ZF Smartcommand User Manual

INSTALLATION, OPERATION
AND TROUBLESHOOTING
MMSC5000 - SMARTCOMMAND USER MANUAL
MARINE PROPULSION SYSTEMS

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.
2 EN 3340.758.001a - 2014-10
TABLE OF CONTENT
MMSC5000 SmartCommand User Manual
Table of Contents
Table of Contents
MMSC5000
SW70327.0I
SmartCommand User Manual ........................................................ 1

Table of Contents................................................................................. 3
List of Figures....................................................................................... 7
List of Tables ........................................................................................ 9
Revision List ....................................................................................... 13
Preface ............................................................................................... 15
1 Introduction........................................................................................ 17
1.1 SmartCommand System ..................................................................................................................17
2 Operation ........................................................................................... 19
2.1 DC Power On ...................................................................................................................................19
2.2 Take Control ....................................................................................................................................19
2.3 Basic Operation ...............................................................................................................................20
2.4 Engine Start Interlock ......................................................................................................................21
2.5 Proportional Pause ..........................................................................................................................21
2.6 Station Transfer at Neutral ..............................................................................................................22
2.7 Station Transfer on the Fly ..............................................................................................................22
2.8 Warm Up Mode (Throttle Only) .......................................................................................................23
2.9 High / Low Idle ................................................................................................................................24
2.10 Twin Screw Synchronization ...........................................................................................................24
2.11 One Lever Operation Mode .............................................................................................................25
2.12 Cruise Mode (Default) ....................................................................................................................29
2.13 Proportional Pause ..........................................................................................................................29
2.14 Dimming Control Head LEDs ...........................................................................................................30
2.15 AutoTroll Mode (Optional) ...............................................................................................................30
2.16 EasiDock Mode (Optional)...............................................................................................................32
2.17 Two Speed Operation (Optional).....................................................................................................35
2.18 Mode Stacking.................................................................................................................................36
3 Installation: Planning.......................................................................... 39
3.1 Processor.........................................................................................................................................39
3.2 Tools For Installation .......................................................................................................................40
3.3 Control Heads..................................................................................................................................40
MMSC5000 Rev B 01/13 Page 3
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TABLE OF CONTENT
Table of Contents
3.4 Engine Stop Switch .........................................................................................................................41

3.5 Control System Power ....................................................................................................................42
3.6 Tachometer Connection ..................................................................................................................42
3.7 Wire Harnesses ...............................................................................................................................43
3.8 System Planning ..............................................................................................................................45
4 Installation ......................................................................................... 49
4.1 Processor.........................................................................................................................................49
4.2 Power, Start Interlock, Clutch Pressure, and Alarm Circuit Harness ..............................................50
4.3 Control Heads..................................................................................................................................54
4.4 Synchronization ...............................................................................................................................57
4.5 Main Engine Speed Control - Throttle Harness ...............................................................................58
4.6 Clutch and Troll Control...................................................................................................................58
4.7 Engine Stop Switch .........................................................................................................................59
5 Set Up Procedures ............................................................................. 61

5.1 Processor Components Used in Set Up ..........................................................................................61
5.2 Activating Set Up Mode...................................................................................................................63
5.3 Set Up Functions & Values ..............................................................................................................65
5.4 System Function Codes (Required) ................................................................................................65
5.5 Assigning Station IDs.......................................................................................................................66
5.6 One Lever Mode (System Function Code A2) ................................................................................67
5.7 JMS Station Pairing (System Function Code A7) ............................................................................67
5.8 Engine Function Codes....................................................................................................................68
5.9 Clutch Function Codes ...................................................................................................................70
5.10 Troll Functions (AutoTroll) ...............................................................................................................74
5.11 Troll Functions .................................................................................................................................75
5.12 Docking Functions (EasiDock) ........................................................................................................79
5.13 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 ....................... 93
6.1 Control Head (Engines Stopped) .....................................................................................................93
6.2 Start Interlock (Engines Stopped) ...................................................................................................93
6.3 Service Field Test Unit (Break-out Box) and Multimeter Use..........................................................93
6.4 E-2 Throttle Minimum and E-3 Throttle Maximum Signal (Engines Stopped).................................95
6.5 Engine Stop Switches Test (Engines Running)................................................................................98
6.6 Lever Movement at Control Heads..................................................................................................98
6.7 Warm-Up Mode Test (Engines Running).........................................................................................98
6.8 E1 - Throttle in Neutral ....................................................................................................................99
6.9 E4 - Throttle Maximum Astern.........................................................................................................99
6.10 E6 - High Idle .................................................................................................................................100
6.11 E5 - Throttle Pause Following Shift ...............................................................................................102
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TABLE OF CONTENT
Table of Contents
7 Sea Trials: Adjustments and Tests Underway ................................. 103

7.1 Engine RPM ...................................................................................................................................103
7.2 Reversal Pause On Direction Change............................................................................................103
7.3 Synchronization Test .....................................................................................................................104
7.4 J1 - Idle Lockup RPM.....................................................................................................................105
7.5 L1 and L2 AutoTroll Minimum and Maximum Adjustments ..........................................................105
7.6 L3 - Troll Throttle Limit ..................................................................................................................108
7.7 L4 - Troll Pulse Duration ................................................................................................................109
7.8 L5 - Troll Pulse Percentage............................................................................................................110
7.9 d1 — Docking Minimum Pressure ..................................................................................................110
7.10 d2 — Docking Maximum Pressure..................................................................................................111
7.11 d3 - Docking Throttle Limit ............................................................................................................111
7.12 d5 - Docking (EasiDock) Pulse Percentage ...................................................................................113
F-259 SmartCommand Sea Trial Report .......................................................................... 115
8 Control Options ................................................................................ 119
8.1 Alarm Capability ............................................................................................................................119
8.2 Clutch Oil Pressure Interlock .........................................................................................................121
9 Periodic Checks and Maintenance .................................................. 123

9.1 Control Processor ..........................................................................................................................123
9.2 Control Head..................................................................................................................................123
9.3 Battery ...........................................................................................................................................123
10 Troubleshooting ............................................................................... 125

10.1 General ..........................................................................................................................................125
10.2 Troubleshooting Questions............................................................................................................129
10.3 System Inspection and Component Identification ........................................................................132
10.4 LED Detailed Information...............................................................................................................133
10.5 Diagnostic Menu............................................................................................................................135
10.6 Audible Tones Detailed Information ..............................................................................................142
10.7 Troubleshooting Station Transfer ..................................................................................................145
10.8 Error Codes....................................................................................................................................145
10.9 Problem Scenarios.........................................................................................................................149
10.10 SmartCommand Control Head Replacement ................................................................................153
10.11 SmartCommand Processor Replacement......................................................................................156
10.12 Harnesses and Plug Pin-Outs ........................................................................................................159
11 Appendix A - System Components and Specifications.................... 179

MMC-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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TABLE OF CONTENT
Table of Contents
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 ................................... 223
MMC-172 Factory Authorized Sales & Service Centers - International........................... 225
MMC-165 Warranty ......................................................................................................... 233
MMC-163 Warranty Registration..................................................................................... 235
13 Appendix C - System Drawings ....................................................... 237
Drawing 13170 SmartCommand Twin Screw System Drawing........................................ 239
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LIST OF FIGURES
List of Figures
List of Figures
Figure 2-1: Take Control at a Station................................................................................................................. 20
Figure 2-2: Control Head Detents ..................................................................................................................... 21
Figure 2-3: Warm Up LED ................................................................................................................................ 23
Figure 2-4: One Lever LED................................................................................................................................ 25
Figure 2-5: One Lever Mode: Inactive Lever Ahead ........................................................................................... 26
Figure 2-6: One Lever Operation: Inactive Lever in Neutral ............................................................................... 27
Figure 2-7: Cruise Mode Response Function..................................................................................................... 29
Figure 2-8: AutoTroll Lever Response Function ................................................................................................. 32
Figure 2-9: EasiDock Response Function .......................................................................................................... 33
Figure 3-1: Processor ....................................................................................................................................... 39
Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation .................. 41
Figure 3-3: Processor Harness Connector Locations ......................................................................................... 43
Figure 3-4: Wire Harness Deutsch Pluggable Connectors ................................................................................. 44
Figure 3-5: System Installation Diagram............................................................................................................ 45
Figure 4-1: Processor Dimensions for Installation.............................................................................................. 49
Figure 4-2: Wiring DC Power Using the APS..................................................................................................... 50
Figure 4-3: Alternative Wiring for APS Power ................................................................................................... 51
Figure 4-4: Connections for Start Interlock Circuit............................................................................................. 53
Figure 4-5: Control Head Assembly .................................................................................................................. 54
Figure 4-6: Deutsch Connector on 70269 Wire Harness ................................................................................... 55
Figure 4-7: Turck Connector on 70269 Wire Harness........................................................................................ 55
Figure 4-8: Daisy Chaining Control Heads......................................................................................................... 56
Figure 5-1: Processor Display and Arrow Push Buttons ..................................................................................... 61
Figure 5-2: Processor Display and Push Buttons ............................................................................................... 62
Figure 5-3: Control Head ID’s Not Set............................................................................................................... 63
Figure 5-4: Display Normal Operating Condition ............................................................................................... 63
Figure 5-5: Display Set Up Activated ................................................................................................................ 64
Figure 5-6: Enter PIN ........................................................................................................................................ 64
Figure 5-7: Change the Value of the Function Code.......................................................................................... 65
Figure 6-1: Service Field Test Unit and Multimeter............................................................................................ 93
Figure 6-2: E1, E2, E3, E4, E6, L3, and d3 Processor, Test Unit, and Multimeter Connections........................... 94
Figure 6-3: L1, L2, d1, and d2 Processor, Test Unit, and Multimeter Connections............................................. 94
Figure 7-1: Multimeter and Test Unit Connections ......................................................................................... 106
Figure 8-1: Alarm Circuit Requirements .......................................................................................................... 119
Figure 8-2: Alarm Circuit Example .................................................................................................................. 120
Figure 8-3: Clutch Pressure Switch Showing Processor Wire Harness and Shuttle Valve................................. 121
Figure 10-1: Basic Control System .................................................................................................................. 125
Figure 10-2: System Diagram ......................................................................................................................... 126
Figure 10-3: Three Power Sources.................................................................................................................. 128
Figure 10-4: Control Head LEDs ..................................................................................................................... 133
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LIST OF FIGURES
List of Figures
Figure 10-5: Processor Display in Run Mode................................................................................................... 135

