The breakout box may not be necessary to adjust this function. In some cases, you may know the percentage of Throttle Ahead you want to use. In those cases, set the parameter without the breakout box.

To use the breakout box:

• Disconnect the Throttle Wire Harness from the SmartCommand Processor.• Connect both eight pin connectors from the Service Field Test Unit to the Processor Throttle

connector and to the Throttle Wire Harness. See Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections for details.

• Power up the engine’s throttle interface. Verify processor power is ON.• Press UP ARROW or DOWN ARROW to activate the Function Menu. • Use UP ARROW or DOWN ARROW to scroll to the E4 Function Code. The Multimeter reads the output

signal for Throttle Maximum Astern.

• Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

• Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

• When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and hold for one second.

• Exit Set Up mode. • Shut down power to the engine and processor.• Remove the Service Field Test Unit and reconnect the Throttle Wire Harness to the processor.

6.10 E6 - High IdleThis function allows the operator to have a second or elevated Idle speed. This second or elevated Idle can be adjusted from 0 to 20% of full throttle. If 00 is selected, High Idle will be the same as normal or low Idle. The default value is 00.

To measure and adjust the E6 parameter:

• Disconnect the Throttle Wire Harness from the SmartCommand Processor.

WARNING: Verify that Warm Up mode is active before adjusting this function. Personal Injury may result if this message is disregarded.

NOTE: To read current on the Service Field Test Unit, press the mA Push Button on the box.

CAUTION: High Idle can be set higher than the safe shift RPM for the gear.

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• Connect both eight pin connectors from the Service Field Test Unit to the Processor Throttle connector and to the Throttle Wire Harness. See Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections for details.

• Power up the engine’s throttle interface. Verify processor power is ON.• Press UP ARROW or DOWN ARROW to activate the Function Menu.

Use UP ARROW or DOWN ARROW to scroll to the E6 Function Code. The Multimeter reads the output signal for High Idle.

• Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

• Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

• When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and hold for one second.

• Shut down power to the engine and processor.• Remove the Service Field Test Unit and reconnect the Throttle Wire Harness to the processor.

To select High Idle at the control head: When power is first applied to the system, idle speed is set to low idle. Move the levers to any detent and press CONTROL/SET on the control head for one half second and release it to set the idle speed to high idle. Release the button and press and hold again for one half second to switch from High Idle back to Low Idle.

NOTE: To read current on the Service Field Test Unit, press the mA Push Button on the box.

NOTE: To make small current adjustments, press RIGHT ARROW and hold while pressing UP ARROW or DOWN ARROW.

NOTE: SmartCommand outputs High Idle when it is in Warm Up mode.

NOTE: Set Port and Starboard High Idle to the same value. Both processors output high idle or low idle at the same time.

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6.11 E5 - Throttle Pause Following Shift

This value defines the pause time from the time the clutch engagement signal is given to the time throttle is allowed to increase above Idle. The pause value can be set from 00.0 to 02.5 seconds. The default value is 00.5 second pause. This is a good starting point for most hydraulic clutches.

Set the value for the E5 Function Code to 0.0 if the vessel has a mechanical clutch, such as a dog or cone clutch. There is no delay built in to these systems.

For hydraulic clutches:

A Move the control head lever to the ahead detent while monitoring the shaft.B Start the stopwatch immediately when you move the lever.C When the shaft begins to rotate, stop the stopwatch.D Record the time expired. Use this value for Function Code E5.E Press UP ARROW or DOWN ARROW to activate the Function Menu.

F Use UP ARROW or DOWN ARROW to scroll to the E5 Function Code.

G Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

H Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

I When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and hold for one second.

NOTE: ZF Marine Propulsion Systems Miramar recommends you use a stopwatch and a test control head to set this parameter. If a test control head is not available, two people may be required to run this test.

NOTE: Read steps A through D carefully before beginning.

NOTE: If the time recorded is greater than 5.0 seconds, install a clutch oil pressure interlock. See Section 8.2: Clutch Oil Pressure Interlock

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SEA TRIALS AND TESTS UNDERWAY


MMSC5000 SmartCommand User ManualSea Trials

7 Sea Trials: Adjustments and Tests Underway

7.1 Engine RPMA If necessary, use Warm Up mode to warm up the engines. B If synchronization is enabled, disable synchronization for this test. To disable synchronization, press

CONTROL/SET at the active control station and hold for five seconds while the levers are in the synchronization range.

C In open water, gradually move control head lever to full speed. Engines should run at full rated RPM. D If you must adjust Maximum Throttle, see section 6.4: E-2 Throttle Minimum and E-3 Throttle

Maximum Signal (Engines Stopped).E Re-enable synchronization.

7.2 Reversal Pause On Direction ChangeReversal Pause allows time for the engine to decelerate and vessel speed to decrease on a High Speed Reversal. To set the value of the C3 Function Code:

7.2.1 Measure the value to use for C3

A Place the control head lever in Full Ahead.B Leave the control head lever there for sixty seconds, or until the vessel’s speed through the

water reaches maximum, whichever is longer. C Simultaneously start the stop watch and quickly move the control head levers to Ahead Idle or

Neutral (depending on whether C2 is set to 00 - In gear or 01 - Neutral). D Stop the stop watch when the engine’s RPM reach idle and the vessel’s speed through the

water is within two knots of the standard Idle Ahead speed.

WARNING:

• Do not attempt to operate SmartCommand away from the dock with any system abnormality.

• Verify that all the dock tests are complete and correct.

• Verify that no error codes display at the processor.

• Complete all Installation, Setup, and Adjustments Secured to Dock before attempting a Sea Trial.

• If any of the tests in this section fail, discontinue the Sea Trial immediately and return to dock. See

section 10: Troubleshooting, or contact a ZF facility before resuming the Sea Trial.

• Personal Injury may result if this message is disregarded.

CAUTION: Start slowly and learn to appreciate that the SmartCommand System provides a light touch that is fast and accurate. Damage to the vessel may occur if this message is disregarded.

NOTE: The pause on a “through Neutral” shift is proportional to the speed commanded and the time at that speed. The value programmed in Function Code C3 PROPORTIONAL PAUSE TIME is the maximum delay possible. When shifting from idle ahead to idle astern or vice versa, the delay is zero. The time required to build up to the maximum pause is six times the value selected. In addition, in order to build up to the maximum delay value, the system must be commanding full throttle. The pause when shifting from Astern to Ahead is either half or the same as the ahead to astern delay depending on the value selected for Function Code C4 PROPORTIONAL PAUSE RATIO.

NOTE: Use a stopwatch to program the C3 Function Code correctly.

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E Program function C3 to match the time on the stop watch.

7.2.2 Test the Proportional Pause:

A Position the boat in open water and slowly increase the throttle to 25% of the speed range. B Leave the control head levers at this position for at least 60 seconds. C Quickly move the control head levers to Idle Astern.

• The engine RPM should drop to idle.• The clutch should stay engaged or shift to Neutral for 25% of the time selected with

Function Code C3 proportional pause time.• After the time has expired, the clutch shifts to Astern.• The engine RPM drops slightly when the Astern load is placed on the engine, but not to the

point where it comes close to stalling. D Increase the throttle slightly until the vessel starts moving in the opposite direction. E If the engine stalled or came very close to stalling, increase the value of Function Code C3 by

one second. Repeat steps A through C. F Repeat steps A through D with the throttle at 50%, 75%, and 100% of the speed range. G If the engine stalls at any time, increase the value of Function Code C3 by one second and

repeat the steps A through D again.

The engine is properly adjusted after you complete a full speed reversal without the engine approaching a stall. The throttle setting drops to Idle and the transmission shifts to Neutral or remains in gear during the pause, depending on the value of the C3 Function Code.

If reversal stalls occur and maximum proportional delay is programmed, speed boost or shaft brakes may be required; contact a ZF representative. Have the following information ready:

• Vessel Length• Hull Type, Planing, Displacement, etc.• Engine Type and horsepower rating• Gear type and reduction ratio

See section 5.9.3: C2 — Reversal Pause, section 5.9.4: C3 — Reversal Pause Time, and section 5.9.5: C4 — Reversal Pause Ratio, for settings related to Reversal Pause.

7.3 Synchronization TestVerify the type of synchronization chosen at the processor. For equal throttle synchronization, Function Code E7 is set to 00. For Active Synchronization, Function Code E7 is set to 01 (Default) or 03. If Function Code E7 is set to 02, synchronization is not enabled.

A Move both control head levers side by side to approximately 25% of the throttle range.• Check the engine tachometers to verify they are within 1% of each other.

B Move both control head levers side by side to approximately 50% of the throttle range.• Check the engine tachometers to verify they are within 1% of each other.

C Move both control head levers side by side to approximately 75% of the throttle range.• Check the engine tachometers to verify they are within 1% of each other.

D Move both control head levers side by side to approximately 100% of the throttle range.• Check the engine tachometers to verify they are within 1% of each other.

If Equal Throttle Synchronization is enabled and the tachometers are more than 1% different at any throttle setting, ZF Marine Propulsion Systems Miramar recommends using active synchronization if throttle min and max are the same at both engines. If Active Synchronization is enabled and the tachometers are more than

CAUTION: Test proportional pause as outlined below to ensure it was properly programmed. Failure to do so could cause transmission damage.

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1% different at any throttle setting, or if the engines appear to be continually “hunting” for the matching RPM, refer to section 10: Troubleshooting.

7.4 J1 - Idle Lockup RPM

This Function Code is not displayed if J0 is set to 08 - ZF Friedrichshafen gears with MTCU. Measure the propeller shaft frequency using the tachometer value in the SmartCommand processor diagnostic menu.

A On the processor, press UP ARROW or DOWN ARROW on the processor to activate the function menu.B Press UP ARROW or DOWN ARROW to scroll to H0 Diagnostics.C Press DOWN ARROW once to see the battery voltage.D Press DOWN ARROW once to see the Output Shaft frequency reading. The Output shaft frequency

reading has two decimal points, as in this example:

E Start the engine and command Idle Ahead without AUTOTROLL or EASIDOCK enabled.F Record the value shown on the processor display in Table 7-1: Output Shaft Idle Lockup RPM. If the

vessel has a troll valve and AutoTroll is set up, record this value in Table 7-2: Troll Minimum and Maximum Values. If the vessel has a troll valve and EASIDOCK is set up, also record the value in F-259 SmartCommand Sea Trial Report.

G Exit the H0 Function Code. Press LEFT ARROW and hold until the H0 LED pads stop blinking.H Return the control head to the Neutral/Idle position and shut down the engine. I Repeat steps A - G for each engine. J Set the J1 value:K Use UP ARROW to scroll to J1 - Idle Lockup RPM.L Press LEFT ARROW and RIGHT ARROW simultaneously and hold for two seconds until the J1 Function

Code blinks or the PIn? prompt appears if PIN not entered yet. M Change the value of the J1 function, or enter the PIN and change the value of the function using UP

ARROW or DOWN ARROW to match the value recorded for the propeller shaft RPM.

7.5 L1 and L2 AutoTroll Minimum and Maximum AdjustmentsThe adjustments and tests in this section are made with the engines running. The AutoTroll Minimum Pressure (L1) function sets the amount of current delivered to the Proportional Valve at Minimum Pressure. The range for this value is between 01.0% and 99.0% of the range between the minimum and maximum troll valve settings (preset through J2 and J3). The value set must be at least 1% less than Troll Maximum if non-inverted is selected or 1% more than Troll Maximum if inverted is selected. The Default Value depends on the gear type installed. Typically, it is approximately 30%.

IMPORTANT: Measure the Propeller Shaft RPM when the transmission oil has reached operating temperature. Do not make adjustments before oil has reached temperature.

Table 7-1: Output Shaft Idle Lockup RPM

Propeller Shaft H0 - Output Shaft RPM Reading

Port

Starboard

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7.5.1 AutoTroll Minimum Pressure (L1)

The Troll Maximum Pressure (L2) function sets the amount of current delivered to the Proportional Valve at Maximum Pressure. The range for this value is between 2.0% and 100.0% of the total current output capability of the circuit. The value set must be at least 1% more than Troll Minimum if non-inverted is selected or 1% less than Troll Minimum if inverted is selected. The Default Value depends on the gear type installed. Typically, it is about 70%.

7.5.2 AutoTroll Maximum Pressure (L2)

The amount of current required to reach minimum and maximum rotation varies from gear to gear. It is not uncommon for two trolling valves on the same vessel to have different settings for Troll Minimum and Maximum.

If J1 is not defined (value is 00), L1 and L2 are percentages of the full range of the open loop troll current.

7.5.3 Adjust Minimum AutoTroll Pressure

Measure and adjust the current at the minimum troll pressure. Use the Service Field Test Unit and a Multimeter:

A Disconnect the Clutch Wire Harness from the SmartCommand Processor.B Connect the twelve pin connectors from the Service Field Test Unit to the Processor Clutch

connector and to the Clutch Wire Harness. Refer to Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections.

C Set Multimeter to read Current (mA). D Attach the black lead to COM and the red lead to mA on the Multimeter.E Attach the black lead to the COM connector and the red lead to the mA connector on the

breakout box as shown in Figure 7-1: Multimeter and Test Unit Connections. Move the Troll Command toggle switch towards TROLL COMMAND to read the current signal (Reference A).

Figure 7-1: Multimeter and Test Unit Connections

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F Power up the Clutch Power Supply. G Verify processor power is ON.H Position the control head lever to the Ahead detent and turn on AutoTroll at the control head.

I Press UP ARROW or DOWN ARROW on the processor to activate the function menu.J Press UP or DOWN ARROW to scroll to the L1 AutoTroll Minimum Pressure Function Code.

K Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

L Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

M When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and hold for one second.

N If you are using closed-loop troll, measure propeller shaft RPM using the Tachometer Sensor Input 2 value in the H0 diagnostics menu (the third H0 value) and record Propeller Shaft RPM in Table 7-2: Troll Minimum and Maximum Values

7.5.4 Adjust Maximum Troll Pressure

Measure and adjust the current at the maximum troll pressure. Use the Service Field Test Unit and a Multimeter, just as for the Minimum Troll Pressure. Do not change the setup:

A Position the control head lever to the Troll Maximum position

B Use the UP ARROW or DOWN ARROW to scroll to the L2 Troll Maximum Pressure Function Code.

C The Multimeter reads the output signal for Troll Maximum when the Troll Command toggle switch on the test unit is flipped towards TROLL COMMAND. See Figure 7-1: Multimeter and Test Unit Connections for details on connections and switch.

WARNING: If either meter lead is disconnected while testing AutoTroll current, the transmission locks up (fully engages). Personal Injury may result if this message is disregarded.

Table 7-2: Troll Minimum and Maximum Values

Troll Setting Shaft RPM Current (mA) Function Percent

Port Starboard Port Starboard Port Starboard

Lock-Up (100%)

L1-Minimum

L2-Maximum

NOTE: It is difficult to use a slipping clutch to control shaft RPM between 70 percent and 100 percent of normal shaft RPM. Adjusting Troll Maximum above 75% typically results in full lock-up.

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D Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

E Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

F When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and hold for one second.

G If you are using closed-loop troll, measure propeller shaft RPM using the Tachometer Sensor Input 2 value in the H0 diagnostics menu and record Propeller Shaft RPM in Table 7-2: Troll Minimum and Maximum Values.

H Position the control head lever into the Neutral/Idle position.I Shut down power to the engine and the processor. J Remove the Service Field Test Unit and reconnect the Clutch Wire Harness to the processor.

7.6 L3 - Troll Throttle LimitThis function sets the maximum amount of throttle command applied to the engine while the Trolling Valve is actively slipping the clutch. The Troll Throttle limit can be adjusted from a lower limit of no increase in throttle above idle, to an upper limit that matches the value set for the top of the AutoTroll Range. The amount of commanded throttle increases from idle at minimum pressure to Troll Throttle Limit at maximum pressure.

The values of this Function are 00% to 20% of Throttle Maximum. The default value is 00.

The upper limit for the troll throttle percentage is 20% of full throttle. The default value for the L3 and d3 Function Codes is 0%. The engine always remains at idle.

7.6.1 Calculating the highest throttle percentage allowed

The maximum RPM allowed in docking and troll is limited by the gear and engine type. Check the transmission’s accompanying literature before setting any throttle above idle. Typically, the limit is 1000 RPM for engines, but can be lower in many circumstances.

After finding the Maximum Throttle RPM at Troll, calculate the highest troll throttle percentage allowed. Verify the L3 Function Code is set below that value. Two examples are shown below:

Example 1: if Maximum Rated RPM are 2300 and Idle RPM are 600, and ZF Type 0 gears are installed (J0 is set to 0):

Get two values from the engine manufacturer’s specifications: Idle RPM and Maximum Rated Engine RPM, and read the Maximum Troll RPM from the transmission manufacturer’s literature.