Figure 10-6: Display With Active Error ............................................................................................................ 135
Figure 10-7: Display When No Control Heads Assigned.................................................................................. 136
Figure 10-8: Display with A000 ...................................................................................................................... 136
Figure 10-9: Display with H000 ...................................................................................................................... 136
Figure 10-10: Display changing from H000 to voltage reading........................................................................ 136
Figure 10-11: Output shaft frequency value display ........................................................................................ 137
Figure 10-12: Input shaft frequency value display ........................................................................................... 138
Figure 10-13: Absent decimal points indicating station number...................................................................... 139
Figure 10-14: Expected A/D counts and processor response .......................................................................... 139
Figure 10-15: Control/Set button closure displays........................................................................................... 141
Figure 10-16: Software revision level display .................................................................................................. 141
Figure 10-17: Control head mounting hardware ............................................................................................. 153
Figure 10-18: Connections between control heads ......................................................................................... 154
Figure 10-19: Control head bottom view......................................................................................................... 154
Figure 10-20: Socket key ................................................................................................................................ 155
Figure 10-21: SmartCommand processor ....................................................................................................... 156
MMC-341 Figure-1: 5200 Standard Control Head........................................................................................... 181
MMC-341 Figure-2: 5200 Low-Profile Control Head ....................................................................................... 181
MMC-341 Figure-3: 5100 Standard Control Head........................................................................................... 182
MMC-341 Figure-4: 5100 Low-Profile Control Head ....................................................................................... 182
Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1............................................ 187
Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2 ................................................................................ 188
Figure MMC-337-3: Port Processor - Hard wiring Drawing 13932A - 15B....................................................... 189
Figure MMC-337-4: Starboard Processor - Hard wiring Drawing 13932A - 15A.............................................. 189
Figure MMC-337-5: 4200 Control Head - Front View Dwg #14132................................................................. 190
Figure MMC-337-6: 4200 Control Head - Side View Dwg #14133.................................................................. 191
Figure MMC-337-7: 4100LP Control Head – Front View Dwg #13932ART-8................................................... 192
Figure MMC-337-8: 4100LP Control Head – Side View Dwg 13932ART-9...................................................... 193
Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293............................................... 194
Figure MMC-337-10: Control Head Mounting Holes and Cutout – Dwg #14649............................................. 195
Figure MMC-329-1: Part Numbering Configurations Detents Available ........................................................... 197
Figure MMC-329-2: Dimensions ..................................................................................................................... 198
Figure MMC-329-3: Terminal Connections ..................................................................................................... 199
Figure MMC-329-4: AFT Facing Control Head ................................................................................................ 199
Figure MMC-280-1: Part Numbering Configurations ...................................................................................... 201
Figure MMC-280-2: Detents Available ............................................................................................................ 201
Figure MMC-280-3: Dimensions ..................................................................................................................... 202
Figure MMC-280-4: Terminal Connections ..................................................................................................... 203
Figure MMC-280-5: AFT Facing Control Head ................................................................................................ 203
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LIST OF TABLES
List of Tables
List of Tables
Table 2-1: Steps to Take Control....................................................................................................................... 20
Table 2-2: Warm Up Mode LED ........................................................................................................................ 23
Table 2-3: L0 Function Code Values.................................................................................................................. 30
Table 2-4: d0 Function Code Values ................................................................................................................. 33
Table 3-1: Maximum Cable Lengths for Control Heads ..................................................................................... 41
Table 3-2: Key to Wire Harness Connections .................................................................................................... 44
Table 3-3: Key for Figure 5: System Installation Diagram .................................................................................. 46
Table 3-4: Control Stations ............................................................................................................................... 46
Table 3-5: Control Head to Control Head Cables............................................................................................... 46
Table 3-6: Control Head to Processor Cables .................................................................................................... 46
Table 3-7: Wire Harnesses and Other Parts ...................................................................................................... 47
Table 4-1: Wire Gauges for Cables at Flag 1 ..................................................................................................... 51
Table 4-2: Wire Gauges for Cables at Flag 2 ..................................................................................................... 51
Table 4-3: Identifiers for Figure 4-2: Wiring DC Power Using the APS............................................................... 51
Table 4-4: Alternative Wiring for APS Power..................................................................................................... 52
Table 4-5: Connections for Start Interlock Circuit .............................................................................................. 53
Table 4-6: Connections Between Control Heads ............................................................................................... 56
Table 5-1: Push Button Keys in Normal Operating Mode................................................................................... 62
Table 5-2: Push Buttons in Function Menu (Function Code LED’s are illuminated steadily)................................ 62
Table 5-3: Push Buttons in Set Up Mode (Function Code LED’s are blinking) .................................................... 62
Table 5-4: Push Buttons at Password Prompt (PIn? Appears on display) ........................................................... 63
Table 5-5: Push Buttons for PIN Entry ............................................................................................................... 63
Table 5-6: Push Buttons In Error Code Display (’Er’ shows in Function Code).................................................... 63
Table 5-7: Engine Throttle Profile Definitions .................................................................................................... 68
Table 5-8: L0 Function Code Values.................................................................................................................. 74
Table 5-9: Trolling Valve Type Selection............................................................................................................ 75
Table 5-10: J6 and J7 Values as Related to J0.................................................................................................. 78
Table 5-11: d0 Function Code Values ............................................................................................................... 79
Table ENG-289-1: Revision List......................................................................................................................... 81
Table ENG-289-2: System Definition Functions (SmartCommand) .................................................................... 82
Table ENG-289-3: Engine Functions and Values (SmartCommand)................................................................... 83
Table ENG-289-4: Dual Throttle Engine Functions and Values (SmartCommand) .............................................. 84
Table ENG-289-5: Clutch Functions and Values (SmartCommand) ................................................................... 84
Table ENG-289-6: Troll Functions and Values (SmartCommand)....................................................................... 85
Table ENG-289-7: Docking Functions and Values (SmartCommand)................................................................. 85
Table ENG-289-8: Governed Electric Troll Functions and Values (SmartCommand)........................................... 86
Table ENG-289-9: Troubleshooting Functions (SmartCommand) ...................................................................... 87
Table ENG-289-10: Steering and Helm Functions (POD)................................................................................... 87
Table ENG-289-11: Low Speed Configuration Functions (POD) ........................................................................ 87
Table ENG-289-12: High Speed Configuration Functions (POD) ....................................................................... 88
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LIST OF TABLES
List of Tables
Table ENG-289-13: Sport Fish Mode Functions (Sport Fish) ............................................................................. 89

Table ENG-289-14: Steering and Helm Functions (SteerCommand) ................................................................. 89
Table ENG-289-15: Low Speed Configuration Functions (SteerCommand) ....................................................... 90
Table ENG-289-16: High Speed Configuration Functions (SteerCommand) ...................................................... 90
Table ENG-289-17: Two Speed Functions ........................................................................................................ 91
Table ENG-289-18: Speed Boost Functions ...................................................................................................... 91
Table ENG-289-19: System Definition Functions (MCU/JMS)............................................................................ 91
Table ENG-289-20: Troubleshooting Functions (MCU/JMS).............................................................................. 92
Table 6-1: Functions Requiring Service Field Test Unit and Multimeter ............................................................. 94
Table 7-1: Output Shaft Idle Lockup RPM ....................................................................................................... 105
Table 7-2: Troll Minimum and Maximum Values ............................................................................................. 107
Table F-259-1: Processor Information ............................................................................................................. 116
Table F-259-2: Power Supply.......................................................................................................................... 116
Table F-259-3: Dock Trials .............................................................................................................................. 117
Table F-259-4: Record at Dock ....................................................................................................................... 117
Table F-259-5: Sea Trials ................................................................................................................................ 117
Table F-259-6: Record During Sea Trial .......................................................................................................... 117
Table F-259-7: Follow Up ............................................................................................................................... 118
Table 10-1: System Components .................................................................................................................... 126
Table 10-2: LED Indications ............................................................................................................................ 134
Table 10-3: Diagnostic Values ........................................................................................................................ 137
Table 10-4: Error Codes.................................................................................................................................. 145
Table 10-5: Problem Scenarios with Error Codes and Possible Solutions......................................................... 149
Table 10-6: Function Code Values .................................................................................................................. 157
Table 10-7: Wire Harness - Processor to Processor (p/n 70261-XX)................................................................ 159
Table 10-8: Wire Harness - Throttle, Voltage (IVECO, Cummins) (p/n 13432-XX)............................................ 160
Table 10-9: Voltage Throttle Harness Pin-Out (p/n 14148-XX) ........................................................................ 160
Table 10-10: Wire Harness - Throttle (Pulse Width Modulation [PWM]), (p/n 13533-XX)................................ 161
Table 10-11: Wire Harness - Cable, Throttle, MAN EDC (p/n 14421-XX)......................................................... 161
Table 10-12: Wire Harness- Throttle & Clutch Ahead/Astern w/Neutral Interlock, MAN- Sc (p/n 70588-XX) ... 162
Table 10-13: Wire Harness- Throttle, Yanmar CAN Interface, SC (p/n 70766-XX) .......................................... 163
Table 10-14: Wire Harness- Throttle, MTU Smartline- SmartCommand (p/n 70747-XX)................................ 163
Table 10-15: Wire Harness- Throttle/Neutral Interlock, MAN (p/n 70263-XX) ................................................. 164
Table 10-16: Voltage Throttle Harness Pin-Out (p/n 71262-XX) ...................................................................... 164
Table 10-17: Wire Harness- Throttle, Dual Voltage- SmartCommand And MiniCommand (p/n 71589-XX) ...... 165
Table 10-18: Wire Harness- Tach (Input And Output Shafts) SmartCommand (p/n 70494-XX) ....................... 165
Table 10-19: Wire Harness- Clutch Ahead/Astern (p/n 15719-XX).................................................................. 166
Table 10-20: Subassembly, Wire Harness Clutches with Troll (p/n 15725-XX) ................................................ 166
Table 10-21: Wire Harness - Clutch/Troll Command (p/n 15732-XX) ............................................................. 167
Table 10-22: Wire Harness - Clutch/Ahead/Astern/Troll Command/Troll On-Off (p/n 70390-XX)..................... 168
Table 10-23: Wire Harness - Clutch/Ahead/Astern- ZFF Transmission (p/n 70673-XX) ................................... 169
Table 10-24: Wire Harness - Clutch ZF Gear, MTU Smartline- SmartCommand (p/n 70901-XX) ..................... 170
10 EN 3340.758.001a - 2014-10
LIST OF TABLES
List of Tables
Table 10-25: Wire Harness - Clutch/Shaft Tach, SmartCommand (p/n 70259-XX) .......................................... 171
Table 10-26: Power, Start Interlock Harness Pin-Out (p/n 13756-XX) ............................................................. 172
Table 10-27: Wire Harness - Power, SI & Clutch Pressure Switch (p/n 13552-XX) .......................................... 172
Table 10-28: Wire Harness - Power, SI, Clutch Pressure Switch & Alarm (p/n 13631-XX) ............................... 173
Table 10-29: Wire Harness- Power Use w/ existing Start Interlock Only (p/n 15023-XX)................................. 173
Table 10-30: Wire Harness- Power/Backup Input For MTU Start Interlock w/ SC (p/n 71021-XX) .................. 174
Table 10-31: Wire Harness - Power, Start Interlock, Pressure SW, Alarm & Backup (p/n 71476-XX) ............... 175
Table 10-32: Wire Harness- Control Head To OBOF Panel, Port and Stbd (p/n 71495-XX).............................. 176
Table 10-33: Wire Harness - Control Head to Control Head (p/n 70268-XX) ................................................... 177
Table 10-34: Wire Harness - Control Head to Processor (p/n 70269-XX) ........................................................ 177
Table 10-35: Wire Harness - Iso CAN (p/n 70559-XX) .................................................................................... 178
Table 10-36: CANtrak termination resistor (p/n 70540-XX) ............................................................................. 178
EN 3340.758.001a - 2014-10 11
12 EN 3340.758.001a - 2014-10
REVISIONS LIST
Revision List
Revision List
Rev Date Description
Cross Reference in Copyright Notices corrected
Fuse Value in Figure 14 in Section 3 corrected
- 12/05 Error codes included in Troubleshooting Section
System drawing in Appendix C updated to Rev. A
Password instructions changed in Section 5
Some changes made in all Sections.
Extensive changes and/or rewrites made to Section 2 - Operations; Section 5 - Set Up; Section 7 - Sea
- 11/06
Trials; Appendix A (Section 11) and Appendix C (Section 13).
Contact information updated for international sales and service centers in Appendix B (Section 12).
Text of Section 10, “Troubleshooting,” has been substantially updated and enhanced. Illustrations of
- 1/07
pinouts for all major SmartCommand wiring situations were added.
Added Start Interlock to Section 2, Operation.
Added Engine Stop Switch warning to Section 2, Operation.
- 9/07 Added Mode Stacking to Section 2, Operation
Added E7 Values to Table 8, Section 5, Set Up Procedures
A 4/08 Replaced MMC-165 - Electronic Propulsion Limited Warranty
Replaced MMC-165 - Electronic Propulsion Limited Warranty
A.1 1/09
Replaced MMC-123, MMC-151, MMC-172 - Factory Authorized Sales & Service Centers Lists
Reformatted to FrameMaker, Restructured manual contents, Updated SW number, Various revisions
A.2 11/11
per ELR00055, ELR00113, ELR00118 and ELR00130, updated all external documents
Revised per ELR00084, ELR00104, ELR00105, ELR00113, ELR00150, ELR00158, ELR00159,
B 01/13
ELR00186 and ELR00202.
EN 3340.758.001a - 2014-10 13
14 EN 3340.758.001a - 2014-10
PREFACE
Preface
Preface
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.
Conventional Symbols Used in the Manual