Maximum Throttle Percentage = 100 x MaximumTrollRPM - Idle RPM

MaximumRatedRPM - Idle RPM

In this example,

Maximum Throttle Percentage = 100 x 1000-60

2300-60

or 23.5%. Set L3 to any value less than or equal to 20, the maximum value allowed for L3.

Example 2: Maximum Rated RPM are 2300, Idle RPM are 600, and the maximum engine rotation in troll is 700 RPM:

NOTE: Adjust the L3 parameter after L1 and L2 are adjusted.

CAUTION: The maximum throttle percentage in AutoTroll mode should not cause the engines to exceed the maximum RPM for Troll. The throttle in troll is limited to prevent overheating damage to the clutch packs, and the maximum value RPM allowed can be found in the transmission manufacturer’s literature. Carefully read section 7.6.1: Calculating the highest throttle percentage allowed carefully before setting the L3 Function Code.

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Get two values from the engine manufacturer’s specifications: Idle RPM and Maximum Rated Engine RPM.

Maximum Throttle Percentage = 100 x MaximumTrollRPM - Idle RPM

MaximumRatedRPM - Idle RPM

For example, if Maximum Rated RPM are 2300 and Idle RPM are 600, and the Maximum Troll RPM is 700 RPM.

Maximum Throttle Percentage = 100 x 700-600

2300-600

or 5.88%. Set L3 to less than or equal to 5 to avoid damaging the clutch packs.

7.6.2 Set the Troll Throttle Limit, and Throttle in Docking Range

A Disconnect the throttle wire harness from the SmartCommand processor.B Connect both 8-Pin connectors from the Service Field Test Unit to the processor throttle

connector and to the Throttle Wire Harness. See Figure 31: E1, E2, E3, E4, E6, L3 and D3 Processor, Test Unit, and Multimeter Connections for details.

C Power on the Engine’s ECM. D Verify processor power is ON.E Use the UP ARROW or DOWN ARROW to scroll to the L3 Troll Throttle Limit Function Code.

F The Multimeter reads the output signal for the Troll Throttle Limit output signal.G Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the

Function Code blinks or the PIn? prompt appears if PIN not entered yet.H Change the value of the function, or enter the PIN and change the value of the function using

UP ARROW or DOWN ARROW.I When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW

simultaneously and hold for one second.J Exit Set Up mode.K Shut down power to the engine and the processor.L Remove the Service Field Test Unit and reconnect the Throttle Wire Harness to the processor.

7.7 L4 - Troll Pulse DurationThis function sets the time in seconds that the Proportional Valve is commanded the current programmed in “Troll Pulse Percentage”. This function gives a pressure boost to the Clutch plate in order to get the Propeller Shaft rotating prior to dropping to the level programmed in Troll Minimum.

The values of this function are 0.0 to 9.9 Seconds. The default value is 0.6 seconds.

To change the value:

A Press UP ARROW or DOWN ARROW on the processor to activate the Function Menu.

NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar, LLC.

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B Press UP ARROW or DOWN ARROW to scroll to the L4 Troll Pulse Duration Function Code.

C Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the Function Code blinks or the PIn? prompt appears if PIN not entered yet.

D Change the value of the function, or enter the PIN and change the value of the function using UP ARROW or DOWN ARROW.

E When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and hold for one to two seconds.

7.8 L5 - Troll Pulse PercentageThis function sets the percentage of Troll Maximum that the Proportional Valve is commanded when first entering Troll mode. This function determines the amount of pressure boost to the clutch plate in order to get the Propeller Shaft Rotating prior to dropping to the level programmed in Troll Minimum. The limits for this function are 0.0% to 100.0%. The default value is 27%.

To change the value:

A Press UP ARROW or DOWN ARROW on the processor to activate the Function Menu.B Press UP ARROW or DOWN ARROW to scroll to the L5 Troll Pulse Percentage Function Code.C Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the

Function Code blinks or the PIn? prompt appears if PIN not entered yet. D Change the value of the function, or enter the PIN and change the value of the function using UP

ARROW or DOWN ARROW.E When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and

hold for one to two seconds.

7.9 d1 — Docking Minimum PressureThe Docking Minimum Pressure (d1) function sets the amount of current delivered to the proportional valve when EASIDOCK mode is selected and the control head lever is in the ahead or astern detent. The d1 value can be set between 0.1% and 99% of the range set by Function Codes J2 and J3 (maximum troll lock-up RPM and troll range). The value selected must be at least 1% less than the docking maximum pressure (d2) value, if non-inverted (normal) operation is set with the docking lever range Function Code (d0), or at least 1% greater than the d2 value if inverted operation is set. The default value is 50.0%.

When adjusting the Docking Minimum Pressure function, consider the following:

• The value selected for the d1 function determines the RPM of the propeller, and the thrust that will result, when EASIDOCK mode is commanded and the control head lever is in the ahead

NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar, LLC.

IMPORTANT: The adjustments described below for minimum and maximum docking pressure functions must be made with the engines running and the transmission(s) at normal operating temperature.

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detent. Adjust the Function Code according to the amount of thrust that will be needed in docking situations.

• When d1 is set to the default value of 50%, the propeller rotates at 50% of the normal idle speed. If this setting causes too much thrust to be produced, decrease the value. Conversely, if not enough thrust is produced, increase the value.

7.10 d2 — Docking Maximum Pressure The Docking Maximum Pressure (d2) function sets the amount of current delivered to the proportional valve when EASIDOCK mode is selected and the control head lever is at the limit of the EASIDOCK range, selected with the d0 Function Code (Docking Lever Range). The recommended setting for the d0 function is 05, “Detent Only.” When the Docking Lever Range is set to this value, Docking Maximum Pressure is not necessary, so the d2 Function Code does not need to be set.

When the Docking Lever Range is set to any value other than 00 or 05, the available range for d0 is between 02% and 100.0% of the range set by Function Codes J2 and J3. The value selected must be 1% greater than the Docking Minimum Pressure (d2) value if non-inverted (normal) operation is set with the docking lever range Function Code (d0), or at least 1% less than the d2 value if inverted operation is set.

When adjusting the Docking Maximum Pressure function (if the d0 Function Code is not set to the value of 05 Detent Only), the value can be increased or decreased depending on the amount of thrust desired when the control head lever is at the limit of the docking range. Make Maximum Docking Pressure adjustments as follows:

1. At the station in command, select EASIDOCK mode. 2. Move the control head lever to the ahead detent.3. On the processor, scroll to Function Code d2.4. Enter setup mode by holding the right and left arrow buttons down simultaneously until “d2” begins to

blink on the left.

5. To increase the amount of thrust, set the d2 value higher; to decrease the thrust, set the value lower.6. Store the new value in the processor memory by depressing the right and left arrow buttons

simultaneously until the value stops blinking.

7.11 d3 - Docking Throttle LimitThis function sets the maximum amount of throttle applied to the engine while the trolling valve is actively slipping the clutch when EASIDOCK mode is commanded. The Docking Throttle Limit can be adjusted from its lowest point of no increase in throttle above idle, to an upper limit of 20% of the throttle range. When a value greater than 00% is selected, the throttle command and resulting engine RPM will increase proportionally with lever movement, while the control head lever is within the range set by the Docking Lever Range Function Code. The d3 default value is 00%, meaning that the engine remains at idle when the control head lever is within the range set by the Docking Lever Range Function Code.

CAUTION: Be aware that an increase in vessel thrust will occur immediately when d2 is reached in setup mode, typically causing a noticeable lurch.

NOTE: Adjust the d3 Function Code after the d1 and d2 Function Codes have been set. When the d0 (Docking Lever Range) Function Code is set to a value of 05, it is not necessary to set the d3 Function Code.

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The upper limit for the troll throttle percentage is 20% of full throttle. The default value for the d3 Function Code is 0%; the engine always remains at idle.

7.11.1 Calculating the Highest Throttle Percentage Allowed

The maximum RPM allowed during docking and troll is determined by the type of transmission and engine being used. Before setting any throttle above idle, refer to transmission documentation. Once you have located the published maximum throttle RPM to be used during trolling (slipping the clutches), calculate the value for the d3 (Docking Throttle Limit) Function Code. Following are two ways of making such a calculation.

Example 1:The maximum rated engine RPM is 2300 and idle RPM is 600. The transmission’s maximum troll RPM is 1000.

Maximum throttle percentage = 100 x maximum troll RPM - idle RPM maximum rated RPM - idle RPM

For example: Maximum throttle percentage = 100 x 1000 - 600 2300 - 600

In this example, the maximum allowable throttle for the transmission is 23.5%. Since this is higher than the maximum value available through the Docking Throttle Limit Function Code (20%,) any d3 setting is permissible.

Example 2:The maximum rated engine RPM is 2300 and idle RPM is 600. The transmission’s maximum troll RPM is 700.

Maximum throttle percentage = 100 x maximum troll RPM - idle RPM maximum rated RPM - idle RPM

For example: Maximum throttle percentage = 100 x 700 - 600 2300 - 600

In this example, the maximum allowable throttle for the transmission is 5.08%. In this case, set the d3 value to 5% or less, to avoid damage to the transmission clutch pack.

7.11.2 Adjusting the Docking Throttle Limit1. On the processor, scroll to Function Code d3. 2. Enter setup mode by holding the right and left arrow buttons down simultaneously until “d3” begins to

blink on the left.3. Press the up push button until the desired value appears on the right-hand LEDs. 4. Store the new value in the processor memory by depressing the right and left arrow buttons

simultaneously until the value stops blinking.

7.11.3 d4 - Docking (EASIDOCK) Pulse Duration

The d4 function sets the amount of time that the current to the proportional valve is commanded at the value set with the Docking Pulse Percentage (d5) Function Code. The d5 and d4 functions work together to boost clutch pressure, when ahead or astern is first commanded in EASIDOCK mode. The pressure is then dropped to the level set by the Docking Minimum Pressure (d1) Function Code.

CAUTION: During clutch slippage, the maximum throttle percentage in EASIDOCK mode should not cause the engines to exceed the maximum engine RPM allowed by the transmission manufacturer. When EASIDOCK is commanded, the throttle is limited to prevent overheating damage to the clutch pack. Therefore, pay particularly close attention to information in the following, section 7.11.1: Calculating the Highest Throttle Percentage Allowed before setting the D3 Function Code.

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The available values are from 0.0 to 9.9 seconds in 0.1 (one tenth) of a second increments. The default value is 3.0 seconds.

7.12 d5 - Docking (EASIDOCK) Pulse PercentageThe d5 function sets the level of the current signal applied to the proportional valve when ahead or astern is first commanded in EASIDOCK mode. The value set through d5 is applied for the time set with the Docking Pulse Duration (d4) Function Code. The pressure is then dropped to the level set by the Docking Minimum Pressure (d1) Function Code.

The available values are from 0.0% to 100%. The default value varies depending on the setting of Docking Maximum Pressure (d2).

NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar.

NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar.

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SmartCommand Sea Trial Report

F-259 Rev A.2 11-11 Page 1

F-259 SmartCommand Sea Trial Report

SmartCommand System Sea Trial ReportThe purpose of this Sea Trial Report is to provide a convenient checklist and record of installation, dock trial set up, and sea trial performance of the ZF Marine Electronics SmartCommand Propulsion Control System. Please enter ALL information. We recommend a copy of this completed form remain aboard the vessel, and require that you fax a copy to ZF Marine Electronics at 425-493-1569.

Date: __________________

Your Name: _______________________________________________________________________________________

Builder: __________________________________ Boat Owner: ___________________________________

Street Address: _______________________________________________________________________________________

City: __________________________________ State: ________ Postal Code: ___________

Contact Name: __________________________________ E-mail: ___________________________________

Phone: __________________________________ Fax: ___________________________________

Vessel Name: ____________________________________________________ Hull #: __________________

No of screws: __________________ Classification: ____________________________________________________

Engine Mfg: _______________________________________________________________________________________

Model: _____________________________________________ HP: ___________ RPM: ___________

Transmission Mfg: _______________________________________________________________________________________

Model: __________________________________ Ratio: ___________________________________

#. of Stations (max 6) _______________________________________________________________________________________

Station 1 Location: ____________________________ Serial #: _____________________________






ZF Marine Electronics12125 Harbour Reach Dr Ste B

Mukilteo, WA 98275P - 425-583-1900F - 425-493-1569

www.zf.com

116 EN 3340.758.001a - 2014-10


F-259 Rev A.2 11/11 Page 116


Table F-259-1: Processor Information

Processor Information Port Starboard

Processor Serial Numbers ___________ ___________

Is the Processor subject to excessive heat? (Above 70 degrees C) Yes No

At least 4 feet (1,2m) from strong magnetic fields? Yes No

Accessible for checkout, adjustments, and maintenance? Yes No

Are the Processors bonded (grounded)? Yes No

Are all Electric Cables supported every 18 inches (45,72cm)? Yes No

Are the electrical cable connections tight at the Processors and Control Heads? Yes No

Is the Processor’s Start Interlock Circuit being used? If not, what type of start interlock is being used? Yes No

Is there an Engine Stop Switch installed at each Remote Station? Yes No

What is the length of the Control Head Harness?

Sta. 1_______ Sta. 2_______

Sta. 3_______ Sta. 4_______

Sta. 5_______ Sta. 6_______

Table F-259-2: Power Supply


What is the source of Processor power and how is it charged? ___________ ___________

Is there a backup power supply? APS or other, explain.___ Yes No

Are the power cables protected by 10 Ampere Circuit Breakers? Yes No

What is the Battery Voltage when not being charged? ___________ ___________

What is the Processor Voltage when not being charged? ___________ ___________

What is the Battery Voltage when connected to Shore Power? ___________ ___________

What is the Processor Voltage when connected to Shore Power? ___________ ___________

What is the Battery Voltage when the engines are running? ___________ ___________

What is the Processor Voltage when the engines are running? ___________ ___________

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F-259 Rev A.2 11/11 Page 117


Table F-259-3: Dock Trials


Does the engine start remotely when the Control System is turned OFF? Yes No

Does the Engine Stop Switch function at all Stations, regardless of RPM? Yes No

Can all Remote Stations take command? Yes No

While in Warm-up, does Engine RPM increase when in the ahead direction? Yes No

High Idle RPM (optional) ____ RPM ____ RPM

Does the vessel surge forward with Control Head lever in the Ahead Detent? Yes No

Table F-259-4: Record at Dock


Throttle in Neutral (Cummins Quantum only) VDC, mA., Hz. or % ___________ ___________

Throttle Minimum VDC, mA., Hz. or % ___________ ___________

Throttle Maximum VDC, mA., Hz. or % ___________ ___________

Troll Minimum (signal) mA ___________ ___________

Troll Maximum (signal) mA ___________ ___________

Table F-259-5: Sea Trials


Do the Dual Control Head levers match position and RPM throughout the speed range? Yes No

Is Synchronization operational? Yes No

Table F-259-6: Record During Sea Trial


Engine Idle RPM ___________ ___________

Shaft Idle RPM (Calculate the Shaft Idle RPM as follows: Engine Idle RPM/Gear Ratio) ___________ ___________

Full Throttle RPM ___________ ___________

Troll Minimum (Shaft RPM) RPM (Actual) (The desired Troll Minimum can be calculated as follows: Shaft Idle RPM x 0.3) ___________ ___________

Troll Maximum (Shaft RPM) RPM (Actual) (The desired Troll Maximum can be calculated as follows: Shaft Idle RPM x 0.7) ___________ ___________

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F-259 Rev A.2 11/11 Page 118


MAIL COMPLETED COPY TO:ZF Marine Propulsion Systems Miramar, LLC,12125 Harbour Reach Drive, Suite B, Mukilteo, WA 98275

OR FAX TO: 425-493-1569 ATTN: Service Department

Table F-259-7: Follow Up

Comments (Please use additional paper as necessary):

General Installation Condition:

Any Irregularities:

Is the Installation and Troubleshooting Manual on board? Yes No If No, request

copy? Yes No

Is a copy of this completed Report aboard? Yes No

Is a copy of this completed Report faxed to ZF Marine Propulsion Systems Miramar? Yes No

Inspector: ___________________________________________________________ Date:

Company: __________________________________ E-mail: __________________________________

Phone: __________________________________ Fax: __________________________________

Street Address: _______________________________________________________________________________________

City: __________________________________ State: _______ Postal Code: ___________

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CONTROL OPTIONS


MMSC5000 SmartCommand User ManualControl Options

8 Control Options

8.1 Alarm CapabilitySmartCommand’s alarm is a single, normally closed alarm connection that opens when there is a system power failure or circuit malfunction.

The alarm circuit in the processor operates an alarm system supplied by others. You can order the SmartCommand Power Wire Harness with a cable for the alarm connection.

Figure 8-1: Alarm Circuit Requirements

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CONTROL OPTIONS



The shipyard is responsible for using the alarm connection in an appropriate alarm circuit. The alarm circuit must have the same common mode voltage (common ground) as the power supply for the SmartCommand processor.