Throughout this manual special attention should be paid to the following symbols
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.
Important Information
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.
EN 3340.758.001a - 2014-10 15
PREFACE
Preface
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.
How to Use the Manual

This 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.
NOTE: ZF Marine Propulsion Systems Miramar is not liable for any damage incurred if these notices are not
followed exactly.
16 EN 3340.758.001a - 2014-10
INTRODUCTION
Introduction
1 Introduction
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.
1.1 SmartCommand System

The 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 Sequencing
b Start Interlock
c High/Low Idle
d Multi Screw Engine Synchronization
e Electric Trolling Valve Control
f Emergency Reversal Protection
g Clutch Oil Pressure Interlock (optional)
Features that make the control head easy to use are:
a Indicator for Station-in-Command
b Six bi-color LEDs for indicating control system mode and status
c 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 connections
c 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.
EN 3340.758.001a - 2014-10 17
INTRODUCTION
Introduction
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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2 Operation
This 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.
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.
2.1 DC Power On
When 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 Control

The 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.
Important: The next control head lever movement shifts the transmission.
• 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.
Note: Only one station has control at any time.
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Figure 2-1: Take Control at a Station

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
Vessel moves in response to
3 C Move levers to ahead detent Ahead detent
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.
2.3 Basic Operation

The 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.
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Figure 2-2: Control Head Detents
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.
2.4 Engine Start Interlock

Engine 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 Pause

Proportional 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.
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2.6 Station Transfer at Neutral
Warning: Follow the steps in this section exactly. Personal Injury may result if this message is disregarded.
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.
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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

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
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.
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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 Idle

The 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.
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.
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 Synchronization

By 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.
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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 Mode

One 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.
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.
Figure 2-4: One Lever 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.
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.
Figure 2-5: One Lever Mode: Inactive Lever Ahead

1. 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.
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.
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
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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.
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.
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 Neutral

1. 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.
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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
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.
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: 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.
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.
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 Pause

The 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.
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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 LEDs

Control 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
AutoTroll
Control Head Lever at Movement through AutoTroll
L0 Value Range (in Movement Beyond Troll Range
Degrees) Ahead and Astern Detents Range
00 Clutch Fully Engaged, Clutch Fully Engaged, Neutral to Full
No Troll NA
Default throttle at idle Throttle
Minimum to Maximum troll
Minimum Troll Clutch Clutch fully engaged, throttle from
01 15 degrees Clutch pressure, throttle from
pressure, throttle at idle minimum to full
idle to maximum troll throttle
Minimum Troll Clutch Clutch fully engaged, throttle from
pressure, throttle at idle minimum to full
Minimum Troll Clutch Minimum to Maximum troll Clutch fully engaged, throttle limited to
pressure, throttle at idle 75% of full
Minimum Troll Clutch Clutch fully engaged, throttle limited to
pressure, throttle at idle 10% of full
Only at detents, Minimum
Clutch fully engaged, throttle from
05 Detents Only Troll clutch pressure, No Movement
minimum to full
throttle at idle
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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.
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

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.
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.
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.
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.
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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
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.
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:
Table 2-4: d0 Function Code Values
Docking Control Head Levers at Movement Beyond Docking
d0 Value Movement through Docking Range
Range Ahead and Astern Detents Range
00 Clutch Fully engaged, Clutch fully engaged, throttle
No docking NA
Default throttle at idle from minimum to full
Minimum to maximum docking clutch Clutch fully engaged, throttle
Minimum Docking Clutch
01 15 degrees pressure, throttle from idle to
pressure, throttle at idle from minimum to full
maximum docking throttle
Minimum docking clutch
pressure, throttle at idle from minimum to full
Minimum docking clutch
pressure, throttle at idle limited to 75% of full
Minimum to Maximum docking Clutch Clutch fully engaged, throttle
Minimum Docking Clutch
pressure, throttle at idle limited to 10% of full
Detent Only Minimum Docking Clutch

Clutch fully engaged, throttle
05 No movement in docking.
pressure, throttle at idle 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.
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.
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
34 EN 3340.758.001a - 2014-10
OPERATION
Operation
approximately one second until the EasiDock LED extinguishes and the clutch is locked up; the clutch
does not slip as it does in EasiDock.
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.
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.
EN 3340.758.001a - 2014-10 35
OPERATION
Operation
2.18 Mode Stacking
Mode Stacking - allows use of One Lever and AutoTroll simultaneously.
2.18.1 Normal to Auto-Troll Mode

1. Move both levers to one of the three detent positions
2. Press the Mode button, 100 ms pushes, until the Auto-Troll LED begins to flash red
3. 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 Mode

1. Move both levers to the Ahead detent position
2. Press the Mode button, 100 ms pushes, until the One Lever LED begins to flash red
3. Press and hold the Control/Set button 500 ms and the One Lever LED will begin flashing red and green
4. Once the One Lever LED begins to flash red and green, there will be a 5000 ms time-out for selection
of the Active Lever
5. 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 detent
6. 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 Mode

1. 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
36 EN 3340.758.001a - 2014-10
OPERATION
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 Mode

1. Move the Active Lever to one of the three detent positions
2. 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 Mode

1. Move the Active Lever to one of three detent positions
2. 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
EN 3340.758.001a - 2014-10 37
38 EN 3340.758.001a - 2014-10
INSTALLATION: PLANNING
Installation: Planning
3 Installation: Planning
Note: ZF Marine Propulsion Systems Miramar recommends installing the system in accordance with current
ABYC E-11 and P-24 standards.
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
Note: Read MMC-287 Grounding (Bonding) and MMC-165 Warranty at the end of this manual. Improper
mounting location may cancel warranty.
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.
EN 3340.758.001a - 2014-10 39
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.
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.
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 Heads

There 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.
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.
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.
40 EN 3340.758.001a - 2014-10
Table 3-1: Maximum Cable Lengths for Control Heads

Number of Control Heads in First Control Head to Second Control Head to Third
Processor to Control Head
Chain Second Control Head 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)
Figure 3-2: System Configuration Showing CAN bus and Control Heads for Six Station Installation
3.4 Engine Stop Switch

The installer must provide and install an Engine Stop Switch at each Remote Station.
EN 3340.758.001a - 2014-10 41
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.
Caution: Voltage differences between the processors on power or ground can damage the processors.
3.6 Tachometer Connection

If 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 Requirements

1. 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
42 EN 3340.758.001a - 2014-10
4. Electronically produced engine tachometer 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 Harnesses

Wire 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.
Note: Every connector should be plugged into either a wire harness or a plug. Do not leave a connector empty
or with pins dangling.
Figure 3-3: Processor Harness Connector Locations
EN 3340.758.001a - 2014-10 43
Table 3-2: Key to Wire Harness Connections

Connector
ID Harness for Connector
Name
1 Throttle Throttle Wire Harness, all types (Processor to Engine Interface)
Power/Start Interlock Wire Harnesses, all types (Processor to Power/Start Interlock connections,
2 Power
optionally Clutch Pressure and Alarm connections)
Clutch Wire Harnesses, all types (Processor to Ahead/Astern, optionally Troll Solenoids and Troll
3 Clutch
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
Sta. A or Sta. CAN Bus: Processor to control head
8
B
Connector Keying
Large Plug side view
Processor Key
Depress & Hold Small Plug end view Connector
Keying
1
Depress
2
Cable &
Hold
3
5
4
11232_ART
Depress & Hold
11230_ART Connector
Keying 15138_ART
15137_ART
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.
44 EN 3340.758.001a - 2014-10
3.8 System Planning

The 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
EN 3340.758.001a - 2014-10 45
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

Figure Reference Part Number Length Port Length Starboard
3A 70269-XX x 2
3B 70269-XX x 2
46 EN 3340.758.001a - 2014-10
Table 3-7: Wire Harnesses and Other Parts

Length
Figure Reference Part Number Length Port
Starboard
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 70260-XX
present if ZFF gears with MTCU are used.
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
EN 3340.758.001a - 2014-10 47
48 EN 3340.758.001a - 2014-10
INSTALLATION
Installation
4 Installation
As 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.
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.
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.)
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.
EN 3340.758.001a - 2014-10 49
INSTALLATION
Installation
4.2 Power, Start Interlock, Clutch Pressure, and Alarm Circuit Harness
Several 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.)
Caution: Turn Power OFF before connecting the Power Harness to the processor.
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 Cable

1. 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
50 EN 3340.758.001a - 2014-10
INSTALLATION
Installation
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
PN: HFB Fuse Holder
C RED wire J
PN: 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
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
EN 3340.758.001a - 2014-10 51
INSTALLATION
Installation
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
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.
Caution: Voltage differences between the processors on power or ground can damage the processors.
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.
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.
52 EN 3340.758.001a - 2014-10
INSTALLATION
Installation
Figure 4-4: Connections for Start Interlock Circuit
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
Start Interlock N.O. Contact: Maximum 5
E L Battery
Amperes
M Starter Solenoid
F Processor
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.
4.2.3 Alarm Circuit and Clutch Pressure (optional)

For information about these connections, refer to section 8: Control Options.
EN 3340.758.001a - 2014-10 53
INSTALLATION
Installation
4.3 Control Heads

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

54 EN 3340.758.001a - 2014-10
INSTALLATION
Installation
• 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.
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.
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.
Figure 4-7: Turck Connector on 70269 Wire Harness
Figure 4-6: Deutsch Connector on 70269 Wire Harness

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.
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INSTALLATION
Installation
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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INSTALLATION
Installation
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 Synchronization
SmartCommand 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.
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.
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.
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INSTALLATION
Installation
4.5 Main Engine Speed Control - Throttle Harness
NOTE: Set up all processors with the same Wire Harness and Engine Set Up selections
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 Control

The 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.
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.
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.
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INSTALLATION
Installation
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
NOTE: Some transmissions do not use an On/Off standard.
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 Switch

The installer must supply the stop switches. Refer to the information supplied with the stop switches and
engine for installation.
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.
EN 3340.758.001a - 2014-10 59
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SETUP PROCEDURES
Set Up Procedures
5 Set Up Procedures
Set 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 Up

Each 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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SETUP PROCEDURES
Set Up Procedures
Figure 5-2: Processor Display and Push Buttons
Table 5-1: Push Button Keys in Normal Operating Mode

Key Action Result
UP ARROW or Press UP ARROW or DOWN ARROW once. Activate Function Menu.
DOWN ARROW
Table 5-2: Push Buttons in Function Menu (Function Code LED’s are illuminated steadily)
Key Action Result
UP ARROW or
DOWN ARROW Press UP ARROW or DOWN ARROW. Scroll the Function displayed.
For H0, first two pads blink. Use DOWN ARROW to view
diagnostic values.
LEFT ARROW and Press LEFT ARROW and RIGHT ARROW All functions except H0: Function Code LEDs blink if the PIN
RIGHT ARROW simultaneously and hold for two seconds.
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.
For Function Codes with values to the right of the decimal
Right Arrow Press and hold. 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
UP ARROW or
Press UP ARROW or DOWN ARROW. Scroll through Function Codes.
DOWN ARROW
LEFT ARROW and Press LEFT ARROW and RIGHT ARROW Save Value: Function Code LEDs stop blinking. Exit Set Up
RIGHT ARROW simultaneously and hold for two seconds. mode.
Escape: Exit set up mode without changes. Function Code
Left Arrow Press LEFT ARROW and hold for one second.
LEDs stop blinking.
For Function Codes with values to the right of the decimal
Right Arrow Press and hold. point, displays the complete Function Code value so you can
see all the digits.
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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
UP ARROW or
DOWN ARROW Press either UP ARROW or DOWN ARROW. Scroll through the error messages.
Clears error if it has been resolved. If there is more than one

Right Arrow Press and Hold for one second.
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.
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

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.
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
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SETUP PROCEDURES
Set Up Procedures
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 Activated

4. 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 PIN

6. 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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Set Up Procedures
1. The Function Code appears. The left two pads blink. Setup mode is activated
Figure 5-7: Change the Value of the Function Code

2. 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 & Values

See 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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Set Up Procedures
decrement the value as required. Press Right Arrow and Left Arrow simultaneously and hold for two
seconds to save the new value.
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.
5.5 Assigning Station IDs

Powering 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.
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.
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.
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SETUP PROCEDURES
Set Up Procedures
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.
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.
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.
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.
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
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SETUP PROCEDURES
Set Up Procedures
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.
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.
5.8 Engine Function Codes

Set 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:
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
Volvo EDC Engines (Voltage) (0.6 to 3.6 VDC)
08
Volvo EVC Engines use a different voltage.
09 Detroit Diesel (Frequency) (120.64 to 360.9 Hz)
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SETUP PROCEDURES
Set Up Procedures
Table 5-7: Engine Throttle Profile Definitions

E0 Value Engine Type
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)
CMD (Voltage) Output V1(0.75 to 3.8 VDC)
30
CMD (Voltage) Output V2 (0.38 to 1.9 VDC)
Inmar (Voltage) Output V1(0.8 to 4.2 VDC)
40
Inmar (Voltage) Output V2 (4.2 to 0.8 VDC)
Crusader (Voltage) Output V1 (0.48 to 4.65 VDC)
41
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.
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5.9 Clutch Function Codes

5.9.1 C0 — Clutch Oil Pressure Interlock
IMPORTANT: Set the value of this function to 01 (INSTALLED) only if the optional clutch oil pressure switch is
used with this application.
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
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.
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.
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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.
.
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.
Neutral Delay (01):

• Transmission shifts to Neutral.
• Control system pauses for the duration of the pause.
Fixed Neutral (02):
• Transmission shifts to Neutral.
• Control system pauses for the duration programmed in Function Code C3 Reversal Pause
Time. The delay is not proportional.
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.
EN 3340.758.001a - 2014-10 71
SETUP PROCEDURES
Set Up Procedures
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.
72 EN 3340.758.001a - 2014-10
SETUP PROCEDURES
Set Up Procedures
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
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.
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.
EN 3340.758.001a - 2014-10 73
SETUP PROCEDURES
Set Up Procedures
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
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.
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
Table 5-8: L0 Function Code Values
Troll Range (in Movement between Ahead Movement through Troll
L0 Value Movement Beyond Troll Range
Degrees) and Astern Detents Range
Clutch Fully Engaged, throttle NA Clutch Fully Engaged, Neutral
00 No Troll
at idle to Full Throttle
Minimum Troll Clutch Minimum to Maximum troll Clutch fully engaged, throttle
01 15 degrees
pressure, throttle at idle Clutch pressure, throttle at idle from minimum to full
02 30 degrees pressure, throttle at idle Clutch pressure, throttle at idle from minimum to full
03 40 degrees
pressure, throttle at idle Clutch pressure, throttle at idle limited to 75% of full
04 50 degrees
pressure, throttle at idle Clutch pressure, throttle at idle limited to 10% of full
Minimum Troll Clutch No Movement: Troll at Detents Clutch fully engaged, throttle
05 Detents Only
pressure, throttle at idle only. from minimum to full
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.
74 EN 3340.758.001a - 2014-10
SETUP PROCEDURES
Set Up Procedures
5.11 Troll Functions

The 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.
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.
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.
Table 5-9: Trolling Valve Type Selection
Value Selection and Definition
Normal - no current when off. The current to the proportional valve increases as clutch pressure increases. When full
00 pressure (lockup) is reached, the current to the valve drops to zero. This is the default value.
Preset for generic 10 - 25% duty cycle.
Inverse - no current when off. The current to the proportional valve decreases as clutch pressure rises. When full
01 pressure (lockup) is reached, the current increases to maximum.
Preset for generic 10 - 25% duty cycle.
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.
02
Preset for ZF Padova 220 - 665 12 VDC Systems. All values assume 12V/10 Ohm proportional solenoid. New or
upgraded transmissions only.
pressure (lockup) is reached, the current to the valve drops to zero.
03
Preset for ZF Padova 220 - 665 24 VDC Systems. All values assume 12V/10 Ohm proportional solenoid. New or
04 pressure (lockup) is reached, the current to the valve drops to zero.
Preset for ZF 2000, 24 VDC systems
Inverse - no current when off. The current to the proportional valve decreases as clutch pressure rises. When full
05 pressure (lockup) is reached, the current increases to maximum.
Preset for ZF 1900 and 2500 24 VDC systems.
Preset for 12 VDC ZF Hurth transmissions with two (2) proportional solenoids only. ZF Hurth with one (1) proportional
06 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).
EN 3340.758.001a - 2014-10 75
SETUP PROCEDURES
Set Up Procedures
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.
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 = 600
2. Reduction ratio = 2:1
3. PPR = 60
4. 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.
76 EN 3340.758.001a - 2014-10
SETUP PROCEDURES
Set Up Procedures
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
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
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
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.
EN 3340.758.001a - 2014-10 77
SETUP PROCEDURES
Set Up Procedures
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.
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 --.--
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.
78 EN 3340.758.001a - 2014-10
SETUP PROCEDURES
Set Up Procedures
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
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.
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.
Table 5-11: d0 Function Code Values
Docking Range Movement between Ahead and Movement through Docking Movement Beyond Docking
d0
(in Degrees) Astern Detents Range Range
Clutch fully engaged, throttle at Clutch fully engaged, idle to full
00 No Docking N/A
idle. throttle.
Minimum docking clutch Minimum to maximum docking Clutch fully engaged, idle to full
01 15 degrees
pressure, throttle at idle. clutch pressure, throttle at idle. throttle.
Minimum docking clutch Minimum to maximum docking Clutch fully engaged, idle to full
02 30 degrees
pressure, throttle at idle. clutch pressure, throttle at idle. throttle.
Minimum docking clutch Minimum to maximum docking Clutch fully engaged, idle to 75%
03 40 degrees
pressure, throttle at idle. clutch pressure, throttle at idle. of full throttle.
Minimum docking clutch Minimum to maximum docking Clutch fully engaged, idle to 10%
04 50 degrees
pressure, throttle at idle. clutch pressure, throttle at idle. of full throttle.
Minimum docking clutch Clutch fully engaged, idle to full
05 Detent Only N/A
pressure, throttle at idle. throttle.
EN 3340.758.001a - 2014-10 79
SETUP PROCEDURES
Set Up Procedures
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 Functions

Use 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.
80 EN 3340.758.001a - 2014-10
ENG-289 Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems
ZF Marine Propulsion Systems Miramar, LLC
12125 Harbour Reach Dr Ste B
SETUP PROCEDURES
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
Function Codes for SmartCommand, JMS, SBW, MCU and POD Systems
Confidentiality Protection Classification: Public
Integrity Protection Classification: Normal
Availability Protection Classification: Normal
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 Release
A 04/09/12 Revised SteerCommand Table ENG-289-14
Table of Contents
SmartCommand Function Codes .............................................................. page 82
POD Function Codes ................................................................................................. page 87
Sport Fish Function Codes........................................................................................ page 89
SteerCommand Function Codes ............................................................................... page 89
Two Speed Function Codes ...................................................................................... page 91
Speed 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.
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.
ENG-289 Rev A 04/12 Page 81
EN 3340.758.001a - 2014-10 81
SETUP PROCEDURES
SmartCommand Function Codes

Table ENG-289-2: System Definition Functions (SmartCommand)
Function Default Actual Setting

Function Name and Description Value Range, or Options
Code Value Port Starboard
01, 02 Each processor must have a unique ID
number.
A0 Processor Identification 00 This function must be the second function set.
AUTOTROLL and WARM UP LEDs are illuminated
RED before this value is set.
02 - Twin Screw
A1 Number of Engines 02
This function must be the first function set.
00 - Disable
A2 One Lever Operation 02 01 - Option 1
02 - Option 2
A3 Number of Stations 00 00 - 06.
00 - No Tone
A4 Neutral Indication Tone 01 01 - Tone upon engaging neutral detent
02 - Tone upon shifting to Neutral
00 – No JMS
A7 JMS Station Pairing 0 01 – JMS, Split Pairing
02 – JMS, Full Pairing
Number of Joystick Stations (Open
A8 00 00 - 03 (value is automatically set by SC5000)
Loop Only)
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.
82 EN 3340.758.001a - 2014-10
SETUP PROCEDURES
Table ENG-289-3: Engine Functions and Values (SmartCommand)
Function Function Name and Description Default Actual Setting

Value Range, or Options
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)
E0 Select Engine Throttle Profile 06
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)
Throttle in Neutral (only available
E1 00.0 00.0 to 25.0% of Throttle Range
with type 03 - throttle profile)
00.1 to 97.0% Will always be 3% or more below
E2 Throttle Minimum 08.2
Maximum.
04.0 to 100.0 % Will always be 3% or more above
E3 Throttle Maximum 59.2
Minimum
E4 Throttle Maximum Astern 100.0 00.0 to 100.0% of Throttle Maximum
E5 Throttle Pause Following Shift * 00.5 00.0 to 05.0 Seconds
E6 High Idle 00.0 00.0 to 20.0% of Throttle Range
00 – Equal Throttle (Open Loop) Synchronization
01 - Active (Closed Loop) Synchronization (reverts to
Equal if Tach Signal lost)
E7 Synchronization 01
02 - No Synchronization
03 - Active (Closed Loop) Synchronization (no
synchronization if Tach Signal is lost)
00 - Cruise mode at Power-up
E8 Initialization Type 00
01 - Warm-up Mode at Power-up
E9 Throttle Rate Increase 0.8 00 - 25
Ea Throttle Rate Decrease 0.8 00 - 25
Throttle Command Incremental/De-
Eb 0.0 0.0- 6.0
incremental
Ec Engine Minimum (Idle) RPM 550-800
Ed Engine RPM Increment 00-100
EE Engine Idle RPM 600 550 - 800
EF 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.
EN 3340.758.001a - 2014-10 83
SETUP PROCEDURES
Table ENG-289-4: Dual Throttle Engine Functions and Values (SmartCommand)

E1 Dual Throttle (V1) in Neutral 00 00.0 to 25.0% of Throttle Range
E2 Dual Throttle (V1) Minimum 8.2
Maximum.
04.0 to 100.0 % Will always be 3% or more
E3 Dual Throttle (V1) Maximum 59.2
above Minimum
e1 Dual Throttle (V2) in Neutral 00 00.0 to 25.0% of Throttle Range
e2 Dual Throttle (V2) Minimum 7
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)

00 - Not-installed
C0 Clutch oil interlock 00 01 - Installed
02 - Throttle clutch pressure interlock mode.
C1 Clutch oil interlock delay 1.0 00.5 to 10.0 seconds.
00 -In gear
01 - Neutral
C2 Reversal pause 00 02 - 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.
00 - 2:1 Ahead to astern: astern to ahead
C4 Proportional pause ratio 00
01 - 1:1 Ahead to astern: astern to ahead
00 - All shift solenoids except ZF Hurth with two
proportional solenoids.
01 - ZF Hurth with two proportional solenoids
C5 Shift solenoid type 00
and 12 V power
02 - 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
00 to 100% ZF Hurth astern lockup percentage
C7 ZF Hurth duty cycle astern 100
PWM
Fixed neutral delay with proportional
C8 0.0 0.0 to 4.0 seconds
pause
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SETUP PROCEDURES
Table ENG-289-6: Troll Functions and Values (SmartCommand)