Figure 8-2: Alarm Circuit Example

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CONTROL OPTIONS



8.2 Clutch Oil Pressure Interlock

The Clutch Oil Pressure Interlock prevents high engine RPM when the clutch is not fully engaged and is typically used when the clutch takes longer than five seconds to engage. The interlock blocks a speed signal to the engine until the hydraulic clutch pressure has reached a value recommended by the transmission manufacturer that ensures clutch engagement.

The power harness 13552-XX has a cable to be used for the clutch oil pressure switch connection.

If the clutch pressure falls below the pressure switch setting, the engine speed drops to Idle RPM. A shuttle valve is required.

Figure 8-3: Clutch Pressure Switch Showing Processor Wire Harness and Shuttle Valve

If an external alarm circuit is being used in addition to the clutch pressure switch, substitute the13631-XX power wire harness for the 13552-XX harness, because the 13631-XX harness has the extra connection necessary for the alarm.

NOTE: The Clutch Oil Pressure Interlock must be set to INSTALLED to be used. See Section 5.9: Clutch Function Codes for the process to set Clutch Oil Pressure Interlock to INSTALLED or NOT INSTALLED.

NOTE:

• The installer must supply the pressure switch.

• The switch must be a Normally Open (N.O.) pressure switch with a trip point that will adjust to match the

transmission manufacturer’s recommended setting.

• The closing of contacts indicates to the processor that the clutch is sufficiently engaged to allow a speed

command above idle speed. This is a safety feature for protection of the clutch.

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PERIODIC CHECK AND MAINTENANCE


MMSC5000 SmartCommand User ManualPeriodic Checks and Maintenance

9 Periodic Checks and Maintenance

9.1 Control ProcessorCheck all terminal connections for loose connections.

9.2 Control HeadOnce a year, verify that control head terminals are secure.

9.3 Battery Specific instruction about battery maintenance is beyond the scope of this manual. However, it is important to remember that batteries must be maintained in good working condition. Be sure to operate and service batteries according to the manufacturers’ specifications and guidelines.

WARNING: Batteries contain sulfuric acid and emit hydrogen gas while charging. Therefore, specific safety precautions must be adhered to while handling and servicing. Specific information on handling and servicing batteries can be obtained from the Battery Council International, Battery Service Manual. Personal Injury may result if this message is disregarded.

CAUTION: In many newer batteries, the vent cap is permanently attached, preventing access to the electrolyte for water level and specific gravity tests. Attempting to pry off these caps could result in premature battery failure. Damage to equipment may occur if this message is disregarded.

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MMSC5000 SmartCommand User ManualTroubleshooting

10 Troubleshooting

10.1 GeneralThe SmartCommand control system consists of one processor per engine, typically mounted in the engine room, and one to six control heads located at remote vessel stations. The processors are designed to precisely control electronic throttles and transmissions equipped with solenoid-activated clutches.

If there is a system malfunction, first determine whether other vessels are around, check whether the vessel is pulling to port or to starboard, and figure out how to get the vessel out of harm’s way. After handling the immediate situation, the operator usually turns to the control head, which has six red/green light-emitting diodes (LED) and two sound transducers (one port and one starboard). These features provide for the emission of visual and audible cues to problems with the control system.

This section contains guidelines for dealing with problems that occur, beginning with general questions and issues and progressing to detailed information.

Figure 10-1: Basic Control System

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Before troubleshooting, review the SmartCommand System Diagram.

Figure 10-2: System Diagram

Become familiar with the various components and the function of each within the control system. All SmartCommand systems contain one or more of the components listed in Table 10-1: System Components

Table 10-1: System Components

Item Component Part Number Quantity

1 Processor SC5000 1 or 2

2 SmartCommand Dual Lever Control Head 5200 or 5200LP Max 6

3 Wire Harness, Control Head to Processor 70269-XX Max 4

4 Wire Harness, Control Head to Control Head 70268-XX Max 8

5 Wire Harness, Throttle

5A Wire Harness, Throttle, MAN 70263-XX 2

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5B Wire Harness, Throttle, CAT (PWM) 13533-XX 2

5C Wire Harness, Throttle, Voltage 13432-XX 2

5D Wire Harness, Throttle, Frequency 15027-XX 2

5E Wire Harness, Throttle, Current 13494-XX 2

5F Wire Harness, Throttle, Voltage (Cummins Plug) 13565-XX 2

5G Wire Harness, Throttle, Voltage (John Deere Plug) 14148-XX 2

6 Wire Harness, Clutch

6A Wire Harness, Clutch (ZFPD Gear) 70259-XX 2

6B Wire Harness, Clutch (MTCU ZFF Gear) 70260-XX 2

6C Wire Harness, Clutch (MTCU POWER ZFF Gear) 70260P-XX 2

6D Wire Harness, Clutch, Ahead, Astern 15717-XX 2

6E Wire Harness, Clutch, Ahead, Astern, Troll, Troll Command 15725-XX 2

6F Wire Harness, Clutch, Ahead, Astern, Troll Command 15732-XX 2

7 Wire Harness, Power, Start Interlock, Clutch Pressure, Alarm Circuit

7A Wire Harness, Power, Start Interlock 13756-XX 2

7B Wire Harness, Power, Start Interlock, Clutch Pressure 13552-XX 2

7C Wire Harness, Power, Start Interlock, Clutch Pressure, Alarm Circuit 13631-XX 2

8 Wire Harness, Processor to Processor CAN 70261-XX 1

9 Wire Harness, Tachometer 70264-XX 1

10 N/A N/A N/A

11 Automatic Power Selector (APS) 13505 1

12 Circuit Breaker, 10 AMP 810ETA 2

Table 10-1: System Components

Item Component Part Number Quantity

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10.1.1 Control Head

The control head transmits and receives CAN bus communications to the processor, and may transmit and receive messages to and from other control heads. The control head has audible (sound transducer) and visual (LED) status indicators, which are activated by messages received from the processor.

The control head has two sound transducers, two push buttons for taking command and for changing modes, and six bi-color (red/green) LEDs to indicate system status and operational mode.

10.1.2 Processor

The processor receives CAN messages from other processors, from control heads, and from other devices. The processor also receives input and output shaft RPM information. Using the information received, the processor supplies appropriate electronic or electric outputs to the engine governor and to the gear box at the correct time and in the correct sequence. Information about throttle and gear type, throttle/gear sequencing, and performance characteristics is stored in the memory of the processor.

10.1.3 Wire Harnesses

Wire harnesses carry voltage, current, and electronic signals from one point to another within the control system (processors and control heads) and the elements being controlled. The harnesses may have plugs on one or both ends. All SmartCommand systems have harnesses for the control head interface, gear box, throttle, serial communication, DC power, and tachometer interfacing. The power and gear box harnesses are available in various configurations to support features such as Start Interlock and Troll.

10.1.4 Power Source

To operate, all electronic equipment must have power. It is very important to choose well-charged, reliable power sources. The SmartCommand system needs at least two separate power sources, which must be made available to each processor through an automatic power selector (APS). The APS automatically selects the power source with the highest voltage, while continuing to maintain isolation between the power sources. Ideally, three power sources would be available, as shown in Figure 10-3: Three Power Sources

Figure 10-3: Three Power Sources

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10.2 Troubleshooting QuestionsIf a problem arises, you may be able to resolve it without ever lifting a tool. If you can fix the problem by finding answers to the following questions, it is possible to save significant time and money.

A Is the system installed on a single, twin, or multiple screw vessel?• If the vessel has a single screw, proceed to the next question.• If the vessel has two or more screws, determine the side (s) on which the problem occurs.• If the problem occurs on one side only, your search has been narrowed to components for that

side of the system.• If the problem affects more than one side, determine the common features. In all probability,

the only common feature is the DC power source. B How many remote stations (control heads) are there?

• Does a problem that happens at one station also occur at all other remote stations?• If the problem happens only at one station, it is possible that the source is in the control head.• If the problem occurs at two or more remote stations, the issue is more than likely not with the

control heads, but somewhere else in the system.C Do you hear any tones when the problem occurs?

The SmartCommand system can produce six discrete tones which are emitted as warnings about potential problems. When a tone is sounded, an error code (or codes) will usually be displayed on the processor.

• Slow, repetitious tone -- also referred to as the “initialization tone” because this is the tone you hear when the SmartCommand system is first powered up. This tone means:

• Power has just been applied to the control system.• The software is operating normally.• The processor is commanding the throttle to idle and the clutch to neutral.• The start interlock relay is open.• If this tone sounds when a remote station is already in control, it means that power has been

lost to the system (perhaps only momentarily) and there is a possible problem.• One long note, three short notes

Indicates that an invalid command signal has been given at the control head in command. When this tone sounds, an error code (or codes) will be displayed on the processor to aid in the diagnostic process.

• Steady tone

Indicates that a significant processor failure has occurred. This tone also will be accompanied by error codes to help with diagnosis of the problem. If the processor LED display is not functioning, measure the DC battery voltage at the processor. If the VDC is less than 8.0, correct the power supply issue. If the VDC is 8.0 or greater, replace the processor.

• Five second steady tone (one time)

Indicates that processor to processor serial communication has been lost. When this tone sounds, an error code (or codes) will be displayed on the processor to aid in the diagnostic process. (See section 10.9: Problem Scenarios for a list of error codes and their meanings.) As long as the processors have power, the tone occurs just one time. When serial communication is lost, modes which require serial

NOTE: Brief information about tones is provided here to aid in initial troubleshooting of problems. In-depth details about the tones can be found later in this section, in section 10.6: Audible Tones Detailed Information

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communication, such as EASIDOCK, AUTOTROLL, ONE LEVER, WARM UP, and Synchronization, will not function.

• Three second steady tone

Signifies that the CONTROL/SET button has remained closed for 12 seconds or longer. An error code will be generated to indicate which station had the problem. If it is determined that the CONTROL/SET button was not physically pressed by someone, the control head at the offending station needs to be replaced.

• Five second steady tone (repeats every minute)

Indicates that a control head cannot communicate with the CAN bus. The tone will be accompanied by multiple error codes and all LEDS on that control head will blink red.

D Are any error messages being displayed on the processor?• If the system malfunctions or detects a fault, a tone or tone pattern will sound and an error

message (or messages) will typically be displayed at the processor.• All error codes are two numeric characters, preceded by the letters “Er.”• If an error message is not displayed, press the “Down” push button once, which will display

A0xx. Then press the left push button to enter the error menu. If A0xx continues to display, this means there are no error messages being generated from this processor.

• If you have multiple screws, check the error menus of all processors.• There may be multiple error messages, depending on the type of malfunction or fault. When

the error menu is displayed, press the “down” arrow to see any additional messages.• Write down all the error codes that appear, specifying for each whether it was generated by

the port or starboard processor.• The table shown in section 10.9: Problem Scenarios is a complete list of error codes that

could be generated.E Which control head LEDs are illuminated?

• Each control head has six bi-color LEDs, which, depending on the situation, can be off or illuminated red or green. The state of illumination, blinking or steady, is also dependent on the situation.

• Write down the state of all LEDs, indicating the color and condition (blinking or steady) of those that are illuminated.

1. The six states of the CONTROL LEDs are:• Illuminated Steady Green: the station is in command, in CRUISE mode, and the transmission

is in neutral.• Slowly Blinking Green: the station is in command, in WARM UP mode, and the transmission

is in neutral.• Illuminated Steady Red: the station is in command, in CRUISE mode, and the transmission is

in gear.• Slowly Blinking Red: the control head is not communicating properly with the CAN bus.• Rapidly Blinking Red: the station is in command, in AUTOTROLL or EASIDOCK mode, and the

transmission is in gear.• Rapidly Blinking Green: the station is in command, in AUTOTROLL or EASIDOCK mode, and the

transmission is in neutral.• Not Lit: the station is not in command or has no DC power.

NOTE: This error message will be displayed when engines are not powered up at the same time. Once both engines have been powered up, the error message can be cleared from the display.

NOTE: Brief information about LED illumination is provided here to aid in initial troubleshooting of problems. In-depth details about the LED status can be found later in this section in section 10.4: LED Detailed Information

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2. The three states of the EASIDOCK LED are:• Illuminated Steady Red: the station is in command and is in EASIDOCK mode• Slowly Blinking red: the station is in command and is awaiting the selection of EASIDOCK

mode.• Not Lit: EASIDOCK is not selected, or this station is not in command, or there is no DC power

to the control head.3. The three states of the AUTOTROLL LED are:

• Illuminated Steady Red: the station is in command and in AUTOTROLL mode• Slowly Blinking red: the station is in command and is awaiting the selection of AUTOTROLL

mode.• Not Lit: AUTOTROLL is not selected, or this station is not in command, or there is no DC power

to the control head.4. The three states of the WARM UP LED are:

• Illuminated Steady Red: the station is in command and in WARM UP mode• Slowly Blinking red: the station is in command and is awaiting the selection of WARM UP

mode.• Not Lit: WARM UP is not selected or this station is not in command or there is no DC power

to the control head.5. The five states of the ONE LEVER LED are:

• Illuminated Steady Red: the station is in command and the port lever is selected in ONE LEVER mode.

• Illuminated Steady Green: the station is in command and the starboard lever is selected in ONE LEVER mode.

• Slowly Blinking Red: the station is in command and is awaiting the selection of ONE LEVER mode.

• Slowly Blinking Red and Green: the station is in command and awaiting the selection of either the port lever or the starboard lever.

• Not Lit: ONE LEVER mode is not selected, or this station is not in command, or there is no DC power to the control head.

6. In addition to the LED conditions listed above, there may be communication faults which could cause LEDs to show as follows:

• EASIDOCK, AUTOTROLL, and CONTROL LEDs on the port side slowly blinking red: the port side of the control head is not communicating with the CAN bus, or the port side of the control head has not been assigned.

• ONE LEVER, WARM UP, and CONTROL LEDs on the starboard side slowly blinking red: the starboard side of the control head is not communicating with the CAN bus, or the starboard side of the control head has not been assigned (mapped).

• Port CONTROL, starboard CONTROL, EASIDOCK, ONE LEVER, AUTOTROLL, and WARM UP LEDS slowly blinking red: the control station hasn’t been assigned or is not communicating with the CAN bus.

F Has anything on the vessel recently changed? Below are several examples of changes which could have an effect on the SmartCommand processor.

• Addition of a thruster: the current required for operation of the thruster could decrease the voltage available to the control processor.

• Re-power of the vessel or a change out of transmission.• Work recently done on the vessel which would seem to be totally unrelated to the control

system and electronics. For instance, there was a case in which a person painting a vessel disconnected a plug attached to a control head to get to an area needing paint, and then did not re-connect it.

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10.3 System Inspection and Component IdentificationIf you have been unsuccessful in resolving a problem by asking and answering the questions in the last section, examine the control system carefully to verify that the system is in compliance with the installation manual. In your inspection of control system components, try to identify which of the following is the source of the problem:

• DC Power Source• Interconnecting Wire Harnesses• Engine or Transmission• Component Calibration• Control Head Failure• Processor Failure

Information contained in the following pages will help you to determine what and where the problem is.

A DC Power Source1. Verify that the processor power is connected to a properly charged 12 VDC or 24 VDC battery through a

10 ampere circuit breaker. An adequate battery charging system should maintain the battery charge when the vessel is both docked and underway, regardless of engine RPM.

2. The use of an APS (automatic power selector) with each processor is highly recommended, because it provides that processor with at least two alternative power sources. Then, when power is needed in one place (for example, to start the engine) and there is a big power draw from somewhere else, the APS will select power from the battery with the most voltage available.

B Component Locations• Control Heads

1. May be situated almost anywhere on the vessel where they are useful, taking the following conditions into consideration:

• A minimum distance of 9.8 inches (249 mm) from a compass must always be maintained.

• The ambient temperature must be at least -13 degrees Fahrenheit (-25 degrees centigrade).

• The ambient temperature must never be higher than 158 degrees Fahrenheit (70 degrees centigrade).

2. The control head design meets the IP56 rating. This rating ensures that the control head is protected against:

• Damage caused by a one mm or greater item (such as a wire)• Dust damage• Damage from powerful jets of water coming from any direction

• Processors 1. Usually located in the engine room, although this is not a requirement. Be sure to take the

following conditions into consideration, wherever the processors are situated:

NOTE: Do not attempt to troubleshoot the system any further than one of the main components listed here. If a control system component is faulty, replace that component. If an engine appears to be causing the problem, contact the service representative for that engine.

NOTE: When you are testing the DC distribution system, keep in mind that a 0.7 volt drop across the diodes of the APS is normal.

WARNING: Do not attempt to open a control head or a processor. If you do, the warranty is voided. These components contain no serviceable parts, and ZF Marine Propulsion Systems Miramar cannot guarantee the operation of a unit once it has been opened. Damage to the equipment may occur if this message is disregarded.

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• A minimum distance of 7.9 inches (200.66 mm) from a compass must always be maintained.

• A minimum distance of four feet (1.22 m) from sources of high heat, electro-magnetic interference (EMI) and radio frequency interference (RFI) must always be maintained.

• The ambient temperature must be at least -13 degrees Fahrenheit (-25 degrees centigrade).

• The ambient temperature must never be higher than 158 degrees Fahrenheit (70 degrees centigrade).

2. The processor design meets the IP56 rating, which specifies protection against:• A one mm or greater wire• Dust• Powerful jets of water coming from any direction

C Component Condition• Control heads

1. Inspect for any signs of physical damage.2. Check for loose connectors or termination resistors.

• Processors1. Inspect for any signs of physical damage.2. Make certain that all harness plugs are fully seated in the processor sockets.

D Interconnecting Wire Harnesses• Check all the interconnecting system harnesses for bent pins or signs of corrosion.

10.4 LED Detailed Information The control heads located at each remote station contain six bi-color (red/green) light emitting diodes (LED). Status information for the LEDs in the illustration below (showing the location of the LEDs on the control head) is listed in Table 10-2: LED Indications.

Figure 10-4: Control Head LEDs

WARNING: Do not open a control head. If you do, the warranty is voided. Control heads contain no serviceable parts, and ZF Marine Propulsion Systems Miramar cannot guarantee the operation of a unit once it has been opened. Damage to the equipment may occur if this message is disregarded.

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Table 10-2: LED Indications (shaded areas show situations in which LEDs are not lighted)

CONTROL EASIDOCK AUTOTROLL WARM UP ONE LEVER Indication

Port and/or Stbd. Steady Green

Not Lit Not Lit Not Lit Not Lit In Control- Commanding Neutral (Cruise Mode)

Port and/or Stbd. Steady Red

Not Lit Not Lit Not Lit Not Lit In Control- Clutch Engaged (Cruise Mode)


Slowly Blinking Red Not Lit Not Lit Not Lit

In Command- Commanding Neutral- Press “Control/Set” within 10 sec. to select EasiDock Mode.


Slowly Blinking Red Not Lit Not Lit Not Lit

In Command- Clutch Engaged- Press “Control/Set” within 10 sec. to select EasiDock Mode.

Port and/or Stbd. Rapidly Blinking Green

Steady Red Not Lit Not Lit Not Lit In Control- Commanding Neutral- EasiDock Mode Selected

Port and/or Stbd. Rapidly Blinking Red

Steady Red Not Lit Not Lit Not Lit In Command- Clutch Engaged- EasiDock Mode Selected


Not Lit Slowly Blinking Red Not Lit Not Lit

In Command- Commanding Neutral- Press “Control/Set” within 10 sec. to select AutoTroll Mode.


Not Lit Slowly Blinking Red Not Lit Not Lit

In Command- Clutch Engaged- Press “Control/Set” within 10 sec. to select AutoTroll Mode.

Port and/or Stbd. Rapidly Blinking Green

Not Lit Steady Red Not Lit Not Lit In Control- Commanding Neutral- AutoTroll Mode Selected

Port and/or Stbd. Rapidly Blinking Red

Not Lit Steady Red Not Lit Not Lit In Command- Clutch Engaged- AutoTroll Mode Selected


Not Lit Not Lit Slowly Blinking Red Not Lit

In Command- Commanding Neutral- Press “Control/Set” within 10 sec. to select Warm Up Mode.

Port and/or Stbd. Slowly Blinking Green

Not Lit Not Lit Steady Red Not Lit In Control- Warm-Up Mode Selected


Not Lit Not Lit Not Lit Slowly Blinking Red

In Command- Clutch Engaged- Press “Control/Set” within 10 sec. to select lead lever in One Lever Mode.


Not Lit Not Lit Not LitSlowly Blinking Red & Green

In Command- Clutch Engaged- Move lever within 2 sec. to select One Lever Mode.

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10.5 Diagnostic MenuOne of the features of the SmartCommand processor display is a diagnostic menu. When a problem cannot be diagnosed on the basis of tones, LED status, and/or error codes, the diagnostic menu can be utilized. If you have already identified the cause of the problem, the diagnostic menu is helpful in confirming the diagnosis. The diagnostic menu provides the following information:

• Applied Battery Voltage• Input and output shaft tachometer sender frequency• Stations one through six analog to digital (A/D) counts• Stations one through six CONTROL/SET Button Status• Software Revision Level

Access the diagnostic menu as follows:

A Locate the display on the Port or Starboard processor. Generally speaking, the display shows the number 5000, with digits flashing sequentially from left to right.

Figure 10-5: Processor Display in Run Mode• If the processor has detected an active error, a blinking Er, followed by a two digit error code,

will be displayed.

Figure 10-6: Display With Active Error

Port Side Slowly Blinking Red

Slowly Blinking Red

Slowly Blinking Red Not Lit Not Lit

Port side of Control Head not communicating with CAN Bus or not assigned.

Stbd Side Slowly Blinking Red

Not Lit Not Lit Slowly Blinking Red

Slowly Blinking Red

Starboard side of Control Head not communicating with CAN Bus or not assigned.

Port & Stbd, Slowly Blinking Red

Slowly Blinking Red

Slowly Blinking Red

Slowly Blinking Red

Slowly Blinking Red

The Control Head is not communicating with the CAN Bus or hasn’t been assigned

Not Lit Not Lit Not Lit Not Lit Not Lit The Control Head is not in control and or has no power.

Table 10-2: LED Indications (shaded areas show situations in which LEDs are not lighted)

CONTROL EASIDOCK AUTOTROLL WARM UP ONE LEVER Indication

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• If none of the control heads has had an ID assigned (mapped), the display shows four dashes blinking simultaneously.

Figure 10-7: Display When No Control Heads Assigned• Regardless of what is shown on the display, the goal is to get to the function menu so you can

scroll through the functions to access diagnostic codes. If 5000 is being displayed, press the UP arrow or the DOWN arrow. If Er is displayed, press the LEFT arrow.

B Press the UP arrow or the DOWN arrow. The characters A0, then 00, 01, or 02 will be displayed.

Figure 10-8: Display with A000C Press and release the UP arrow or the DOWN arrow until H000 is displayed.

Figure 10-9: Display with H000D Press and hold the RIGHT arrow and the LEFT arrow simultaneously for a couple of seconds, until the

H0 begins to blink. When you release the push buttons, the first thing to be displayed will be the battery voltage that is being applied to the processor. This is a “real time” reading, accurate within 0.50 VDC.

Figure 10-10: Display changing from H000 to voltage reading

NOTE: If the control head IDs have not been set, follow the instructions in section 5.5: Assigning Station IDs to gain access to the function menu.

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E Press the DOWN arrow to scroll through the diagnostic values, which are displayed (beginning with battery voltage) in the order shown in Table 10-3: Diagnostic Values.

F Output Shaft (Propeller) Frequency

Press the DOWN arrow to display the output shaft frequency. This signal is used in both AUTOTROLL and EASIDOCK modes. The value shown on the display is a product of the propeller shaft RPM (engine RPM divided by gear ratio) times the number of pulses per revolution (PPR), divided by 60.

For example:Engine RPM = 600Gear Ratio = 2:1Sensor PPR = 10600/2 = 300 * 10 = 3000/60 =50 Hz

Figure 10-11: Output shaft frequency value display

Table 10-3: Diagnostic Values

Press Arrow Keys to move up and down through the list

Input battery voltage (+/- 0.5VDC)

Output shaft (propeller shaft) frequency

Input shaft (engine) frequency

Station No. 1 Lever A/D






Station No. 1 Control/Set button status






Software Revision Level

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To obtain the value necessary to program Function Code J1 (IDLE LOCKUP HZ), command ahead/idle from a control station and note the displayed value. If this signal is lost, a one-time three second steady tone will sound from all control stations and error code Er93 will be displayed at the associated processor. EASIDOCK mode will also be disabled and AUTOTROLL will no longer be automatic, but will perform in open-loop fashion only.

G Input Shaft (Engine) Frequency

Press the DOWN arrow to display the input shaft frequency. This signal is used for engine synchronization and, where applicable, two-speed operation. The value shown on the display is a product of the engine RPM times the number of pulses per revolution (PPR), divided by 60.

For example:Engine RPM = 600Sensor PPR = 25600 * 25 = 1500/60 = 250 Hz

Figure 10-12: Input shaft frequency value display

Using the input shaft frequency value, the necessary value for programming Function Code U0 (pulses per revolution -- used in two-speed operation only) can be calculated. Multiply the displayed input shaft frequency value by 60 and then divide by engine RPM at “idle.”

For example:250 * 60 =1500015000/600 = 25

If this signal is lost, “closed loop” (active) engine synchronization will be disabled, but “open loop” (equal throttle) synchronization will still function. Vessels equipped with two-speed gear boxes will fail to shift to second gear. When this happens, the error code Er92 will be displayed by the associated processor.

H Stations No. 1 through 6 Lever A/D

Press the DOWN arrow once to display information about station No. 1, press the DOWN arrow twice to display information about station No. 2, three times for station No. 3, and so on through station No. 6. If you lose count when going through the stations, you can press the UP arrow to go back and start at the beginning, or take note of the decimal points missing from the display (explained below and shown in Figure 10-13: Absent decimal points indicating station number).

Moving from right to left:

• If the right most decimal point is absent, station No. 1 is displayed. • If the second decimal point from the right is absent, station No. 2 is displayed.• If the third decimal point from the right is absent, station No. 3 is displayed.• If the fourth decimal point from the right is absent, station No. 4 is displayed.• If the right most and left most decimal points are absent, station No. 5 is displayed.

NOTE: Generally speaking, on vessels with multiple engines, the RPM is identical among them. However, there may be certain cases where there are slight differences in RPM from one engine to the next.

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• If the second from the right and the left most decimal points are absent, station No. 6 is displayed.

Figure 10-13: Absent decimal points indicating station number

The A/D count, which represents the current position of the control head lever, is communicated to the processor on the CAN bus. Based on A/D information, the processor knows what to command and when (i.e., when to command a shift and/or when to increase throttle, etc.).

Figure 10-14: Expected A/D counts and processor response shows a control head with the expected A/D counts and the resulting response of the processor.

Figure 10-14: Expected A/D counts and processor response• Out of range (100 A/D) -- This is a fault condition which, if it were to occur, would require the

replacement of a control head. Depending on which station experiences this fault, an error

Station No. 1 A/D Counts Station No. 4 A/D Counts



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code of 23 through 28 would be displayed at the associated processor. In addition, the audible tone fault pattern of one long and three short notes would sound from all remote stations, and would continue until control is taken by a station other than the one which is experiencing the fault. Also, the throttle command would drop to idle and the clutch on the affected side would be disengaged.

• WOT (wide open throttle) (162 A/D) -- This is the point at which full throttle in the astern direction is reached.

• Throttle release (398 A/D) -- This is the point at which the throttle command signal starts to increase above idle. The astern throttle range is between 398 (idle) and 162 A/D (full throttle).

• Astern clutch engage (452 A/D) -- When you move the control head lever from neutral (a higher A/D count) to this point, the processor initiates the sequence to output the astern clutch engagement signal.

• Astern clutch disengage (462 A/D) -- When you move the control head lever toward neutral from the astern direction, the processor initiates the sequence to remove the output to the astern clutch when this A/D value is reached.

• Neutral (460 - 535 A/D) -- This is the value the processor needs to allow control to be taken at a station. If the value of either the port lever or the starboard lever is outside this range, the processor will not allow a station transfer to take place.

• Ahead clutch engage (532 A/D) -- When you move the control head lever from neutral (a lower A/D count) to this point, the processor initiates the sequence to remove the output to the ahead clutch when this A/D value is reached.

• Astern clutch disengage (542 A/D) -- When you move the control head lever from neutral (a lower A/D count) to this point, the processor initiates the sequence to output the ahead clutch engagement signal.

• Throttle release (598 A/D) -- This is the point at which the throttle command signal starts to increase above idle. The ahead throttle range is between 598 (idle) and 832 A/D (full throttle).

• WOT (wide open throttle) (832 A/D) -- This is the point at which full throttle in the ahead direction is reached.

• Out of range (900 A/D) -- This is a fault condition which, if it were to occur, would require the replacement of a control head. Depending on which station experiences this fault, an error code of 13 through 18 would be displayed at the associated processor. In addition, the fault tone of one long and three short notes would sound from all remote stations, and would continue until control is taken by a station other than the one which is experiencing the fault. Also, the throttle command would drop to idle and the clutch on the affected side would be disengaged.

I Stations No. 1 through 6 Control/Set Button Status

Press the DOWN arrow once to display station No. 1 button status, press the DOWN arrow twice to display station No. 2 button status, three times for station No. 3, and so on through station No. 6. A zero (0) represents an open switch contact and a one (1) represents a closed contact. Closure of this switch is required to take CONTROL at a remote station and to SET the various modes of operation. Items in Figure 10-15: Control/Set button closure displays show what the display looks like for each of the remote stations when the closure of the CONTROL/SET button is associated with that station.

Station CONTROL / SET Button (Open)

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.

Figure 10-15: CONTROL/SET button closure displaysJ Software Revision Level

Press the DOWN arrow once again to display the current software revision level of the processor. A blinking “rr” will appear, followed by a two digit number. Make a note of this number, including the decimal points. This information will be necessary if you should have to speak with a ZF Marine Propulsion Systems Miramar representative. An example of a software revision level code is shown in Figure 10-16: Software revision level display

Figure 10-16: Software revision level displayK Exiting the Diagnostic Menu

Exit the diagnostic menu in either of the following two ways:

• Press the LEFT arrow down for at least a second, until H000 appears on the display. Then press the UP arrow or DOWN arrow until the Function Code you want appears.

• Cycle the power to the processor, by turning it off and then back on. The diagnostic menu display will be suppressed when the power comes back.

Station No. 1 CONTROL / SET Button (Closed) Station No. 4 CONTROL / SET Button (Closed)



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10.6 Audible Tones Detailed InformationThe SmartCommand system is capable of producing six distinct tones that can be emitted from the control heads; each signifies a particular system state or identifies a fault.

10.6.1 Initialization Tone Pattern

The initialization tone is a slow, repetitive tone pattern which is generated at all remote stations when power is initially applied to the control system, indicating:

• Power has just been applied to the system.• The software program is running normally.• The processor is commanding the throttle to idle.• The processor is commanding the clutch to neutral.• The start interlock relay is open.

Expect to hear this tone pattern when power is initially applied to the processor. If this tone is sounded during normal operation (i.e. other than at initialization of power), it means there is an error. When this happens, the emission of the tone will be accompanied by the symptoms:

• Engine throttle dropping to idle.• Clutch command changing to neutral.• CONTROL LEDs at the control head in command going out.

These symptoms mean that the power supply voltage of the processor has momentarily dropped below 10 VDC and then returned to the adequate level. This might happen for one of the following reasons:

• There is a loose or corroded battery power cable connection.• A battery is under-charged or defective.• There is an excessive voltage drop due to high current flow and insufficient conductor sizes.• The engine starting battery is also supplying power to the processor in a 12 VDC system.

To try and isolate the cause of the power loss, you can perform the following tests:

A Check the error menu on the processor display for code 57, which indicates low battery voltage. This error code is generated when the battery voltage applied to the processor has dropped below 10 VDC for at least two seconds. (Therefore, this error code will not be generated when there is a low voltage period of under two seconds.)

B On the processor display, scroll to the diagnostic menu (as described in section 10.5: Diagnostic Menu). From this menu, take note of the applied battery voltage.

C Measure the voltage at its source, which is either the battery or the distribution panel that supplies power to the processor. This measurement should be greater than 12.4 volts in 12 VDC systems and 24.8 volts in 24 VDC systems. If the voltage is lower, the battery or its charging system needs to be serviced.

D When a station is in command and the processor is at neutral/idle, the difference in voltage between the source and the processor should not be greater than 3%. With 12 VDC systems, this means the maximum difference is 0.4 volts and in 24 VDC systems, the maximum difference is 0.8 volts.

• If the voltage difference exceeds these maximum levels, it means there is a high resistance connection or the conductor sizes are inadequate for the length of the power cable.

• Possible causes of high resistance include loose connections or corroded connections and relay contacts (typically non semi-precious contacts).

E If the source voltage measured in step C above is within specifications, and you have ruled out a voltage drop between the source and the processor, check to make certain that the

NOTE: If the processor power supply has an automatic power selector (APS), take into account the 0.7 VDC forward voltage drop of the diodes. This increases the permissible voltage drop from the power source to the processor to 1.1 VDC in 12 VDC systems and 1.5 VDC in 24 VDC systems.

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power source is not loaded down by another piece of equipment. When you monitor the power source in the investigation of a problem, turn on all other equipment which requires substantial amounts of current, such as heaters, starters, thrusters, large DC motors, etc.