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 menu
01 - 15 Degrees (100% throttle allowed)
L0 Troll Lever Range 00 02 - 30 Degrees (100% throttle allowed)
05 - Troll at detent only (only L1 must be set and
operational)
01- 99% of the AutoTroll range. Will always be
less/more (normal/inverted) than Troll Maximum
L1 Troll Minimum Pressure 1.0 by at least 1%. If J1 is set to 00 (open loop troll),
L1 is the percentage of open loop current
available.
02 - 100% of the AutoTroll range. Will always be
more/less (inverted/normal) than Troll Minimum
L2 Troll Maximum Pressure 100.0 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
00.0- 09.9 Seconds. Time that the troll valve is
L4 Troll Pulse Duration 00.6 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)

00 - No Docking
If this function is set to 00, the other d Function
Codes do not appear in the function menu
Docking Lever Range
No docking Function Codes are 01 - 15 Degrees (100% throttle allowed)
d0 available until L0 is set to a value above 00 02 - 30 Degrees (100% throttle allowed)
zero and J1 is defined to a value above 03 - 40 Degrees (75% throttle allowed)
00. 04 - 50 Degrees (10% throttle allowed)
05 - Docking at detent only (only d1 must be set
and operational)
01- 99% of the Troll (J2) Range. Will always be
d1 Docking Minimum Pressure 50.0 less/more (normal/inverted) than Docking
Maximum by at least 1%.
02- 100% of the Troll (j3) range. Will always be
d2 Docking Maximum Pressure 100.0 more/less (inverted/normal) than Docking
Minimum by at least 1%.
d3 Docking Throttle Limit 00 00 - 20% of Maximum Throttle
00.0- 09.9 Seconds. Time that the troll valve is
d4 Docking Pulse Duration 3.0 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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SETUP PROCEDURES
Table ENG-289-8: Governed Electric Troll Functions and Values (SmartCommand)

00 - Normal no current when at Lock up preset
for generic 10 - 25% duty cycle
01 - Inverse, no current when at Lock up preset
for generic 10-25% duty cycle
02 - 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
03 - Normal, no current when at lock up preset
for ZF220 - 665 24 VDC Systems - ZF Padova
J0 Troll Valve Function 00 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 Systems
05 - Inverse, no current when at lock up preset
for ZF 1900 0r 2500 24 VDC Systems
06 - Preset for 12 VDC ZF Hurth Systems
07 - Preset for 24 VDC ZF Hurth Systems
08 - Preset for ZF Friedrichshafen gears with
MTCU
J1** Idle Lockup Hz 0 5 Hz to 3 kHz - taken from H0 Tach 2 reading
Preset per J1: 30% of lockup shaft RPM (or 30%
J2** Min. Troll LU RPM 30
of J1 value in terms of shaft frequency feedback)
J3** Max Troll LU RPM 70** Preset per J1: 70% of lockup shaft RPM
J4** Troll Range 00** 0 - 20% Preset per J1
J5** Troll Time out 0.3** 1.0 sec. in 0.1 second increments Preset per J1
01.0- 99.0%. Will always be less/more (normal/
J6** Min. Troll% PWM 10.0** inverted) than Troll Maximum by at least 0.1%.
Preset per J1
1.1- 100.0%. Will always be more/less
J7** Max Troll% PWM 25.0** (inverted/normal) than Troll Minimum by at least
0.1%.Preset Per J1.
00 – Auto Setup not Initiated/ Failed
01 – Initiate Auto Setup
02 – Auto Setup Initiated
03 – Clutch Fill Time Detection
J8 Automatic Troll Setup Start & Monitor 0
04 – Minimum Troll Current Detection
05 – Maximum Troll Current Detection
06 – Recalculating Clutch Fill Time
07 – Auto Setup Successful
J9 Automatic Troll Setup Maximum Time 60 20- 250 Sec.
Automatic Troll Setup Samples Per
JA 3 1- 5 Samples
Step
Automatic Troll Setup Deadband
Jb 2 01- 100%
Window
* 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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SETUP PROCEDURES
Table ENG-289-9: Troubleshooting Functions (SmartCommand)

Input Voltage (+/- 0.5VDC)
Tachometer Frequency Output Shaft Sensor
(Tach 2)
Tachometer Frequency Input Shaft Sensor
(Tach 1)
Station 1 Lever A/D
Station 2 Lever A/D
H0 Diagnostic NA Station 3 Lever A/D
Station 4 Lever A/D
Station 5 Lever A/D
Station 6 Lever A/D
Control/Set Button, Stations 1, 2, 3, 4, 5 and
6,
Software Revision Level
Store to Return to Factory Defaults (For
H1 Return to Factory Defaults 00
Authorized Personnel Only)
POD Function Codes

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

c0 Steering Actuator Configuration 04 04
c1 Number of Helms 01 00 - 02
c2 Number of Wheel Turns 2.0 00.5 – 9.9
c3 Helm Station in Control 01 00 -01
c4 Helm Force Feedback Minimum 00 0 – 59
c5 Helm Force Feedback Maximum 00 0 – 50
00 - Disable
c6 Auto Pilot Enable 00
01 - Enable
00- Normal
c7 AutoPilot Direction 00
01- Reversed
c8 AutoPilot Speed 100 100 - 5000
c9 Counts Per Degree 100 00 - 9999
00- No Feedback, No Resistance, No Zero
01- Resistance, No Zero
cA Helm Feedback Type 00
02- No resistance, with Zero
03- Resistance and Zero
cc Throttle Limit with Faulted Steering 20 0- 100%
Table ENG-289-11: Low Speed Configuration Functions (POD)

b0 Minimum adjustment of the port Pod 41 0 to +50°
Center adjustment of the Pod on the port 0.0
b1 "b2" to "b0"
side
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Table ENG-289-11: Low Speed Configuration Functions (POD)

Maximum adjustment of the Pod on the
b2 -11 -20 to 0
port side
Minimum adjustment of the Pod on the
b3 11 0 to +20°
starboard side
Center adjustment of the Pod on the
b4 0.0 “b5” to “b3”
starboard side
b5 -41 -50 to 0
starboard side
Maximum Traveling Speed for the Port
b6 3000 100 - 3500
Pod
Maximum Traveling Speed for the
b7 3000 100 - 3500
Starboard Pod
Table ENG-289-12: High Speed Configuration Functions (POD)

r0 10 0 to +50°
port side
Center adjustment of the Pod on the port
r1 0.0 “r2” to “r0”
side
r2 Maximum adjustment of the Pod on the -10 -20 to 0
port side
r3 10 0 to +20°
starboard side
r4 Center adjustment of the Pod on the 0.0 “r5” to “r3”
starboard side
r5 -10 -50 to 0
starboard side
r6 Start high speed mode calculation. 1190 10 - 3000
r7 End high speed mode calculation. 1785 10 - 3000
Frequency of the throttle command Helm
r8 will start calculating the minimum zero 1190 10 - 3000
and force feedback to the helms.
Frequency of the throttle command at
which the Helm will end calculating the
r9 1785 0 - 3000
maximum zero and force feedback to the
helms.
Frequency of the throttle command at
rA which the Helm will start calculating the 1000 0 - 3000
minimum auto zero to the helms.
Adjustment of the Joystick Direction to
n0 0.0 -5.00 – 5.00 degrees
the Port. (c2)
n1 0.0 -5.00 – 5.00 degrees
the Port. (c3)
n2 0.0 -5.00 – 5.00 degrees
the Starboard. (c6)
n3 0.0 -5.00 – 5.00 degrees
the Starboard. (c7)
Soft Engagements of the Gear when using
n9 0.0 00 - 150
the Joystick
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SETUP PROCEDURES
Table ENG-289-12: High Speed Configuration Functions (POD)

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.
Sport Fish Function Codes

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

u0 Min Angle of pods when in Troll mode 00 0 to 20
u1 Max Angle of pods when in Troll mode 00 0 to 20
Max throttle used to deflect pods in Troll
mode. When this throttle is being
u2 00 0 to 99
commanded then the pod angle should
be the value found in 'u1'
Min Angle of pods when in EasiDock
u3 00 0 to 20
mode
u4 Max Angle of pods when in EasiDock 00 0 to 20
mode
Max throttle used to deflect pods in
EasiDock mode. When this throttle is
u5 00 0 to 99
being commanded then the pod angle
should be the value found in 'u4'
u6 Min Angle of pods when in Cruise mode 00 0 to 20
u7 Max Angle of pods when in Cruise mode 00 0 to 20
Max throttle used to deflect pods in Cruise
mode. When this throttle is being
u8 00 0 to 99
commanded then the pod angle should
be the value found in 'u7'
SteerCommand Function Codes

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

0 - No Actuators
1 - Opposing Actuators Port Pushing, Stbd
Pulling, for Port Turn.
2 - Opposing Actuators Port Pulling, Stbd
Pushing, for Port Turn.
c0 Steering Actuator Configuration 00 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 Turn
6 - Single Actuator Pushing, for Port Turn
c1 Number of Helms 01 00 - 02
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Table ENG-289-14: Steering and Helm Functions (SteerCommand)

c2 Number of Wheel Turns 2.0 00.5 – 9.9
c3 Helm Station in Control 01 00 -01
c4 Helm Feedback 00 0 – 50
c5 Low Speed Helm Holding 10 0 – 50
00 - Disable
c6 Auto Pilot Enable 00
01 - Enable
00 - Normal
c7 AutoPilot Direction 00
01 - Reversed
c8 AutoPilot Speed 100 100-5000
c9 Counts Per Degree 100 00 - 9999
00- No Feedback, No Resistance, No Zero
01- Resistance, No Zero
cA Helm Feedback Type 00
02- No resistance, with Zero
03- Resistance and Zero
cb Hold Current 00 0-50
cc Throttle Limit with Faulted Steering 00 0 to 100
cd Auto - Zero Configuration 90 01 to 360
Table ENG-289-15: Low Speed Configuration Functions (SteerCommand)

b0 Minimum adjustment of the port Actuator 1000 0 to 1600
Center adjustment of the Actuator on the
b1 0 -100 to +1000
port side
Maximum adjustment of the Actuator on
b2 -100 -160 to 0
the port side
Minimum adjustment of the Actuator on
b3 1000 00 to 1600
the starboard side
b4 starboard side 0 -100 to 0
b5 -100 -160 to 00
the starboard side
Maximum Traveling Speed for the Port
b6 30000 100 to 4000
Actuator
Maximum Traveling Speed for the
b7 3000 100 to 4000
Starboard Actuator
Table ENG-289-16: High Speed Configuration Functions (SteerCommand)

r0 800 0 to 1600
the port side
r1 0 -80 to 800
port side
r2 -80 -160 to 0
the port side
r3 800 0 to 1600
the starboard side
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Table ENG-289-16: High Speed Configuration Functions (SteerCommand)

r4 0 -80 to 0
starboard side
r5 -80 -160 to 0
the starboard side
r6 Start high speed mode calculation. 1000 10 to 3000
r7 End high speed mode calculation. 2263 10 to 3000
Start Auto Zero & Force Feedback
r8 1000 10 to 3000
Calculation for Helm
End Auto Zero & Force Feedback
r9 2263 10 to 3000
Calculation for Helm
Maximum Traveling Speed for Port
rA 1000 0 to 3000
Actuator
Two Speed Function Codes

Table ENG-289-17: Two Speed Functions

Code Function Name and Description Value Value Range, or Options
Port Starboard
U1 Pulses Per Revolution 00 0 - 255
U1 Down Shift RPM 00 0 - 9999
U2 Up Shift RPM 00 0 - 9999
U3 Maximum Down Shift RPM Docking 00 0 - 9999
Speed Boost Function Codes

Table ENG-289-18: Speed Boost Functions

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

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

01 – Hold Heading only when moving
sideways
A0 Hold Heading mode 01
sideways, ahead or astern
sideways or astern
00 – Off
A1 Bow Thruster Enable Relay Output 00
01 – On, Relay for bow thruster is enabled
A2 Bow Thruster Enable Relay Time out 0300 1 to 9999 seconds
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Table ENG-289-19: System Definition Functions (MCU/JMS)