F If you find that the voltage drops significantly at the power source, the processor needs to be provided with an alternate source of power, either through an APS or some other way.

10.6.2 One Long - Three Short Tone Pattern

This tone indicates that the lever information (A/D) from the station in command is out of the valid range. (The explanation for A/D count measurement and verification is given above in section 10.5: Diagnostic Menu).

• In addition to the tone, one or more error codes from the ranges 13 through 18 and/or 23 through 28 will be displayed.

• The processor will command the throttle to idle and the clutch to neutral. • Regardless of symptoms and the exact cause of the problem, ZF Marine Propulsion Systems

Miramar recommends that you replace the control head from which the tone is emanating. You will find instructions for control head replacement in section 10.10: SmartCommand Control Head Replacement.

10.6.3 Steady Tone

A steady tone sounds in two situations, which are entirely different from each other. These two situations, along with symptoms that may occur in addition to the tone, are described in detail in (A) and (B) below.

A Stuck CONTROL/SET button

If the CONTROL/SET button contact closes and remains closed for at least 12 seconds, the steady tone is emitted from all control stations for as long as the switch remains closed. The various situations which could cause this to occur, and accompanying symptoms, are described below.

• Fault at station not in command, with levers at neutral/idle• Control is automatically transferred to the station with the problem, giving that

station full control capabilities, if the station levers are in the neutral/idle position.

• Processors command both engines to neutral/idle.• CONTROL LEDS of the station originally in command turn off.• Press the CONTROL/SET button at the station originally in command to silence

the tone and return command to this station. (The CONTROL LEDS will light.)• An error code from the range 33 through 38 will be displayed on each

processor.• In subsequent power-ups, command is given automatically to the control

head with the faulty switch contact, as long as both levers are in the neutral/idle position (accompanied after 12 seconds by the steady tone).

• Fault at station not in command, with levers not at neutral/idle• The only indication to the operator at this station that a malfunction has

occurred is the inability to take command at this station, even when the control head levers are moved to neutral/idle.

• An error code from the range 33 through 38 will be displayed on each processor.

• Fault at station in command• Regardless of control head lever positions, control remains at this station.• Silence the tone by pressing the CONTROL/SET button at another control station

to transfer control to that station.• The only way for this station to regain control is if the power is turned off and

then back on. The steady tone will recur when this station is in command.• An error code from the range 33 through 38 will be displayed on each

processor.

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• In subsequent power-ups, command is given automatically to the control head with the faulty switch contact (accompanied after 12 seconds by the steady tone.)

B Processor fault The steady tone is generated when there is a processor fault, sometimes accompanied by an error code from the range 56 through 59. Usually, a processor fault indicates that the processor needs to be replaced, but before doing that, make the following checks.

• Make certain the processor is bonded as described in MMC-287 Grounding (Bonding).• In some cases, the processor display cannot show any messages simply because the

voltage is too low. To determine if this is the case, remove the power harness from the power socket of the processor and measure the voltage across pin 10(+) and pin 11 (-) of the plug. If the voltage is below 6.0 VDC, there may not be enough current to show anything on the processor display.

• If there has been a recent electrical storm, cycle the power off and then on again. If the problem still exists, replace the processor.

10.6.4 Five Second Steady Tone

After power-up, a one-time five second steady tone indicates that communication between the processors has been lost. In addition to the tone, other symptoms that may show up include:

• EASIDOCK, AUTOTROLL, and ONE LEVER modes are disabled.• Engine synchronization is disabled.• Error code 49 displays at both processors.• An error code from the range 50 through 54 is displayed on each processor.

When communication between processors is lost, make the following checks:

• Make sure that the plugs on the serial communication harness (part no. 70261-xx) are fully seated in the port and starboard processors.

• Check for broken, bent, or corroded pins on the serial communication sockets and plugs.• Make certain that power is applied to both processors.• Verify that Function Code A1 is set to the correct number of processors.• Verify that the port processor A0 Function Code is set to 1 and the starboard processor A0

Function Code is set to 2.

10.6.5 Three Second Steady Tone

If communication is lost between the processor and the Marine Transmission Control Unit (MTCU), a one-time three-second tone is generated.

• EASIDOCK and AUTOTROLL modes become inoperative, but associated control head LEDs would incorrectly indicate that these modes are operational.

• Clutch and throttle functions operate normally.• Error code 88 or 89 displays at the appropriate processor.

10.6.6 Five Seconds Per Minute

The five seconds per minute tone indicates that a control head which has an assigned ID is not communicating with the processor. The tone sounds only at the control head where the fault occurs, at either the station in command or another station. In both cases, other symptoms in addition to the tone may occur, as described below:

• Fault at station not in command• The CONTROL, EASIDOCK and AUTOTROLL LEDS blink red if the fault is on the port side.

NOTE: This fault will only occur in applications where Function Code J0 is set to 08.

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• The CONTROL, ONE LEVER and WARM UP LEDS blink red if the fault is on the starboard side.• An error code from the range 68 through 73 will be displayed on the associated processor.• Control cannot be transferred to this station.

• Fault at station in command• In addition to the five-second tone sounded at the faulty station, a tone of one long and

three short notes will sound at other control stations.• The CONTROL, EASIDOCK and AUTOTROLL LEDS blink red if the fault is on the port side.• The CONTROL, ONE LEVER and WARM UP LEDS blink red if the fault is on the starboard side.• The processor on the side without the fault will remain in command.• If EASIDOCK, AUTOTROLL, ONE LEVER and/or synchronization are selected, they will be

disabled.• An error code from the range 68 through 73 will be displayed on the associated processor.• An error code from the range 23 through 28 will be displayed on the associated processor.• Control can be transferred to another station, which will silence the one long-three short

audible indication tone• The five seconds per minute tone continues until the problem is corrected.

10.7 Troubleshooting Station TransferIn order for command to be transferred from one remote station to another, the following conditions must exist:

• DC power must be available to both the port side and the starboard side of the control head. If there is any doubt whether power is present on both sides, turn the power to the control system off and back on again. Then the slow repetitive tone (signifying that this station is in neutral and is in command) should be heard from both sides of the control head.

• The processor and the control head must be communicating. (If the LEDS are blinking red, they are not communicating.)

• There must be valid CAN bus communication between the control head and the processor.• The lever position information transmitted across the CAN bus from the control head to the processor

must indicate that the control head levers are at the neutral/idle position. For details, refer to the information in section 10.5: Diagnostic Menu.

• The CONTROL/SET button must be pressed and the fact that it’s being pressed must be recognized by the processor, through the CAN bus. For details, refer to the information in section 10.5: Diagnostic Menu.

• The CONTROL/SET button’s contact is not stuck in a closed position. For details, refer to the information in section 10.5: Diagnostic Menu.

10.8 Error CodesThe SmartCommand system can produce numerous error messages to help identify the causes of problems that may arise. The following table lists the two digit error codes, titles, and descriptions for all error messages. (On the processor display, the two digit numeric codes are preceded by the characters Er.) Some of the messages are not currently used, but are reserved for future features. Possible solutions can be found in Table 10-5: Problem Scenarios with Error Codes and Possible Solutions.

Table 10-4: Error Codes

Error # Title Description01 - 06 Reserved - Clutch Solenoid Reserved for Clutch Solenoid Errors.07 - 10 Reserved - Troll Solenoid Reserved for Troll Solenoid Errors.11-12 Reserved N/A

13 Remote Station # 1 Faulted High Station # 1 Control Head lever position is out of range. The input appears to be too high.



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19- 22 Reserved NA

23 Remote Station # 1 Faulted Low Station # 1 Control Head lever position is out of range. The input appears to be too low.






29 - 32 Reserved NA

33 Remote Station # 1 CONTROL/SET Button Stuck ClosedStation # 1 Control Head CONTROL/SET Button has either been closed too long or has been closed since power up.






39 - 42 Reserved NA

43 Processor-to-Processor Serial Communication Bus Stuffing Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a stuffing type error.

44 Processor-to-Processor Serial Communication Form Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a form type error.

45 Processor-to-Processor Serial Communication Acknowledge Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a acknowledge type error.

46 Processor-to-Processor Serial Communication Bit 1 Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a Bit 1 type error.


Error # Title Description

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47 Processor-to-Processor Serial Communication Bit 0 Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a Bit 0 type error.

48 Processor-to-Processor Serial Communication CRC Error

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a CRC type error.

49 Processor-to-Processor Serial Communication Bus Failure

The Processor-to-Processor Serial Communication’s protocol has detected an error in communication with other devices in the network. The error type is a Bus Failure type error. This error cannot be recovered from without recycling power to the Processor.

50 Processor ID 1 Time-out A Processor has lost communication with Processor ID No. 1.





55 Reserved N/A

56 High Battery Voltage Fault The applied battery voltage has exceeded 30 VDC for 2 or more seconds.

57 Low Battery Voltage Fault The applied battery voltage has dropped to 10 VDC or less for 2 or more seconds.

58 - 61 Reserved - Software NA62 - 67 Reserved NA

68 Station #1 CAN Bus Error The Processor has lost communication with Station No. 1.






74 Communication Error Communications lost between Joystick and SmartCommand.

75 - 77 Reserved - Station CAN Bus Error NA

78 Control head installed backwards Control head installed backwards or both processors set to same ID.

79 Yanmar CAN Throttle Error E0=11 but Smart Command does not detect a Yanmar Engine CAN Throttle input.

80 Communication Time-out with Port Rudder Actuator

This usually is an indication that the cable has been broken, disconnected, wrongly terminated or one of the elements on the bus are not communicating at the right baud rate or protocol.



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81 Communication Time-out with STBD Rudder Actuator


82 Communication Time-out with the Main Helm Motor


83 Communication Time-out with the FlyBridge Helm Motor


84 Port Rudder Actuator Drive Controller has had an internal fault.

The Smart Command will attempt to resolve many types of internal errors but some will need to have the power cycled.

85 STBD Rudder Actuator Drive Controller has had an internal fault.


86 Main Helm Drive Controller has had an internal fault.The Smart Command will attempt to resolve many types of internal errors but some will need to have the power cycled.

87 FlyBridge Helm Drive Controller has had an internal fault.


88 MTCU CAN Fault The processor has lost communication with the ZF Marine Transmission Control Unit (MTCU).

89 MTCU Internal Fault The MTCU is communicating a fault condition to the Processor.

90 Communication Error between the MCU and Smart Command


91 Autopilot CAN Communication Time-out


92 Tach Input 1Tach Input 1: This error is generated only if Smart Command is in a mode that uses the Tach input, such as EASIDOCK or AUTOTROLL.

93 Tach Input 2

Tach Input 2 This error is generated only if Smart Command is in a mode that uses the Tach input, such as EASIDOCK or AUTOTROLL.. This error is generated when the EasiDock LED shows a fast blink error indication.

Most likely this is due to an adjustment of the trolling valve. If the system commands clutch engagement with troll, and the propeller does not rotate within a given time frame, this error will be displayed. Other less likely causes could be mis-adjusted or defective sensor or bad tach connection.

94 ZF Bow Thruster Error The thruster controller has broadcast that it has an error that might reduce or prevent thruster operation.

95 ZF Bow Thruster WarningThe thruster controller has broadcast that it is experiencing a problem and that the operator should be aware that continued use may result in an error.

96 - 99 Reserved NA



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10.9 Problem ScenariosThe following table lists the error codes currently in use, along with possible causes for each error, and potential solutions (including Function Codes in parentheses, where applicable). In most cases the error will appear on the display of the processor (port or starboard) which is directly affected by the fault. However, there may be instances -- such as processor to processor communication -- in which the opposite side is the cause. This table is not an exhaustive itemization of every cause and solution for every error code, but a list of some possible eventualities.

Table 10-5: Problem Scenarios with Error Codes and Possible SolutionsError # Cause Solution

13 Station #1 control head is defective (A to D too low). Replace station #1 control head. Reassign station ID (A3).






23 Station #1 control head is defective (A to D too high). Replace station #1 control head. Reassign station ID (A3).






33

a) The CONTROL/SET button on the station No. 1 control head was held down for 12 seconds or longer. a) Clear the error code from the processor memory.

b) Station No. 1 control head CONTROL/SET button is defective. b) Replace the station No. 1 control head.

34



35



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36



37



38



43 A termination resistor is missing from a processor. Replace the processor.

44 A termination resistor is missing from a processor. Replace the processor.

45 A processor is faulty. Replace the processor.

46a) The serial harness is longer than 120 ft. (37m).

a) Relocate the processors so that the length of the serial harness is less than 120 ft. (37m). Install the shorter serial harness.

b) The serial harness is not properly shielded. b) Install a serial harness with the shields terminated at pin 8 on both sides.










50

a) Power was applied to the starboard processor before it was applied to the port processor. Typically, the port processor is set to ID 1 (A001).

a) Turn off power to both processors and reapply power to the processors simultaneously.

b) Power was lost to processor ID 1 (A001). b) Determine and correct the cause of power loss, and repower the processors.

c) The A0 Function Code of both processors is set to 02.

c) Set Function Code A0 to 01 on the port processor. Cycle power.

d) The port processor is faulty. d) Replace the port processor.


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51

a) Power was applied to the port processor before it was applied to the starboard processor. Typically, the starboard processor is set to ID 2 (A0-02).

a) Turn off power to both processors and reapply power to the processors simultaneously.

b) Power was lost to processor ID 2 (A0-02) b) Determine and correct the cause of power loss, and repower the processors.

c) The A0 Function Code of both processors is set to 01.

c) Set Function Code A0 to 02 on the starboard processor. Cycle power.

d) The starboard processor is faulty. d) Replace the starboard processor.

56a) The battery is being over-charged. a) Correct the charging system as necessary.

b) Loose battery connections while the engine/ alternator is running.

b) Making certain that the battery switches are turned off, clean and tighten all battery connections.

57

a) The battery is not being charged. a) Correct the charging system as necessary.

b) Defective battery. b) Replace the battery.

c) Excessive resistance in the power circuit.

c) Measure the voltage at the battery and at the processor. The difference should not be greater than 3% (taking into consideration the normal 0.7 V drop across the APS).

68

a) Station No. 1 control head cable is not connected. a) Connect the harness to station No. 1 control head.

b) Station No. 1 control head harness is defective. b) Replace the station No. 1 control head harness.

c) Station No. 1 control head ID does not match the programmed processor ID. c) Re-assign station IDs using the A3 Function Code.

d) Defective station No. 1 control head. d) Replace the station No. 1 control head.

69





70





71






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72





73





78

a) The control head is installed backwards (the button labels and LEDs face away, rather than toward, the operator).

a) Remount the control head so the button labels and LEDs face toward the operator.

b) Port and starboard control head cables are reversed. b) Reverse the port and starboard control head harnesses.

88

a) The plugs of the clutch harness are not properly seated.

a) Reconnect the clutch harness plugs at the processor and the MTCU.

b) The clutch harness is defective. b) Replace the clutch harness.

c) The MTCU is defective. c) Replace the MTCU.

d) The processor is defective. d) Replace the processor.

89a) Loss of power to the MTCU. a) Determine and correct the cause of power loss.

b) Defective MTCU. b) Replace the MTCU.

92

a) The sensor is too far from the rotating surface. a) Readjust the air gap.

b) The tachometer wire harness is not properly seated. b) Re-seat the plugs at the processor and the transmission.

c) The tachometer wire harness is defective. c) Replace the tach wire harness.

d) The input shaft sensor is defective. d) Replace the input shaft sensor.

93

a) The sensor is too far from the rotating surface. a) Readjust the air gap.

b) AUTOTROLL or EASIDOCK modes have been selected without the engines running.

b) Before selecting the AUTOTROLL or EASIDOCK modes, start the engines.

c) The tachometer wire harness is not properly seated. c) Re-seat the plugs at the processor and the transmission.

d) The 9 VDC power supply is lost. d) Check pin 1 at the processor tach plug for 9 VDC.

e) The tachometer wire harness is defective. e) Replace the tach wire harness.

f) The output shaft sensor is defective. f) Replace the output shaft sensor.


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10.10 SmartCommand Control Head ReplacementIf you have determined that a control head needs to be replaced, follow the steps below to remove the faulty control head and to install a new one.

10.10.1 Control Head Removal

To remove the control head with the fault:

1. Turn power to the control system off.2. Loosen and remove the four (4) M5 nuts, washers, and lock-washers from the threaded studs, as

shown in Figure 10-17: Control head mounting hardware. Do not discard these. Reattach them to the dismounted control head, for future use.

Figure 10-17: Control head mounting hardware3. Label each wire harness either port or starboard, as appropriate, to avoid confusion when the

harnesses are re-attached.• There are two (2) harness connections and two (2) termination resistors.

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• If additional control heads are connected down the line, there are four (4) harness connections. Refer to Figure 10-18: Connections between control heads.

Figure 10-18: Connections between control heads4. Remove the screw-type harness connections from the control head.