00 – Off
A3 Bow Thruster Active Relay Output 00 01 – On, Active Relay for bow thruster is
enabled
Low Side Driver for Bow Thruster on Relay 00 00 – off (uses high side driver)
A4
Outputs 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)

SW71333.XX, where XX indicates the two-
H0 Software Version --
digit version of the JMS software installed.
Cancels pairing of joystick and control heads.
H1 Reset Station List -- Can only be done upon start-up or after
power-cycling.
H2 Station Pairing -- Pairs joystick with control head
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DOCK TRIALS: ADJUSTMENTS AND TESTS SECURED TO DOCK
Dock 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)
NOTE: If any of the tests in this section fail, verify Start Interlock Installation and Start Interlock Connections.
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 Use
ZF 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
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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
Section 7.5: L1 and L2 AutoTroll Minimum and Maximum Adjustments Do not use this setup procedure for L1
L1 and L2
or L2 if MTCU-equipped ZF Friedrichshafen gears are installed.
L3 Section 7.6: L3 - Troll Throttle Limit
Section 7.6: L3 - Troll Throttle Limit. Do not use this setup procedure for d1 or d2 if MTCU-equipped ZF
d1 and d2
Friedrichshafen gears are installed.
d3 Section 7.6: L3 - Troll Throttle Limit
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
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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.
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).
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.
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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 box
d 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.
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.
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.
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.
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.
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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.
WARNING: Do not attempt to continue tests until the Engine Stop Switches function correctly. Personal Injury
may result if this message is disregarded.
6.6 Lever Movement at Control Heads
CAUTION: Verify the vessel is secured to the dock. Step B engages the transmission briefly.
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.
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.
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)
NOTE: To confirm Speed Command operation, use Warm-Up mode on each engine from each station, one
engine at a time.
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
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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.
6.8 E1 - Throttle in Neutral
NOTE: Only use this function when the E0 SELECT ENGINE THROTTLE PROFILE is set to: 03 - CUMMINS QUANTUM.
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 Astern

This 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
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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:
WARNING: Verify that Warm Up mode is active before adjusting this function. Personal Injury may result if this

• Use UP ARROW or DOWN ARROW to scroll to the E4 Function Code. The Multimeter reads the output
signal for Throttle Maximum Astern.
NOTE: To read current on the Service Field Test Unit, press the mA Push Button on the box.
Function Code blinks or the PIn? prompt appears if PIN not entered yet.
• When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and
• Exit Set Up mode.
6.10 E6 - High Idle

This 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.
CAUTION: High Idle can be set higher than the safe shift RPM for the gear.
To measure and adjust the E6 parameter:

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Use UP ARROW or DOWN ARROW to scroll to the E6 Function Code. The Multimeter reads the output signal for
High 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.
• When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and
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: 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.
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.
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.
NOTE: Read steps A through D carefully before beginning.
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.
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
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
H Change the value of the function, or enter the PIN and change the value of the function using UP
I When the value you want displays, store it. Press RIGHT ARROW and LEFT ARROW simultaneously and
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7 Sea Trials: Adjustments and Tests Underway

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.
7.1 Engine RPM

A 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 Change

Reversal 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:
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.
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.
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E Program function C3 to match the time on the stop watch.

7.2.2 Test the Proportional Pause:
CAUTION: Test proportional pause as outlined below to ensure it was properly programmed. Failure to do so
could cause transmission damage.
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 Test

Verify 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.
C Move both control head levers side by side to approximately 75% of the throttle range.
D Move both control head levers side by side to approximately 100% of the throttle range.
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
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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
IMPORTANT: Measure the Propeller Shaft RPM when the transmission oil has reached operating temperature.
Do not make adjustments before oil has reached temperature.
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.
Table 7-1: Output Shaft Idle Lockup RPM
Propeller Shaft H0 - Output Shaft RPM Reading
Port
Starboard
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 Adjustments

The 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%.
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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.
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.
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
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
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
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
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.
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.
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D Activate Set Up mode: press LEFT ARROW and RIGHT ARROW and hold for two seconds, until the
E Change the value of the function, or enter the PIN and change the value of the function using
F When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW
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 Limit

This 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.
NOTE: Adjust the L3 parameter after L1 and L2 are adjusted.
The values of this Function are 00% to 20% of Throttle Maximum. The default value is 00.
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.
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:
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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
H Change the value of the function, or enter the PIN and change the value of the function using
I When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW
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 Duration

This 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.
NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar, LLC.
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.
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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
D Change the value of the function, or enter the PIN and change the value of the function using UP
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 Percentage

This 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%.
NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar, LLC.
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
D Change the value of the function, or enter the PIN and change the value of the function using UP
E When the value you want displays, store it: press RIGHT ARROW and LEFT ARROW simultaneously and
hold for one to two seconds.
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.
7.9 d1 — Docking Minimum Pressure

The 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
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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.
CAUTION: Be aware that an increase in vessel thrust will occur immediately when d2 is reached in setup
mode, typically causing a noticeable lurch.
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 Limit

This 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.
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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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.
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 Limit
1. 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.
112 EN 3340.758.001a - 2014-10

Sea Trials
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.
NOTE: Do not change this function unless directed to do so by ZF Marine Propulsion Systems Miramar.
7.12 d5 - Docking (EASIDOCK) Pulse Percentage

The 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.
EN 3340.758.001a - 2014-10 113

114 EN 3340.758.001a - 2014-10

ZF Marine Electronics
F-259 SmartCommand Sea Trial Report 12125 Harbour Reach Dr Ste B
SEA TRIALS AND TESTS UNDERWAY Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
SmartCommand System Sea Trial Report

The 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
__________________________________ E-mail: ___________________________________
Name:
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 #: _____________________________
F-259 Rev A.2 11-11 Page 1
EN 3340.758.001a - 2014-10 115

F-259 SmartCommand Sea Trial Report
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
Yes No
being used?
Is there an Engine Stop Switch installed at each Remote Station? Yes No
Sta. 1_______ Sta. 2_______
What is the length of the Control Head Harness? 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? ___________ ___________
F-259 Rev A.2 11/11 Page 116
116 EN 3340.758.001a - 2014-10

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)
F-259 Rev A.2 11/11 Page 117
EN 3340.758.001a - 2014-10 117

Table F-259-7: Follow Up
Comments (Please use additional paper as necessary):
General Installation Condition:
Any Irregularities:
Is the Installation and Troubleshooting If No, request

Manual on board? Yes No 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: ___________
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
F-259 Rev A.2 11/11 Page 118
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CONTROL OPTIONS
Control Options
8 Control Options
8.1 Alarm Capability
SmartCommand’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
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
Control Options
8.2 Clutch Oil Pressure Interlock
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.
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.
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.
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 the
13631-XX power wire harness for the 13552-XX harness, because the 13631-XX harness has the extra
connection necessary for the alarm.
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PERIODIC CHECK AND MAINTENANCE
Periodic Checks and Maintenance
9 Periodic Checks and Maintenance

9.1 Control Processor
Check all terminal connections for loose connections.
9.2 Control Head

Once 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.
EN 3340.758.001a - 2014-10 123

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TROUBLESHOOTING
Troubleshooting
10 Troubleshooting
10.1 General
The 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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Troubleshooting
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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Table 10-1: System Components
Item Component Part Number Quantity
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
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Troubleshooting
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 Questions

If 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.
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
• 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
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Troubleshooting
communication, such as EASIDOCK, AUTOTROLL, ONE LEVER, WARM UP, and Synchronization, will not
function.
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.
• 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.
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
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.
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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
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
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 Identification

If 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.
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.
A DC Power Source
1. 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.
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.
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
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.
• 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:
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Troubleshooting
• 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.
• Processors
1. 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
In Control- Commanding Neutral
Stbd. Steady Not Lit Not Lit Not Lit Not Lit
Green (Cruise Mode)
Port and/or In Control- Clutch Engaged (Cruise

Stbd. Steady Not Lit Not Lit Not Lit Not Lit
Mode)
Red
Port and/or In Command- Commanding Neutral-

Slowly
Stbd. Steady Not Lit Not Lit Not Lit Press “Control/Set” within 10 sec. to
Blinking Red
Green select EasiDock Mode.
Port and/or In Command- Clutch Engaged- Press

Slowly
Stbd. Steady Not Lit Not Lit Not Lit “Control/Set” within 10 sec. to select
Blinking Red
Red EasiDock Mode.
Port and/or In Control- Commanding Neutral-

Stbd. Rapidly Steady Red Not Lit Not Lit Not Lit
EasiDock Mode Selected
Blinking Green
Port and/or In Command- Clutch Engaged-

Stbd. Rapidly Steady Red Not Lit Not Lit Not Lit
EasiDock Mode Selected
Blinking Red
Port and/or In Command- Commanding Neutral-

Slowly
Stbd. Steady Not Lit
Blinking Red
Not Lit Not Lit Press “Control/Set” within 10 sec. to
Green select AutoTroll Mode.
Port and/or Slowly

In Command- Clutch Engaged- Press
Blinking Red
Red AutoTroll Mode.
Port and/or In Control- Commanding Neutral-

Stbd. Rapidly Not Lit Steady Red Not Lit Not Lit
AutoTroll Mode Selected
Blinking Green
Port and/or
In Command- Clutch Engaged-
Stbd. Rapidly Not Lit Steady Red Not Lit Not Lit AutoTroll Mode Selected
Blinking Red
Port and/or Slowly

In Command- Commanding Neutral-
Stbd. Steady Not Lit Not Lit Not Lit Press “Control/Set” within 10 sec. to
Blinking Red
Green select Warm Up Mode.
Port and/or
Stbd. Slowly Not Lit Not Lit Steady Red Not Lit In Control- Warm-Up Mode Selected
Blinking Green
Port and/or In Command- Clutch Engaged- Press

Slowly
Blinking Red
Red lead lever in One Lever Mode.
Port and/or Slowly In Command- Clutch Engaged- Move

Stbd. Steady Not Lit Not Lit Not Lit Blinking Red lever within 2 sec. to select One Lever
Red & Green Mode.
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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 Side Slowly Slowly Slowly Port side of Control Head not
Blinking Red Blinking Red Blinking Red Not Lit Not Lit communicating with CAN Bus or not
assigned.
Stbd Side Slowly Slowly

Starboard side of Control Head not
Slowly Blinking Not Lit Not Lit communicating with CAN Bus or not
Blinking Red Blinking Red
Red assigned.
Port & Stbd, The Control Head is not

Slowly Slowly Slowly Slowly
Slowly Blinking communicating with the CAN Bus or
Blinking Red Blinking Red Blinking Red Blinking Red
Red hasn’t been assigned
The Control Head is not in control and

Not Lit Not Lit Not Lit Not Lit Not Lit
or has no power.
10.5 Diagnostic Menu

One 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
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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.
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.
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 A000

C Press and release the UP arrow or the DOWN arrow until H000 is displayed.
Figure 10-9: Display with H000

D 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
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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.
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
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 = 600
Gear Ratio = 2:1
Sensor PPR = 10
600/2 = 300 * 10 = 3000/60 =50 Hz
Figure 10-11: Output shaft frequency value display
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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 = 600
Sensor PPR = 25
600 * 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 =15000
15000/600 = 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.
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.
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.
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• If the second from the right and the left most decimal points are absent, station No. 6 is
displayed.
Station No. 1 A/D Counts Station No. 4 A/D Counts
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
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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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Station No. 1 CONTROL / SET Button (Closed) Station No. 4 CONTROL / SET Button (Closed)
Figure 10-15: CONTROL/SET button closure displays

J 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 display

K 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.
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10.6 Audible Tones Detailed Information

The 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).
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.
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
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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.
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.
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.
NOTE: This fault will only occur in applications where Function Code J0 is set to 08.
• 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.
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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.
• 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 Transfer