10.10.2 Control Head Installation

Once the faulty control head has been removed, install the replacement as follows:

1. Insert the new control head into the existing cutout space, lining up screw holes.2. Install the four (4) washers, lock washers and nuts.3. Tighten the nuts enough to prevent them from loosening through vibration, but not excessively tight.4. Each control head has two sets of sockets, one set designated as Port input/output (I/O) and the other

as Starboard I/O. See Figure 10-19: Control head bottom view.

Figure 10-19: Control head bottom view

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5. Insert the Port harness plug into either of the Port sockets and the Starboard harness plug into either of the Starboard sockets. Make sure to align the plug and socket keys. See Figure 10-20: Socket key.

6. Remove termination resistors from all control heads except the last one in the chain.

Figure 10-20: Socket key7. Screw the plugs in until they are hand-tight.8. Insert the termination resistors into I/O (b) on the last control head in the chain and hand tighten.

9. Turn DC power to the processors on, but don’t press the CONTROL/SET button on a control head.

10. At the port processor, press the “Down” arrow until A3xx is displayed.11. Press and hold the “Left” and “Right” arrows simultaneously until you are prompted for the pin number

(PIn?), and then release. A second or two later, four dashes will be displayed.12. Press the “Up” arrow once. The number “1” will appear on the first LED.13. Press the “Right” arrow once. A dash will appear at the second LED.14. Press the “Down” arrow once. The number “9” will appear on the second LED15. Press the “Right” arrow once. A dash will appear on the third LED.16. Press the “Down” arrow twice. The number “8” will appear on the third LED.17. Press the “Right” arrow once. A dash will appear on the fourth LED.18. Press the “Down” arrow three times. The number “7” will appear on the fourth LED.19. Press the “Right” arrow once. “A301” will appear with the “A3” blinking.20. Press the “Left” and “Right” arrows simultaneously for approximately two seconds. Release. Repeat this

step until “A300” is displayed.21. Go to the starboard processor and press the “Down” arrow until “A3xx” is displayed.22. Repeat steps 10 through 19.23. At the primary control station (Station No. 1) make sure that the levers are at the neutral/idle detent. All

six LEDs should be blinking red and you should hear a tone.24. Press the CONTROL/SET button. At this point, the blinking red LEDs should go out, the tone should stop,

and the CONTROL LEDs should light green.25. Go to the next control station (if installed) and make sure that the levers are at the neutral/idle detent.

Once again, all six LEDs should be blinking red and you should hear a tone.

IMPORTANT: It is essential that wire harnesses connected to the port side of the processor be connected to the port side of the control head, and that wire harnesses connected to the starboard side of the processor be connected to the starboard side of the control head. If any wires are crossed, some or all of the system components associated with the incorrect control bus will be inoperable.

NOTE: If a station has more than one control head and the control heads are “daisy-chained” together, remove termination resistors and attach control head to control head wire harnesses in place of the resistors.

NOTE: If an error code appears on the display of either processor, ignore it at this time; press the left arrow to exit the error menu and enter the function menu.

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26. Press the CONTROL/SET button. Again, the blinking red LEDs should go out, the tone should stop, and the CONTROL LEDs should light green.

27. Repeat steps 24 and 25 at all remaining stations.28. The new Control Head is ready for operation.

10.11 SmartCommand Processor ReplacementIf you have determined that a processor needs to be replaced, follow the steps below to remove the faulty processor and to install a new one.

10.11.1 Processor Removal

To remove the processor with the fault:

1. Turn DC power to the processors on.2. Take control at any remote station.3. If the part number is scrolling across the processor display, press the “Down” arrow. Refer to Figure 10-

21: SmartCommand processor.

Figure 10-21: SmartCommand processor4. If an error code is displayed, press the “Left” arrow.

• If the display LEDs are not lighted, obtain values from the original setup data inF-259 SmartCommand Sea Trial Report.

• If you cannot find the values in the manual, use values from the functioning processor as a guide. The values are essentially the same, with the exception of the A0 Function Code (ID) The ID of a port processor should always be 01 and a starboard processor is always 02.

5. Function Code A0 should be displayed. Press and hold the “Right” arrow down until all four LEDs are dedicated to displaying the value.

6. Write the value of that Function Code down in Table 10-6: Function Code Values.7. Release the “Right” arrow.8. Press the “Down” arrow once.9. Once again, press and hold the “Right” arrow down until the full four digit value is displayed (on all four

LEDs). Again, write the value of that Function Code down in Table 10-6: Function Code Values.

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10. Repeat the previous two steps until you have recorded the values for all Function Codes in Table 10-6: Function Code Values.

11. Turn DC power to the processors off.12. Unplug the connectors for the clutch, power, throttle, station A, station B, serial, tach, and -- if used --

the ZF CAN 1 and CAN 2 from the defective processor. 13. Disconnect the bonding (grounding) connection from the processor frame.14. Remove the processor’s mounting hardware and set it aside.15. Remove the processor.

10.11.2 Processor Installation

Using the existing hardware, mount the replacement processor, and then:

1. Connect the bonding (grounding) connection to the processor frame.2. Plug the connectors for the clutch, power, throttle, station A, station B, serial, tach, and - if used - the

ZF CAN 1 and CAN 2 into the processor.3. Turn DC power to the processors on. Do not press the CONTROL/SET button at any control head.

4. At the processor which was not removed, press the “Down” arrow until A3xx is displayed.

5. Press and hold the “Left” and “Right” arrows simultaneously until you are prompted for the pin number (PIn?), and then release. A second or two later, four dashes will be displayed.

6. Press the “Up” arrow once. The number “1” will appear on the first LED.7. Press the “Right” arrow once. A dash will appear at the second LED.8. Press the “Down” arrow once. The number “9” will appear on the second LED9. Press the “Right” arrow once. A dash will appear on the third LED.10. Press the “Down” arrow twice. The number “8” will appear on the third LED.11. Press the “Right” arrow once. A dash will appear on the fourth LED.12. Press the “Down” arrow three times. The number “7” will appear on the fourth LED.13. Press the “Right” arrow once. “A301” will appear with the “A3” blinking.14. Press the “Left” and “Right” arrows simultaneously for approximately two seconds. Release. Repeat this

step until “A300” is displayed.15. Go to the new Processor and press the “Down” arrow until “A3xx” is displayed.16. Repeat steps 5 through 14.17. At the primary control station (Station No. 1) make sure that the levers are at the neutral/idle detent. All

six LEDs should be blinking red and you should hear a tone.

Table 10-6: Function Code ValuesFunction Code Value Function Code Value Function Code Value Function Code Value Function Code Value

A0 E5 C7 d2 J3A1 E6 C8 d3 J4A2 E7 L0 d4 J5A3 C0 L1 d5 J6A4 C1 L2 d6 J7E0 C2 L3 d7 U0 *E1 C3 L4 d8 U1 *E2 C4 L5 J0 U2 *E3 C5 d0 J1 U3 *E4 C6 d1 J2 U4 ** The U Function Codes are used only with two-speed applications and, therefore, may not be displayed.

NOTE: If an error code appears on the display of either processor, ignore it at this time; press the left arrow to exit the error menu and enter the function menu.

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18. Press the CONTROL/SET button. At this point, the blinking red LEDs should go out, the tone should stop, and the CONTROL LEDs should light green.

19. Go to the next control station (if installed) and make sure that the levers are at the neutral/idle detent. Once again, all six LEDs should be blinking red and you should hear a tone.

20. Press the CONTROL/SET button. Again, the blinking red LEDs should go out, the tone should stop, and the CONTROL LEDs should light green.

21. Repeat steps 19 and 20 at all remaining stations.22. The control heads are now ready for operation.23. At the new Processor and press the “Up” arrow until “A3xx” is displayed.24. Check the value you see against the value noted in Table 10-6: Function Code Values. Remember that

the Port value should be 01 and Starboard should be 02.25. If the value is incorrect and needs to be changed, enter set-up mode by pressing the “left” and “Right”

arrows until A0 starts to blink and then release.26. Press the “Up” or “Down” arrow until you see the appropriate value, and then press and hold the “Left”

and “Right” arrows simultaneously to enter the new value into memory.27. Press the “Down” arrow to display the next Function Code.28. Press and hold the “Right” arrow down until the full four digit value is displayed (on all four LEDs).29. If the value is incorrect and needs to be changed, enter set-up mode by pressing the “left” and “Right”

arrows until the Function Code starts to blink and then release.30. Press the “Up” or “Down” arrow until you see the value you want and then press and hold the “Left” and

“Right” arrows simultaneously to enter the new value into memory. (In some cases, it may be necessary to press and hold the “Right” arrow while you are pressing the “Up” or “Down” arrow.

31. Repeat steps 26 through 30 to set the values for the remaining Function Codes.32. Press the “Left” arrow on both processors to display the error menu. At this point, there should be no

blinking error code values (signifying active errors). Clear inactive errors -- i.e., those which appear, but are not blinking -- by pressing and releasing the “Right” arrow one error code at a time.

NOTE: If there are no errors, either active or inactive, pressing the left arrow (as directed at the beginning of the last step) will have no effect.

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10.12 Harnesses and Plug Pin-OutsEvery effort is made to manufacture harnesses that work perfectly with the SmartCommand control system. However, occasionally a harness may not function correctly due to factors such as pins that are not fully seated, screw holes that have been drilled through the cable, etc. Pin-out information for the various SmartCommand harnesses is provided below, to aid in the testing and verification of the integrity of the harnesses.

10.12.1 Basic Control System Harnesses

10.12.1.1 Serial Wire Harnesses

The pin-out diagrams shown in the figures below are for the harnesses associated with power.

Table 10-7: Wire Harness - Processor to Processor (p/n 70261-XX)

Termination A Termination B

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10.12.1.2 Throttle Harnesses

The pin-out diagrams shown in the figures below are for the harnesses associated with throttles.

Table 10-8: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX)


Table 10-9: Voltage Throttle Harness Pin-Out (p/n 14148-XX)


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Table 10-10: Wire Harness - Throttle (Pulse Width Modulation [PWM]), (p/n 13533-XX)


Table 10-11: Wire Harness - Cable, Throttle, MAN EDC (p/n 14421-XX)


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Table 10-12: Wire Harness- Throttle & Clutch Ahead/Astern w/Neutral Interlock, MAN- Sc (p/n 70588-XX)


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Table 10-13: Wire Harness- Throttle, Yanmar CAN Interface, SC (p/n 70766-XX)


Table 10-14: Wire Harness- Throttle, MTU Smartline- SmartCommand (p/n 70747-XX)


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Table 10-15: Wire Harness- Throttle/Neutral Interlock, MAN (p/n 70263-XX)


Table 10-16: Voltage Throttle Harness Pin-Out (p/n 71262-XX)


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10.12.1.3 Tachometer Harnesses

Table 10-17: Wire Harness- Throttle, Dual Voltage- SmartCommand And MiniCommand (p/n 71589-XX)


Table 10-18: Wire Harness- Tach (Input And Output Shafts) SmartCommand (p/n 70494-XX)


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10.12.1.4 Clutch Harnesses

Table 10-19: Wire Harness- Clutch Ahead/Astern (p/n 15719-XX)


Table 10-20: Subassembly, Wire Harness Clutches with Troll (p/n 15725-XX)


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Table 10-21: Wire Harness - Clutch/Troll Command (p/n 15732-XX)


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Table 10-22: Wire Harness - Clutch/Ahead/Astern/Troll Command/Troll On-Off (p/n 70390-XX)


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Table 10-23: Wire Harness - Clutch/Ahead/Astern- ZFF Transmission (p/n 70673-XX)


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Table 10-24: Wire Harness - Clutch ZF Gear, MTU Smartline- SmartCommand (p/n 70901-XX)


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Table 10-25: Wire Harness - Clutch/Shaft Tach, SmartCommand (p/n 70259-XX)


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10.12.1.5 Power Harnesses

Table 10-26: Power, Start Interlock Harness Pin-Out (p/n 13756-XX)


Table 10-27: Wire Harness - Power, SI & Clutch Pressure Switch (p/n 13552-XX)


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Table 10-28: Wire Harness - Power, SI, Clutch Pressure Switch & Alarm (p/n 13631-XX)


Table 10-29: Wire Harness- Power Use w/ existing Start Interlock Only (p/n 15023-XX)


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Table 10-30: Wire Harness- Power/Backup Input For MTU Start Interlock w/ SC (p/n 71021-XX)


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Table 10-31: Wire Harness - Power, Start Interlock, Pressure SW, Alarm & Backup (p/n 71476-XX)


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10.12.1.6 Control Head Harnesses

Table 10-32: Wire Harness- Control Head To OBOF Panel, Port and Stbd (p/n 71495-XX)


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Table 10-33: Wire Harness - Control Head to Control Head (p/n 70268-XX)


Table 10-34: Wire Harness - Control Head to Processor (p/n 70269-XX)


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10.12.1.7 CANtrak Display Wire Harnesses

The wire harnesses and the resistor shown in the figures below are necessary when CANtrak Displays are installed on a vessel.

Table 10-35: Wire Harness - Iso CAN (p/n 70559-XX)


Table 10-36: CANtrak termination resistor (p/n 70540-XX)


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APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS


MMSC5000 SmartCommand User ManualAppendix A

11 Appendix A - System Components and Specifications

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MMC-341 5000 Series Control Head Variations


5000 Series Control Head Variations

MMC-341 Figure-1: 5200 Standard Control Head

MMC-341 Figure-2: 5200 Low-Profile Control Head


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MMC-341 Figure-3: 5100 Standard Control Head

MMC-341 Figure-4: 5100 Low-Profile Control HeadRefer to Section 13: Appendix C - System Drawings to see SmartCommand system drawings and power connection diagrams.

P/N

S/N

ZF MARINE ELECTRONICS, LLC

S/W

PCA

P/N

S/N

ZF MARINE ELECTRONICS, LLC

S/W

PCA

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IMPORTANT: Every effort has been made to ensure that this drawing is to scale. However, there can be no absolute guarantee that the drawing size is exact. Therefore, it is important that you verify all measurements before cutting.

WARNING: Mount SmartCommand control heads at least 250 mm (9.84 in.) from compasses. If a safe mounting distance is not maintained, electromagnetic fields could influence SmartCommand control head electronic circuits, cause erratic operation, and possibly impair compass directions. Personal injury could result if this message is disregarded.

WARNING: Note that the dimensions are out of scale, pay attention to properly size the cut out before use !

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MMC-337 4000 Series Standard Control Head Variations


4000 SERIES CONTROL HEAD VARIATIONS

This Service Sheet reflects all current variations of the standard 3-detent (Neutral, Forward, Reverse) ZF Marine Propulsion Systems Miramar 4000 Series Control Heads.

4100 Control Head(Dwg 13932)Control Head, 4000 Series, Single Screw. This control head has a bridge between the levers to join them.

4100LP Control Head (Low Profile)(Dwg 13932)Control Head, 4000 Series, Single Screw, Low Profile. This control head has a bridge between the levers to join them.

4200 Control Head(Dwg 13932)Control Head, 4000 Series, Twin Screw.

4200LP Control Head (Low Profile)(Dwg 13932)

Control Head, 4000 Series, Twin Screw, Low Profile. 4200AF Control Head(Dwg 13932)

Control Head, 4000 Series, Twin Screw, Aft Facing


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Requirements:

INCLUDED WITH THE CONTROL HEAD:

Mounting Studs with washers and nuts.mounting and installation:

1. Select the desired mounting location(s) and make cutout(s) per dimensions shown in Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293.

2. Check that the four mounting studs on the Control Head will start into the cutout mounting holes. Remove Control Head from cutout.

3. Run cable/wire harnesses between Processor and Control Head. Label both ends with the Station ID. (EXAMPLE: Port Bridge, Stbd Bridge or Port Wing, etc.).

CONNECTIONS

The 4000 series Control Heads are only available with pluggable connections and must not be modified in any way. However, there are two types of Wire Harnesses available for connecting the Control Head to the Processor (CruiseCommand, ClearCommand, etc.):

• Pluggable on both ends.• Pluggable on one end and hard wired on the other.

The Wire Harnesses for CruiseCommand and the MiniCommand Processors are always pluggable at both ends. The Wire Harnesses for the 9000 Processors (MicroCommander and ClearCommand) can be pluggable at both ends or pluggable at the Control Head end and hard wired at the Processor end.

PLUGGABLE1. Plug Control Head wire harness into the corresponding connector/pigtail coming from the Processor. Ensure the

correct Processor Cable is being plugged into the correct Control Head pigtail. (Example: Port to Port, Starboard to Starboard.)

When making the connection, ensure that the mating connectors (plug and receptacle) are fully inserted such that the connector latches are locked in place. (Note: To disconnect the connectors, the release button or buttons must be depressed and held until the plug and receptacle are fully disconnected.)

Control System Wire Harness Description

MicroCommander/ ClearCommand (non-pluggable)

(1) Control Head wire harness per lever. See Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2, Figure MMC-337-3: Port Processor - Hard wiring Drawing 13932A - 15B and Figure MMC-337-4: Starboard Processor - Hard wiring Drawing 13932A - 15A

Pluggable Micro Commander/Clear Command

(1) Control Head wire harness per lever. See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1

CruiseCommand (1) Control Head wire harness per lever. See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1

MiniCommand (1) Control Head wire harness per Control Head. See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1

CAUTION: Disconnecting plugs without depressing and holding the release button or buttons will damage the plug.

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CABLE/HARNESS CONNECTIONS PLUGGABLE

Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1

PLUGGABLE CONNECTIONS

WARNING: Pluggable Control Heads are supplied with a harness pigtail for each lever. When disconnecting the plugs, ensure that the release button or buttons are depressed and held until the plug is fully disconnected. Disconnecting the plugs without depressing and holding the release button or buttons WILL damage the plug.

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HARD WIRED CONNECTIONS NON-PLUGGABLE

Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2

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PORT & STARBOARD PROCESSOR HARD WIRING

Figure MMC-337-3: Port Processor - Hard wiring Drawing 13932A - 15B

Figure MMC-337-4: Starboard Processor - Hard wiring Drawing 13932A - 15A

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4200 CONTROL HEAD FRONT VIEW

Figure MMC-337-5: 4200 Control Head - Front View Dwg #14132

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4200 CONTROL HEAD SIDE VIEW

Figure MMC-337-6: 4200 Control Head - Side View Dwg #14133

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4100LP CONTROL HEAD FRONT VIEW

Figure MMC-337-7: 4100LP Control Head – Front View Dwg #13932ART-8

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4100LP Control Head Side View

Figure MMC-337-8: 4100LP Control Head – Side View Dwg 13932ART-9

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4000 SERIES CONTROL HEAD MOUNTING DIMENSIONSCAUTION: NOT TO SCALEDO NOT USE AS A TEMPLATE

Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293 SEE FOLLOWING PAGE FOR TEMPLATE

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4000 SERIES CONTROL HEAD MOUNTING CUTOUT

Figure MMC-337-10: Control Head Mounting Holes and Cutout – Dwg #14649


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MMC-329 Rev E.2 02/12 Page 197

MMC-329 MC2000 Series Standard Control Head Variations


MC2000 Series Standard Control Head Variations

This Service Sheet reflects all current variations of the standard 3-detent ZF MC2000 Series Control Heads.

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

REQUIREMENTS:

MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head lever. CruiseCommand: one (1) Control Head Harness per Control Head lever. Included with the Control Head:

• Mounting screws• Terminals (For 8-Conductor or 1-Connector Harnesses)• Watertight cable grip for the cable entrance on the Processor (For 8-Conductor)

When the Control Head is properly mounted on a console, it is spray proof from the top only. An adhesive gasket is mounted on the bottom of the Control Head to seal it to the mounting surface. However, below the mounting surface it needs protection from water or spray. Consider using a Weather Mount Enclosure, which is available from ZF.

MOUNTING AND INSTALLATION:

A Select the desired mounting locations and make cutouts per template. Refer to Figure MMC-329-2: Dimensions.

B Check that the two mounting screws will start into the Control Head. Remove Control Head from cutout.

C Run cable/harnesses between Processor and Control Head. Label both ends with the Station ID. (EXAMPLE: Port, Center, or Starboard; Port Thrust, Port Throttle; etc.)

Revision List


- to E.1 03/11 Previous date unavailableE.2 02/15/12 Added compass distance note

WARNING: Do not mount control head less than 250mm from Compass.Mounting a control head too close to compass can cause the compass to malfunction.


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Dimensions

Figure MMC-329-2: DimensionsThere are two types of Control Head connections available: Plug or Terminal Connected. Both types may be used with MicroCommander, ClearCommand, or CruiseCommand using the appropriate cable or harness. Follow the appropriate steps for the Control Head that has been supplied for your system.

Pluggable

A Plug Control Head cable into the pigtail at the Control Head. (Ensure the correct Processor Cable is being plugged into the corresponding Control Head lever pigtail).

B When connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully connected or disconnected.

C Connecting or disconnecting plugs without depressing and holding the release button or buttons will damage the plug.

Standard Cable

A Strip back the PVC cover on the shielded cable approximately 2-1/2” (63,5mm) at the Control Head. B At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end

of the PVC cover (the drain wire at the Control Head is not connected to ground).C Strip 3/8” (9,5mm) insulation off each wire.D Twist the individual strands of the wires to minimize fraying.E Crimp a locking fork terminal (included with each Control Head) to each of the conductors.F Make connections to the Control Head as indicated in the following TERMINAL CONNECTIONS

diagrams.

ALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM FOR ANY UNIQUE CONTROL HEAD CONNECTIONS FOR YOUR SYSTEM.

When cable connections are complete, MOUNT Control Head to the console using the two (2) mounting screws and washers supplied with the Control Head.

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CABLE/HARNESS CONNECTIONS:

Dual Control Head Connections

Figure MMC-329-3: Terminal ConnectionsCable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.

Pluggable Connections

Pluggable Control Heads are supplied with a harness pigtail for each lever. When disconnecting/connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully disconnected or connected. Disconnecting/connecting plugs without depressing and holding the release button or buttons WILL damage the plug.

Aft Facing Control HeadsFor dual lever Control Head Stations that have the user facing aft: Reverse connections 5 and 7. For single lever Control Head Stations that have the user facing aft and the one Control Head lever on the user’s right, reverse connections 5 and 7.

Figure MMC-329-4: AFT Facing Control HeadHandheld Control is an option. Contact your ZF Dealer for further information on Handheld requirements and options.

MicroCommander/ClearCommand CruiseCommand/9000 Series

Port Lever: Starboard Lever: Port Lever: Starboard Lever:

Terminal 3 Red Terminal 3 Red Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER

Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER

Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue

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WARNING: Do not mount control head less than 250mm from Compass.Mounting a control head too close to compass can cause the compass to malfunction.

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400 Series Control Head Variations

This Service Sheet reflects all current variations of the standard 3-detent ZF 400 Series Control Heads.

Figure MMC-280-1: Part Numbering Configurations

Figure MMC-280-2: Detents Available1. Requirements:

MicroCommander/ClearCommand: one (1) 8-Conductor Cable per Control Head lever.Pluggable MicroCommander/ClearCommand: one (1) Control Head Harness per Control Head lever. CruiseCommand: one (1) Control Head Harness per Control Head lever. Included with the Control Head:

• Gasket• Mounting screws and washers• Terminals (For 8-Conductor or 1-Connector Harnesses)• Watertight cable grip for the cable entrance on the Processor (For 8-Conductor)

When the Control Head is properly mounted on a console, it is spray proof from the top only. An adhesive gasket must be used to seal it to the mounting surface. However, below the mounting surface it needs protection from water or spray. Consider using a Weather Mount Enclosure, which is available from ZF.

Revision List


- to N.1 07/10 Previous date unavailableN.2 02/15/12 Added compass distance note


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2. Mounting And Installation:A Select the desired mounting locations and make cutouts per template. Refer to Figure MMC-280-3:

Dimensions.B Check that the four mounting screws will start into the Control Head. Remove the Control Head from

the cutout.C Remove the backing from the adhesive gasket and apply the gasket adhesive side to the console

around the cutout. D Run cable/harnesses between Processor and Control Head. Label both ends with the Station ID.

(EXAMPLE: Port, Center, or Starboard; Port Thrust, Port Throttle; etc.)There are two types of Control Head connections available: Plug or Terminal Connected. Both types may be used with MicroCommander, ClearCommand, or CruiseCommand using the appropriate cable or harness. Follow the appropriate steps for the Control Head that has been supplied for your system.

3. Type 1 - PluggablePlug Control Head cable into the pigtail at the Control Head. (Ensure the correct Processor Cable is being plugged into the corresponding Control Head lever pigtail). 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.

4. Type 2 - Hard-wiredA Strip back the PVC cover on the shielded cable approximately 2-1/2” (63,5mm) at the Control Head. B At the Control Head end of the cable strip and cut off the shielding and drain wire flush with the end

of the PVC cover (the drain wire at the Control Head is not connected to ground). C Strip 3/8” (9,5mm) insulation off each wire. D Twist the individual strands of the wires to minimize fraying.E Crimp a locking fork terminal (included with each Control Head) to each of the conductors. F Make connections to the Control Head as indicated in the following TERMINAL CONNECTIONS

diagrams.

Figure MMC-280-3: DimensionsALWAYS REFER TO THE MANUAL THAT IS SUPPLIED WITH THE CONTROL SYSTEM FOR ANY UNIQUE CONTROL HEAD CONNECTIONS FOR YOUR SYSTEM.When cable connections are complete, MOUNT Control Head to the console using the four (4) mounting screws and washers supplied with the Control Head.

WARNING: Do not mount control head less than 100mm from Compass.Mounting control head too close to compass can cause the compass to malfunction.

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5. CABLE/HARNESS CONNECTIONS:

Figure MMC-280-4: Terminal ConnectionsCable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.

6. Pluggable ConnectionsPluggable Control Heads are supplied with a harness pigtail for each lever. When disconnecting/connecting the plugs, ensure that the release button or buttons are depressed and held until plug is fully disconnected or connected. Disconnecting/connecting plugs without depressing and holding the release button or buttons WILL damage the plug.

7. AFT FACING CONTROL HEADS

Figure MMC-280-5: AFT Facing Control HeadFor dual lever Control Head Stations that have the user facing aft: Reverse connections 5 and 7. For single lever Control Head Stations that have the user facing aft and the one Control Head lever on the user’s right, reverse connections 5 and 7.Handheld Control is a Station option. Contact your ZF Dealer for further information on Handheld requirements and options.

MicroCommander/ClearCommand CruiseCommand/9000 Series

Port Lever: Starboard Lever: Port Lever: Starboard Lever:

Terminal 3 Red Terminal 3 Red Terminal 3 Red & JUMPER Terminal 3 Red & JUMPER

Terminal 5 Blue Terminal 5 Yellow Terminal 5 Blue Terminal 5 JUMPER

Terminal 7 Yellow Terminal 7 Blue Terminal 7 JUMPER Terminal 7 Blue

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WARNING: Do not mount control head less than 100mm from Compass.Mounting control head too close to compass can cause the compass to malfunction.


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S-214 Rev H.1 03/11 Page 207

S-214 APS [Model 13505] Automatic Power Selector

S-214 Automatic Power Selector Model: 13505

Automatic Power Selector (APS) Model: 13505ATTACHMENTS: DC POWER SOURCE DWG 11488

A GENERAL INFORMATIONThe APS, Model 13505, provides a simple, solid state solution to the need for routing redundant DC power sources for vital electronic equipment while maintaining isolation of the DC power sources.Two independent batteries rated at the same nominal voltage are wired to separate terminals on the APS and internal diodes maintain total isolation between them. A single output terminal is wired to the ZF Marine Propulsion Control System.The APS is rated for loads of up to 70 Amps on 12-24VDC systems. The unit is ruggedly constructed with heavy-duty wiring studs and epoxy-potted components in an anodized aluminum case.

B APS SPECIFICATIONSModel: 13505Maximum Load Current: 70 ampsOperating Temperature: - 40 degrees C to +80 degrees C; derate linearly from 100% @ 50 degrees C to 70% @ 80 degrees CVoltage Drop: 0.7 VDC @ 50% load; 0.9 VDC @ full loadDimensions: 3.25" x 4.5" x 3.1" (8,3 x 11,4 x 7,9 cm)

C MATERIALS PROVIDEDThe single APS is supplied with a hardware packet containing (6) hex nuts, (3) lock washers, (4) self-tapping mounting screws, (1) instructions diagram.

The twin APS is supplied with (2) single APS hardware packets.

D INSTALLATIONRefer to Drawing 11488 DC Power Source Kit.

1. Shut off all charging sources and disconnect the negative (ground) side of each battery which will be wired to the APS.

2. Mount the APS(s) in a suitable location which will keep wire runs to a minimum length, and is preferably ventilated, for cooler operation. The case of the APS is electrically isolated from the internal diodes, so mounting on either a metal or non-metal surface is acceptable.

3. Complete the wiring as indicated.4. Reconnect the negative battery posts.

E IMPORTANT NOTE ABOUT BATTERY SOURCESWhenever the load is turned on, it can be drawing power from the batteries. Therefore, if the batteries are not simultaneously being recharged, or if charging will not be available for an extended period, it is recommended that the load be shut off to prevent complete discharge of batteries.

NOTE: Not all of the hardware will be used in the installation; some spares are provided. Nut size is M-6.


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Drawing 11488 DC Power Source Kit

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MMC-287 Rev G.2 08/12 Page 219

MMC-287 Grounding (Bonding)

MMC-287 Grounding (Bonding)

Grounding (Bonding)

Grounding (Bonding) - 46 CFR 111.05 and ABYC Section E-11: July 2012Grounding (Bonding) should be done according to ABYC Section E-11 and Code of Federal Regulations 46 CFR 111.05.

Each grounded system must have only one point of connection to ground regardless of the number of power sources operating in parallel in the system.A vessel's hull must not carry current as a conductor. A metallic hull, or the bonding and DC grounding systems, shall not be used as a return conductor.There are some limited exceptions: (1) Impressed current cathodic protection systems. (2) Limited and locally grounded systems, such as a battery system for engine starting that has a one-wire system and the ground lead connected to the engine. (3) Insulation level monitoring devices if the circulation current does not exceed 30 milliamperes under the most unfavorable conditions. (4) Welding systems with hull return except vessels subject to 46 CFR Subchapter D. Grounding conductors should be identified via a green or green with a yellow stripe jacket, and shall not be used as a return. Where grounding conductors are attached to Processors or other CE marked devices – a tinned copper braid is the preferred grounding method - per References: CFR Sec. 111.05-11, Sec. 111.05-13 and ABYC E-11 sect. 11.4.

a Grounding diagram is used courtesy of American Boat and Yacht Council. All parts of figure except processors and processor connection © 2003 American Boat and Yacht CouncilMetal - Hull Vessels

The hull of a metal hull vessel may serve as the common grounding conductor. If it is desirable for the item being installed to be bonded to the vessel grounding system, and the installation or mounting method does not provide the desired path, a separate grounding conductor may be required.


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MMC-288 Rev E.1 06/09 Page 221

MMC-288 References and Parts Sources

MMC-288 References and Parts Source

References and Parts Sources

References

A American Boat & Yacht Council (ABYC)3069 Solomons Island RoadEdgewater, MD 21037-1416

E-3 Wiring Identification on BoatsE-11 AC and DC Electrical Systems on BoatsH-2.4e or 32.4g Ambient Temp. 50 degrees CP-24 Electric/Electronic Propulsion Controls

B Code of Federal Regulations33 CFR 183 Subpart I - Electrical Systems33 CFR 183.410 Ignition protection33 CFR 183.415 Grounding33 CFR 183.425 Conductors: General33 CFR 183.430 Conductors in circuit of less than 50 Volts33 CFR 183.445 Conductors: Protection33 CFR 183.455 Over-current and Protection: General46 CFR 111.01 - 15(b) Ambient Temp. Machinery Spaces 50 degrees C46 CFR 111.05- System Grounds

C Society of Automotive Engineers400 Commonwealth DriveWarrendale, PA 15096

J1171 External Ignition ProtectionJ1428 Marine Circuit BreakersJ378 Marine Engine Wiring

D National Marine Manufacturers Association401 North Michigan AvenueChicago, IL 60611

E Underwriters Laboratories

Parts Source

Anti-Static Wrist Strap - - - - - - - - - P/N 517 [Thomas & Betts (P/N AWCC)]Automatic Power Selector - - - - - - - P/N 13505Circuit Breaker- UL Approved - - - - - - P/N 810 [E-T-A (P/N 41-2-514-LN2-10)]Fuse- - - - - - - - - - - - - - - - - - P/N 1030 [Bussman (P/N. GDC-1A)]Relay 12 VDC - - - - - - - - - - - - - P/N 1114 [Potter-Brumfield (P/N KRPA5D6-12)]Relay 24 VDC - - - - - - - - - - - - - P/N 1122 [Potter-Brumfield (P/N KRPA5D6-24)]Service Field Test Unit (Break-out Box) - P/N 13927WAGO Tool - - - - - - - - - - - - - - P/N 397 [WAGO (P/N 236-332)]Field Test Control Head - Dual - - - - - P/N 14000


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APPENDIX B - SALES AND SERVICE INFORMATION


MMSC5000 SmartCommand User ManualAppendix B

12 Appendix B - Sales and Service Information

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MMC-172 Factory Authorized Service Centers - International

MMC-172 Rev A.8 07/10 Page 225

MMC-172 Factory Authorized Sales & Service Centers - Inter-national

Factory Authorized Sales & Service Centers - International

Argentina Australia

Brazil

Chili

Company: Transmsiones Marinas S.A.