In 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 Codes

The 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 Description
01 - 06 Reserved - Clutch Solenoid Reserved for Clutch Solenoid Errors.
07 - 10 Reserved - Troll Solenoid Reserved for Troll Solenoid Errors.
11-12 Reserved N/A
Station # 1 Control Head lever position is out of range.
13 Remote Station # 1 Faulted High
The input appears to be too high.
14 Remote Station # 2 Faulted High Station # 2 Control Head lever position is out of range.
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17 Remote Station # 5 Faulted High The input appears to be too high.
19- 22 Reserved NA
23 Remote Station # 1 Faulted Low
The input appears to be too low.
29 - 32 Reserved NA
Station # 1 Control Head CONTROL/SET Button has either
33 Remote Station # 1 CONTROL/SET Button Stuck Closed been closed too long or has been closed since power
up.
up.
up.
up.
up.
up.
39 - 42 Reserved NA
The Processor-to-Processor Serial Communication’s
Processor-to-Processor Serial Communication Bus protocol has detected an error in communication with
43
Stuffing Error other devices in the network. The error type is a stuffing
type error.
Processor-to-Processor Serial Communication Form protocol has detected an error in communication with
44
Error other devices in the network. The error type is a form
type error.
Processor-to-Processor Serial Communication protocol has detected an error in communication with
45
Acknowledge Error other devices in the network. The error type is a
acknowledge type error.
Processor-to-Processor Serial Communication Bit 1 protocol has detected an error in communication with
46
Error other devices in the network. The error type is a Bit 1
type error.
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Processor-to-Processor Serial Communication Bit 0 protocol has detected an error in communication with
47
Error other devices in the network. The error type is a Bit 0
type error.
Processor-to-Processor Serial Communication CRC protocol has detected an error in communication with
48
Error other devices in the network. The error type is a CRC
type error.
protocol has detected an error in communication with
Processor-to-Processor Serial Communication Bus
49 other devices in the network. The error type is a Bus
Failure
Failure type error. This error cannot be recovered from
without recycling power to the Processor.
A Processor has lost communication with Processor ID
50 Processor ID 1 Time-out
No. 1.
51 Processor ID 2 Time-out No. 2.
No. 3.
No. 4.
No. 5.
55 Reserved N/A
The applied battery voltage has exceeded 30 VDC for 2
56 High Battery Voltage Fault
or more seconds.
The applied battery voltage has dropped to 10 VDC or
57 Low Battery Voltage Fault
less for 2 or more seconds.
58 - 61 Reserved - Software NA
62 - 67 Reserved NA
The Processor has lost communication with Station No.
68 Station #1 CAN Bus Error
1.
2.
3.
4.
5.
73 Station #6 CAN Bus Error 6.
Communications lost between Joystick and
74 Communication Error
SmartCommand.
75 - 77 Reserved - Station CAN Bus Error NA
Control head installed backwards or both processors set
78 Control head installed backwards to same ID.
E0=11 but Smart Command does not detect a Yanmar
79 Yanmar CAN Throttle Error
Engine CAN Throttle input.
This usually is an indication that the cable has been
80 Communication Time-out with Port Rudder Actuator 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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broken, disconnected, wrongly terminated or one of the
81 Communication Time-out with STBD Rudder Actuator
82 Communication Time-out with the Main Helm Motor
Communication Time-out with the FlyBridge Helm broken, disconnected, wrongly terminated or one of the
83
Motor elements on the bus are not communicating at the right
The Smart Command will attempt to resolve many types
Port Rudder Actuator Drive Controller has had an of internal errors but some will need to have the power
84
internal fault. cycled.
STBD Rudder Actuator Drive Controller has had an
85 of internal errors but some will need to have the power
internal fault.
cycled.
86 Main Helm Drive Controller has had an internal fault. of internal errors but some will need to have the power
cycled.
FlyBridge Helm Drive Controller has had an internal
87 of internal errors but some will need to have the power
fault. cycled.
The processor has lost communication with the ZF
88 MTCU CAN Fault
Marine Transmission Control Unit (MTCU).
The MTCU is communicating a fault condition to the
89 MTCU Internal Fault
Processor.
90 Communication Error between the MCU and Smart broken, disconnected, wrongly terminated or one of the
Command elements on the bus are not communicating at the right
91 Autopilot CAN Communication Time-out
Tach Input 1: This error is generated only if Smart
92 Tach Input 1 Command is in a mode that uses the Tach input, such
as EASIDOCK or AUTOTROLL.
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.
93 Tach Input 2
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.
The thruster controller has broadcast that it has an error
94 ZF Bow Thruster Error
that might reduce or prevent thruster operation.
The thruster controller has broadcast that it is
95 ZF Bow Thruster Warning 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 Scenarios

The 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 Solutions
Error # Cause Solution
13 Station #1 control head is defective (A to D too low). Replace station #1 control head. Reassign station ID
(A3).
Replace station #2 control head. Reassign station ID
14 Station #2 control head is defective (A to D too low).
(A3).
(A3).
(A3).
(A3).
(A3).
23 Station #1 control head is defective (A to D too high).
(A3).
24 Station #2 control head is defective (A to D too high). (A3).
(A3).
(A3).
(A3).
(A3).
a) The CONTROL/SET button on the station No. 1 control
a) Clear the error code from the processor memory.
head was held down for 12 seconds or longer.
33
b) Station No. 1 control head CONTROL/SET button is
defective. b) Replace the station No. 1 control head.

head was held down for 12 seconds or longer. a) Clear the error code from the processor memory.
34
b) Replace the station No. 2 control head.
defective.
35
defective.
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36
defective.
37
defective.
38
defective.
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.
a) Relocate the processors so that the length of the
a) The serial harness is longer than 120 ft. (37m). serial harness is less than 120 ft. (37m). Install the
46 shorter serial harness.
b) Install a serial harness with the shields terminated at
b) The serial harness is not properly shielded.
pin 8 on both sides.
b) The serial harness is not properly shielded. b) Install a serial harness with the shields terminated at
a) Power was applied to the starboard processor a) Turn off power to both processors and reapply
before it was applied to the port processor. Typically,
the port processor is set to ID 1 (A001). power to the processors simultaneously.
b) Power was lost to processor ID 1 (A001). b) Determine and correct the cause of power loss, and
50 repower the processors.
c) The A0 Function Code of both processors is set to c) Set Function Code A0 to 01 on the port processor.
02. Cycle power.
d) The port processor is faulty. d) Replace the port processor.
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a) Power was applied to the port processor before it
a) Turn off power to both processors and reapply
was applied to the starboard processor. Typically, the
power to the processors simultaneously.
starboard processor is set to ID 2 (A0-02).
b) Determine and correct the cause of power loss, and
51 b) Power was lost to processor ID 2 (A0-02)
repower the processors.
c) The A0 Function Code of both processors is set to c) Set Function Code A0 to 02 on the starboard
01. processor. Cycle power.
d) The starboard processor is faulty. d) Replace the starboard processor.
a) The battery is being over-charged. a) Correct the charging system as necessary.
56 b) Loose battery connections while the engine/ b) Making certain that the battery switches are turned
alternator is running. off, clean and tighten all battery connections.
a) The battery is not being charged. a) Correct the charging system as necessary.
b) Defective battery. b) Replace the battery.
57 c) Measure the voltage at the battery and at the
processor. The difference should not be greater than
c) Excessive resistance in the power circuit.
3% (taking into consideration the normal 0.7 V drop
across the APS).
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.
68 c) Station No. 1 control head ID does not match the
c) Re-assign station IDs using the A3 Function Code.
programmed processor ID.
d) Defective station No. 1 control head. d) Replace the station No. 1 control head.
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a) The control head is installed backwards (the button
a) Remount the control head so the button labels and
labels and LEDs face away, rather than toward, the
LEDs face toward the operator.
78 operator).
b) Reverse the port and starboard control head
b) Port and starboard control head cables are reversed.
harnesses.
a) The plugs of the clutch harness are not properly a) Reconnect the clutch harness plugs at the processor
seated. and the MTCU.
88 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.
a) Loss of power to the MTCU. a) Determine and correct the cause of power loss.
89
b) Defective MTCU. b) Replace the MTCU.
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
92 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.
a) The sensor is too far from the rotating surface. a) Readjust the air gap.
b) AUTOTROLL or EASIDOCK modes have been selected b) Before selecting the AUTOTROLL or EASIDOCK modes,
without the engines running. start the engines.
c) Re-seat the plugs at the processor and the
93 c) The tachometer wire harness is not properly seated.
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 Replacement

If 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 hardware

3. 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 heads

4. 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.
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.
Figure 10-20: Socket key

7. 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.
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.
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 LED
15. 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.
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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 Replacement

If 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 processor

4. 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.
Table 10-6: Function Code Values
Function Code Value Function Code Value Function Code Value Function Code Value Function Code Value
A0 E5 C7 d2 J3
A1 E6 C8 d3 J4
A2 E7 L0 d4 J5
A3 C0 L1 d5 J6
A4 C1 L2 d6 J7
E0 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.
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.
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.
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 LED
9. 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.
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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-Outs

Every 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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Table 10-17: Wire Harness- Throttle, Dual Voltage- SmartCommand And MiniCommand (p/n 71589-XX)
10.12.1.3 Tachometer Harnesses

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
Appendix A
11 Appendix A - System Components and Specifications
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MMC-341 5000 Series Control Head Variations ZF Marine Propulsion Systems Miramar, LLC
APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
5000 Series Control Head Variations
MMC-341 Figure-1: 5200 Standard Control Head
MMC-341 Figure-2: 5200 Low-Profile Control Head
MMC-341 Rev A 03/12 Page 181
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MMC-341 5000 Series Control Head Variations
ZF MARINE ELECTRONICS, LLC

P/N S/W
S/N PCA
MMC-341 Figure-3: 5100 Standard Control Head
ZF MARINE ELECTRONICS, LLC

P/N S/W
S/N PCA
MMC-341 Figure-4: 5100 Low-Profile Control Head

Refer to Section 13: Appendix C - System Drawings to see SmartCommand system drawings and power
connection diagrams.
MMC-341 Rev A 03/12 Page 182
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MMC-341 5000 Series Control Head Variations
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.
MMC-341 Rev A 03/12

WARNING: Note that the dimensions are out ofPage 183
scale, pay attention to properly size the cut out before use !
EN 3340.758.001a - 2014-10 183

184 EN 3340.758.001a - 2014-10

P - 425-583-1900
F - 425-493-1569
www.zf.com
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.
4100LP Control Head (Low Profile)

4100 Control Head (Dwg 13932)
(Dwg 13932) Control Head, 4000 Series, Single Screw, 4200 Control Head
Control Head, 4000 Series, Single Screw. Low Profile. This control head has a (Dwg 13932)
This control head has a bridge between bridge between the levers to join them. Control Head, 4000 Series, Twin Screw.
the levers to join them.
4200LP Control Head (Low Profile)

(Dwg 13932) 4200AF Control Head
Control Head, 4000 Series, Twin Screw, Low Profile. (Dwg 13932)
Control Head, 4000 Series, Twin Screw, Aft Facing
MMC-337 Rev A 01/11 Page 185
EN 3340.758.001a - 2014-10 185

MMC-337 4000 Series Standard Control Head Variations
Requirements:
Control System Wire Harness Description
(1) Control Head wire harness per lever.
MicroCommander/
ClearCommand (non- 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
pluggable)
Drawing 13932A - 15A
Pluggable Micro
Commander/Clear See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1
Command
CruiseCommand
See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1
(1) Control Head wire harness per Control Head.
MiniCommand
See Figure MMC-337-1: Cable / Harness Connections - Pluggable Drawing 14119-1
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.
PLUGGABLE
1. 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.)
CAUTION: Disconnecting plugs without depressing and holding the release button or buttons will damage the
plug.
MMC-337 Rev A 01/11 Page 186
186 EN 3340.758.001a - 2014-10

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.
MMC-337 Rev A 01/11 Page 187
EN 3340.758.001a - 2014-10 187