Contact: Ing. Daniel Canoura

Address: Hernandarias 3656

B7603GNH Mar Del Plata

Argentina

Phone: 54-223- 410 7975

Fax: 54-223- 480 7174

Email: [email protected]; [email protected]

Website: www.tmgroup.com

Company: Trimer S.A.

Contact: Carlos Dorian Freidlander

Address: Attn: Mariano Castroverde

PO Box 772

1000 Buenos Aires, Argentina

Shipping: Fray J.S.M. de Oro 2030-40

1425 Buenos Aires, Argentina

Phone: 54-11-4580-0444

Fax: 54-11-4580-0440

Email: [email protected]

Company: ZF Services Australia Pty, Ltd.

Contact: Gary Bain, Rodney Lean

Address: Locked Bag 6305

Blacktown BC NSW 2148

Australia

Shipping: 14 Lidco Street

Arndell Park, NSW 2148

Australia

Phone: 61- (0)2-9679-5555

Fax: 61-(0)2-9679-5500

Email: [email protected] or [email protected]

Website: www.zf.com.au

Company: ZF do Brazil S.A.

Contact: Richard Bergamini

Address: Avenida Conda Zepplin, 1935

CEP 18103-0000 Sorocaba, Brazil

Phone: 5515-235-2301

Fax: 5515-235-2233


Website: www.zf.com

Company: Equipamiento Marino Ltda

Contact: Christian Rogers Nickelmann

Address: Rafael Correa 1268 Vitacura

Santiago, Chili

Phone: (56-2) 4158737

Fax: (56-2) 9-9975059



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APPENDIX B - SALES AND SERVICE INFORMATIONMMC-172 Factory Authorized Service Centers - International

MMC-172 Rev A.8 07/10 Page 226

China Denmark

Ecuador

Finland

France

Company: Foilborne Engineering, Ltd.

Contact: Paul Chow

Address: Unit A 7-9, 13/F Veristrong

34-36 Au Pui Wan Street / FO-Tan

Shatin, N.T.

Hong Kong, China

Phone: 852-2687-2988

Fax: 852-2687-1996


Company: Renford Marine Equipment (China) Ltd.

Contact: Anthony Yuen

Address: 501 Laws Commercial Plaza

788 Cheung Sha Wan Road

Hong Kong, China

Phone: 852-27427111

Fax: 852-27427171


Company: Renford Marine Equipment (Shanghai) Ltd.

Contact: Anthony Yuen

Address: 811 Jiaxing Building

877 Dong Fang Road, Pudong

Shanghai, China 200122

Phone: 8621-50589000

Fax: 8621-505880007


Company: ZF Shanghai Rep. Office

Contact: Tang Zhou Qing, Gong Lan

Address: Room 2504, Jiangnan Building

No. 600 Luban Road

Shanghai, 200023, PR China

Phone: 0086-21-6301-4338

Fax: 0086-21-6301-6449


Website: www.zf-marine.com

Company: ZF Danmark APS

Contact: Michael Johansson, Frank Kiessling

Address: Taastrupgaardsvej 8-10

Taastrup, DK-2630, Denmark

Phone: 45-7022-6243

Fax: 45-7022-2643



Company: ZF Marine’s Consulting

Contact: Pedro Aspiazu

Address: Urdesa Central 1A #13184 Costanera

Guaaquil – Guayas, Ecuador

Phone: (593-4) 238-9306

Fax: (593-4) 238-4010


Company: Atoy Oy

Contact: Antti Hiidenheim

Address: PO Box 137

FIN-00101, Helsinki

Finland

Phone: 35-8968271

Fax: 35-896827305


Company: ZF France

Contact: Ronald Gamere

Address: 3, rue Henri Poincare’

92167 ANTONY CEDEX, France

Phone: +33 (01) 40 96 42 74

Fax: +33 (01) 40 96 42 74


Website: www.zf.com/sso/fr

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Germany

Greece

Iceland

Ireland

Italy

Japan

Company: Otto Piening Propeller GMBH

Contact: Mathias Pien

Address: AM Altendeich 83

D25348 Glückstadt

Germany

Phone: 49-4124-916812

Fax: 49-171-4853376


Website: www.piening-propeller.de

Company: Amaltheia Marine, Ltd

Contact: Demetris Kyriazis

Address: 13 Papaflessa Str.

143 43 N. Halkidona

Athens, Greece

Phone: 30210-25-88-985

Fax: 30210-25-89-986


Company: Maras ehf

Address: Gudmundur Bragasson

Akralind 2

201 Kopavogur

Iceland

Phone: 354-555-6444

Fax: 354-565-7230


Company: ZF Services Great Britain, Ltd

Contact: Adi License

Address: Abbeyfield Road, Lenton

Nottingham, United Kingdom

NG7 2SX, England

Phone: 44-115-986-9211

Fax: 44-115-986-9261



Company: Saim SPA

Contact: Antonio Renzetti, Alessandro Busetto

Address: Via Donizetti, 9/11

20090 Assago (MI)

Italy

Phone: 39-02-488-521

Fax: 39-02-45703070


Website: www.saim-group.com

Company: ZF Marine Japan Co. Ltd

Contact: Y. Ikeda, Nobora Kasajima

Address: Fujikoshi Bldg. 1-10-11 Iriya taito-ku

Tokyo, 110-0013

Japan

Phone: 81-03-5808-4521

Fax: 81-03-5808-4531



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Korea

Mexico

New Zealand

Norway

Peru

Company: SE Jung Engineering Co.

Contact: M.G. Song

Address: #35-4 Namhangdong-1KA

Yeongdogu

Pusan, Korea

Phone: 82-51-415-0591

Fax: 82-51-412-6361


Company: Baja Naval, s.a. de c.v.

Contact: Jaime Hernandez, Alfredo Soqui, Mario Herrera

Address: Av. de le Marina, 10

Ensenada,

Baja California Norte 22800

Phone: 011 52 646 174 0020

Fax: 011 52 646 174 0028


Company: RAL LINE, S.A. DE C.V.

Contact: Ing. Ernesto Cadavid

Address: Av. Gran Via Tropical #8

Fraccionamiento Las Playas

Acapulco, Gro. Mexico

Phone: 744-482-6365

Fax: 744-482-6365


Company: ZF Services Australia Pty, Ltd

Contact: Gary Bain, Rodney Lean

Address: Locked Bag 6305

Blacktown BC

NSW, Australia 2148

Shipping: 14 Lidco Street

Arndell Park, NSW

Australia 2148

Phone: 61-02-9679-5555

Fax: 61-02-9679-5500

Email: [email protected] or [email protected]

Company: KGK Norge AS

Contact: Bjorn Reiersen

Address: Casper Storms Vei 19

N-0064 Oslo

Norway

Phone: 47-22-884-680

Fax: 47-22-720-902


Company: PGO International S.A.C

Contact: Pedro Gonzalez – Orbegoso

Address: AV. Arequipa 2450 of 1108

Lima 14, Peru

Phone: (51-1) 421-6055

Fax: (51-1) 421-6664


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Russia

Scotland

Singapore

South Africa

Spain

Company: ZF Russia

Contact: Anastassia Selverstova

Address: 71, Marata Street Ste 313

St Petersburg

Russia 191119

Phone: 7-812-324-54-72

Fax: 7-812-140-18-15


Company: ZF Services Great Britain, Ltd

Contact: Adi License

Address: Abbeyfield Road, Lenton

Nottingham, United Kingdom

NG7 2SX England

Phone: 44-115-986-9211

Fax: 44-115-986-9261



Company: Mammoth Enterprises Pte, Ltd

Contact: Steven Wee

Address: PO Box 283

Siglap Post Office

Singapore 914503

Shipping: 6-A Waringin Park

Singapore 416320

Phone: 65-6-44-88266

Fax: 65-6-44-89800


Company: ZF South East Asia

Contact: Sharon Ho

Address: 11, Tuas Drive 1

Singapore

Phone: 6861-0177

Fax: 6861-9173

Email: sharon.ho@zf-seasia

Company: ZF South Africa Pty, Ltd

Contact: Heather Hermann

Address: PO Box 2098

Kempton Park, 1620 South

Africa

Shipping: C/O Barlows Power Systems

Cnr Peter Barlow and Kasselss Vlei Rd

Phone: 27-11-453-1818

Fax: 27-11-453-7506


Company: ZF Espana S.A.

Contact: Maria Valladolid

Address: Avda. Fuentemar, 11

Coslada (Madrid) 28820

Spain

Phone: 34 (0) 91485-2695

Fax: 34 (0) 91485-0036



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Sweden

Switzerland

Taiwan

Thailand

The Netherlands (Holland)

U.A.E.

Company: KG Knutsson AB

Contact: Karl-Henry Pragsten

Address: Tansmissions Divisionen

Hammarbracken 8

S-191 81 Sollentuna

Sweden

Phone: 46-08-923-312

Fax: 46-08-929-599


Website: www.kgk.se

Company: Marine Parts Technic

Contact: Fabian Kraemer

Address: Pfaffikerstrasse 6

CH-8604 Volketswil

Zurich, Switzerland

Phone: 41-1997-4090

Fax: 41-1997-4094


Website: www.marineparts.ch

Company: Asia Diesel electric Corp

Contact: Mike Ou

Address: 8F-1, No. 34, Min Chuan 1s. Road

Kaohsiung, Taiwan. #80205

Phone: 886-7-3331191

Fax: 886-7-3346808


Website: www.asiadiesel.com.tw

Company: ZF Thailand Co. Ltd

Contact: Reungpoj V

Address: 159/33 Soi Vipawasee 64

Vipawasee-Rangsit Road

Laksi, Bangkok 10210 Thailand

Phone: 66-2-521-6520

Fax: 66-2-521-6523


Company: ADS/van Stigt

Contact: Ton Hekman, Rob van der Linde

Address: Avelingen – West 30

NL-4202 MS Gorinchem

The Netherlands

Phone: 31-0-183-650000

Fax: 31-0—183-650001


Website: [email protected]

Company: ZF Middle East, LLC

Contact: M. Narasimhan (Narsi), A.T. Moorthy

Address: PO Box 26093

Sharjah, U.A.E.

Shipping: #502 Golden Tower Building

Sharjah, U.A.E.

Phone: 971-6-5747074

Fax: 971-6-5747174


Website: www.zf.com

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United Kingdom

USA

Venezuela

Company: Atlantis Marine Power, Ltd

Contact: Peter Middleton, Paul Lakey

Address: Western wood Way

Language Science Park

Plymouth, Devon, PL7 5BG

5BG England

Phone: 44-1752-208810

Fax: 44-1752-208811


Website: www.atlantismarine.co.uk

Company: ZF Marine Propulsion Systems Miramar – US Headquarters

Contact: A.J. Halavacs

Address: 15351 SW 29th Street, Ste 300

Miramar, FL 33027

Phone: 954-441-4040

Fax: 954-441-4140


Website: www.zf.com

Company: ZF Marine Propulsion Systems Miramar, LLC – Gulf Coast

Contact: Mike Gauthreaux

Address: 161 James Drive West

Suite 120

St Rose, LA 70087

Phone: 504-443-0501

Fax: 504-443-0504


Website: www.zf.com

Company: ZF Marine Propulsion Systems Miramar –West Coast

Contact: Kevin Zwicker

Address: 12125 Harbour Reach Drive Ste B

Mukilteo,WA 98275

Phone: 425-583-1900

Fax: 425-493-1569


Website: www.zf.com

Company: Sistemas de Propulsion C.A.

Address: AV 67a Entre 149By 150

2 Etapa Zona Industrial

Maracaibo, Venezuela

Phone: 58-261-736-0747

Fax: 58-261-736-0746


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MMC-165 Rev G.1 04/09 Page 233

MMC-165 Electronic Propulsion Control Systems Limited Warranty

MMC-165 Warranty

Electronic Propulsion Control Systems Limited Warranty

A Limited Warranty: Your ZF product was designed and manufactured by experienced engineers and craftsmen. ZF Marine Propulsion Systems Miramar, LLC warrants for the period indicated below, each product manufactured by ZF Marine Propulsion Systems Miramar, LLC to be free from defects in materials and workmanship. If during the applicable warranty period a product is determined by ZF Marine Propulsion Systems Miramar, LLC to be in breach of this limited warranty, ZF Marine Propulsion Systems Miramar, LLC, at its option, will repair or replace the defective product.

B Warranty Exclusions: This warranty covers only failures due to defects in materials or workmanship that occurs during normal use. This warranty does not cover damage that occurs in shipment, failures that are caused by products not supplied by ZF Marine Propulsion Systems Miramar, LLC, failures that result from installation that is not in compliance with ZF specifications, accident, misuse, abuse, neglect, water damage, mishandling, misapplication, setup adjustments, improper maintenance, alterations, modification or service by anyone other than a ZF Authorized Service Center, damage that is attributable to acts of God or other causes unrelated to defects in materials and workmanship.

C Warranty Period: The length of the applicable warranty period will depend on the use of your vessel. For Commercial Craft the standard warranty period is for 24 months from the date of original shipment by ZF or 12 months after commissioning of the craft, whichever occurs first. A commercial craft is defined as any vessel used for any commercial purpose including but not limited to any use as a workboat, passenger vessel, charter or rental fleet.

D For Pleasure Craft the warranty period is 36 months from the date of original shipment by ZFME or 24 months after commissioning of the craft, whichever occurs first. A Pleasure Craft is any vessel that is or has not been used for any commercial purpose including but not limited to any use as a workboat, passenger vessel, charter or rental fleet.

E Repair or replacement parts provided under this Warranty will not be covered by the remainder of the unexpired warranty in effect on the complete unit.

F No Coverage Under Warranty: The exclusive remedy under this warranty is the repair or replacement of the defective component and this warranty specifically does not provide coverage for:

1. Towing or transportation of the vessel, or travel to and from the job site or vessel.2. Original installation charges or start-up costs.3. Loss of use or income from the vessel and/or rental of equipment during the performance of warranty repairs.

G To Obtain Warranty Service: Please go to www.zf.com or call 1-425-583-1900 or (U.S. only) 1-800-546-5455 for the nearest ZF Factory or Authorized Service Center.

1. The Service Center will contact ZF Service Department for a Service Return Authorization (SRA) number. Return the product freight prepaid, marked clearly with the SRA number, and with a description of the malfunction included.

2. If there are defects covered by this warranty, ZF will, at its option, either repair or replace the defective part or product. If after inspection, ZF determines that the product is not defective, ZF will charge a testing fee and return the product to the sender, freight collect.

3. Repair or replacement during the warranty period will not extend the warranty period. 4. All SRA claims must be requested and submitted within 30 days from the date of repair service.5. Claims for over 3 hours labor must be pre-approved by the ZF Service Department.

This warranty is expressly in lieu of all other warranties, express or implied. Except to the extent prohibited by applicable law, ZF hereby disclaims all other implied or express warrantiesof any kind, including warranties of merchantability and fitness for a particular purpose. Under no circumstances shall ZF be liable for any incidental or consequential damagessustained in connection with the product or its use, including any costs or damages that result from loss of use of the product or any engine or boat with which it is used. ZF does notauthorize any representative or agent to assume for it any obligation or liability other than those expressly set forth above. Some States and other jurisdictions do not allow limitations onhow long an implied warranty lasts or the exclusion or limitation of consequential damages, so above limitations may not apply to you. All implied warranties, if any, are limited to theduration of this express warranty. This warranty gives you legal rights, and you may have other rights that may vary from State to State.


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MMC-163 Rev C.1 04/09 Page 235

MMC-163 Warranty Registration

MMC-163 Warranty Registration

Warranty Registration

ZF Marine Propulsion Systems Miramar, LLC. Product First Seen At:

Processor, Serial # Serial #

Number of Remote Stations

Purchase Date

Dealer's Name

Installer's Name

Phone Number Cell Number

E-Mail Address Fax Number

Purchaser's Name

Street Address

City State Zip

Phone

YOUR VESSEL:

Engine, Make & Model

Length

Manufacturer

Boat Show Dealer Magazine Friend


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APPENDIX C - SYSTEM DRAWINGS


MMSC5000 SmartCommand User ManualAppendix C

13 Appendix C - System Drawings

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Page 241

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Page 239

Drawing 13170 SmartCommand Twin Screw System Drawing

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Page 245

ZF Padova S.r.l.Via Penghe, 48I - 35030 Caselle di Selvazzano (PD)ITALYPhone +39 049 8299 311Fax +39 049 8299 550www.zf.com

EN 3

340.

758.

001a

- 2

014-

10

ZF Padova S.r.l.Via Penghe, 48I - 35030 Caselle di Selvazzano (PD)ITALYPhone +39 049 8299 311Fax +39 049 8299 550www.zf.com

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