HARD WIRED CONNECTIONS NON-PLUGGABLE
Figure MMC-337-2: 9000 Hard Wired Drawing 14119-2
MMC-337 Rev A 01/11 Page 188
188 EN 3340.758.001a - 2014-10

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
MMC-337 Rev A 01/11 Page 189
EN 3340.758.001a - 2014-10 189

4200 CONTROL HEAD FRONT VIEW
Figure MMC-337-5: 4200 Control Head - Front View Dwg #14132
MMC-337 Rev A 01/11 Page 190
190 EN 3340.758.001a - 2014-10

4200 CONTROL HEAD SIDE VIEW
Figure MMC-337-6: 4200 Control Head - Side View Dwg #14133
MMC-337 Rev A 01/11 Page 191
EN 3340.758.001a - 2014-10 191

4100LP CONTROL HEAD FRONT VIEW
Figure MMC-337-7: 4100LP Control Head – Front View Dwg #13932ART-8
MMC-337 Rev A 01/11 Page 192
192 EN 3340.758.001a - 2014-10

4100LP Control Head Side View
Figure MMC-337-8: 4100LP Control Head – Side View Dwg 13932ART-9
MMC-337 Rev A 01/11 Page 193
EN 3340.758.001a - 2014-10 193

4000 SERIES CONTROL HEAD MOUNTING DIMENSIONS

CAUTION: NOT TO SCALE
DO NOT USE AS A TEMPLATE
Figure MMC-337-9: Control Head Mounting Holes and Cutout – Dwg #13293
SEE FOLLOWING PAGE FOR TEMPLATE
MMC-337 Rev A 01/11 Page 194
194 EN 3340.758.001a - 2014-10

4000 SERIES CONTROL HEAD MOUNTING CUTOUT
Figure MMC-337-10: Control Head Mounting Holes and Cutout – Dwg #14649
WARNING: Note that the dimensions are out of scale, pay attention to properly size the cut out before use !
MMC-337 Rev A 01/11 Page 195
EN 3340.758.001a - 2014-10 195

196 EN 3340.758.001a - 2014-10

MMC-329 MC2000 Series Standard Control Head Variations ZF Marine Propulsion Systems Miramar, LLC
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
MC2000 Series Standard Control Head Variations

Revision List
- to E.1 03/11 Previous date unavailable
E.2 02/15/12 Added compass distance note
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.)
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.
MMC-329 Rev E.2 02/12 Page 197
EN 3340.758.001a - 2014-10 197

MMC-329 MC2000 Series Standard Control Head Variations
Dimensions
Figure MMC-329-2: Dimensions

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.
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.
MMC-329 Rev E.2 02/12 Page 198
198 EN 3340.758.001a - 2014-10

CABLE/HARNESS CONNECTIONS:
Dual Control Head Connections
Figure MMC-329-3: Terminal Connections

Cable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.
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
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 Heads
For 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 Head

Handheld Control is an option. Contact your ZF Dealer for further information on Handheld requirements and
options.
MMC-329 Rev E.2 02/12 Page 199
EN 3340.758.001a - 2014-10 199

Mounting a control head too close to compass can cause the compass to malfunction.
MMC-329 Rev E.2 02/12 Page 200
200 EN 3340.758.001a - 2014-10

P - 425-583-1900
F - 425-493-1569
www.zf.com
400 Series Control Head Variations

Revision List
- to N.1 07/10 Previous date unavailable
N.2 02/15/12 Added compass distance note
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 Available

1. 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.
MMC-280 Rev N.2 02/12 Page 201
EN 3340.758.001a - 2014-10 201

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.
Mounting control head too close to compass can cause the compass to malfunction.
3. Type 1 - Pluggable
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).
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-wired
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.
Figure MMC-280-3: Dimensions

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 four (4) mounting
screws and washers supplied with the Control Head.
MMC-280 Rev N.2 02/12 Page 202
202 EN 3340.758.001a - 2014-10

5. CABLE/HARNESS CONNECTIONS:
Figure MMC-280-4: Terminal Connections

Cable/Jumper connections 5 and 7 at the Port and Starboard terminal block are direction sensitive.
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
6. 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.
7. AFT FACING CONTROL HEADS
Figure MMC-280-5: AFT Facing Control Head

For 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.
MMC-280 Rev N.2 02/12 Page 203
EN 3340.758.001a - 2014-10 203

204 EN 3340.758.001a - 2014-10

Mounting control head too close to compass can cause the compass to malfunction.
WARNING:
MMC-280 Rev N.2 02/12 Note that the dimensions are out ofPage
scale,
205 pay attention to properly size the cut out before use !
EN 3340.758.001a - 2014-10 205

206 EN 3340.758.001a - 2014-10

S-214 Automatic Power Selector Model: 13505 ZF Marine Propulsion Systems Miramar, LLC
APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
Automatic Power Selector (APS) Model: 13505

ATTACHMENTS: DC POWER SOURCE DWG 11488
A GENERAL INFORMATION
The 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 SPECIFICATIONS
Model: 13505
Maximum Load Current: 70 amps
Operating Temperature: - 40 degrees C to +80 degrees C; derate linearly from 100% @ 50 degrees C to 70%
@ 80 degrees C
Voltage Drop: 0.7 VDC @ 50% load; 0.9 VDC @ full load
Dimensions: 3.25" x 4.5" x 3.1" (8,3 x 11,4 x 7,9 cm)
C MATERIALS PROVIDED
The single APS is supplied with a hardware packet containing (6) hex nuts, (3) lock washers, (4) self-tapping
mounting screws, (1) instructions diagram.
NOTE: Not all of the hardware will be used in the installation; some spares are provided. Nut size is M-6.
The twin APS is supplied with (2) single APS hardware packets.
D INSTALLATION
Refer 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 SOURCES
Whenever 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.
S-214 Rev H.1 03/11 Page 207
EN 3340.758.001a - 2014-10 207

208 EN 3340.758.001a - 2014-10

Drawing 11488 DC Power Source Kit
Page 209
EN 3340.758.001a - 2014-10 209

210 EN 3340.758.001a - 2014-10

Page 211
EN 3340.758.001a - 2014-10 211

212 EN 3340.758.001a - 2014-10

Page 213
EN 3340.758.001a - 2014-10 213

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Page 215
EN 3340.758.001a - 2014-10 215

216 EN 3340.758.001a - 2014-10

Page 217
EN 3340.758.001a - 2014-10 217

218 EN 3340.758.001a - 2014-10

MMC-287 Grounding (Bonding) ZF Marine Propulsion Systems Miramar, LLC
APPENDIX A - SYSTEM COMPONENTS AND SPECIFICATIONS 12125 Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
Grounding (Bonding)
Grounding (Bonding) - 46 CFR 111.05 and ABYC Section E-11: July 2012
Grounding (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 Council
Metal - 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.
MMC-287 Rev G.2 08/12 Page 219
EN 3340.758.001a - 2014-10 219

220 EN 3340.758.001a - 2014-10

MMC-288 References and Parts Source ZF Marine Propulsion Systems Miramar, LLC
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
References and Parts Sources
References
A American Boat & Yacht Council (ABYC)
3069 Solomons Island Road
Edgewater, MD 21037-1416
E-3 Wiring Identification on Boats
E-11 AC and DC Electrical Systems on Boats
H-2.4e or 32.4g Ambient Temp. 50 degrees C
P-24 Electric/Electronic Propulsion Controls
B Code of Federal Regulations
33 CFR 183 Subpart I - Electrical Systems
33 CFR 183.410 Ignition protection
33 CFR 183.415 Grounding
33 CFR 183.425 Conductors: General
33 CFR 183.430 Conductors in circuit of less than 50 Volts
33 CFR 183.445 Conductors: Protection
33 CFR 183.455 Over-current and Protection: General
46 CFR 111.01 - 15(b) Ambient Temp. Machinery Spaces 50 degrees C
46 CFR 111.05- System Grounds
C Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096
J1171 External Ignition Protection
J1428 Marine Circuit Breakers
J378 Marine Engine Wiring
D National Marine Manufacturers Association
401 North Michigan Avenue
Chicago, IL 60611
E Underwriters Laboratories
Parts Source
Anti-Static Wrist Strap - - - - - - - - - P/N 517 [Thomas & Betts (P/N AWCC)]
Automatic Power Selector - - - - - - - P/N 13505
Circuit 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 13927
WAGO Tool - - - - - - - - - - - - - - P/N 397 [WAGO (P/N 236-332)]
Field Test Control Head - Dual - - - - - P/N 14000
MMC-288 Rev E.1 06/09 Page 221
EN 3340.758.001a - 2014-10 221

222 EN 3340.758.001a - 2014-10
APPENDIX B - SALES AND SERVICE INFORMATION
Appendix B
12 Appendix B - Sales and Service Information
EN 3340.758.001a - 2014-10 223

224 EN 3340.758.001a - 2014-10

MMC-172 Factory Authorized Sales & Service Centers - Inter- ZF Marine Propulsion Systems Miramar, LLC
national APPENDIX B - SALES AND SERVICE INFORMATION 12125 Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
Factory Authorized Sales & Service Centers - International

Argentina Australia
Company: Transmsiones Marinas S.A. Company: ZF Services Australia Pty, Ltd.
Contact: Ing. Daniel Canoura Contact: Gary Bain, Rodney Lean
Address: Hernandarias 3656
Address: Locked Bag 6305
B7603GNH Mar Del Plata Blacktown BC NSW 2148
Argentina Australia
Phone: 54-223- 410 7975
Shipping: 14 Lidco Street
Fax: 54-223- 480 7174 Arndell Park, NSW 2148
Email: TM@tmgroup.com.ar;
tmventas@tmgroup.com.ar Australia
Website: www.tmgroup.com Phone: 61- (0)2-9679-5555
Fax: 61-(0)2-9679-5500
Company: Trimer S.A. Email: gary.bain@zf.com.au or oesales@zf.com
Contact: Carlos Dorian Freidlander Website: www.zf.com.au
Address: Attn: Mariano Castroverde

PO Box 772 Brazil
1000 Buenos Aires, Argentina Company: ZF do Brazil S.A.
Shipping: Fray J.S.M. de Oro 2030-40 Contact: Richard Bergamini
1425 Buenos Aires, Argentina Address: Avenida Conda Zepplin, 1935
Phone: 54-11-4580-0444 CEP 18103-0000 Sorocaba, Brazil
Fax: 54-11-4580-0440 Phone: 5515-235-2301
Email: trimer@trimer.com.ar Fax: 5515-235-2233
Email: richard.bergamini@zf.com
Website: www.zf.com
Chili
Company: Equipamiento Marino Ltda
Contact: Christian Rogers Nickelmann
Address: Rafael Correa 1268 Vitacura
Santiago, Chili
Phone: (56-2) 4158737
Fax: (56-2) 9-9975059
Email: info@equipamientomarino.cl
MMC-172 Rev A.8 07/10 Page 225
EN 3340.758.001a - 2014-10 225

MMC-172 Factory Authorized Service Centers - International
China Denmark
Company: Foilborne Engineering, Ltd. Company: ZF Danmark APS
Contact: Paul Chow Contact: Michael Johansson, Frank Kiessling
Address: Unit A 7-9, 13/F Veristrong Address: Taastrupgaardsvej 8-10
34-36 Au Pui Wan Street / FO-Tan Taastrup, DK-2630, Denmark
Shatin, N.T. Phone: 45-7022-6243
Hong Kong, China Fax: 45-7022-2643
Phone: 852-2687-2988 frank.kiessling@zf.com;
Email: michael.johansson@zf.com
Fax: 852-2687-1996 Website: www.zf-marine.com
Email: paulchow@foilborne.biz.com.hk
Ecuador
Company: Renford Marine Equipment (China) Ltd. Company: ZF Marine’s Consulting
Contact: Anthony Yuen Contact: Pedro Aspiazu
Address: 501 Laws Commercial Plaza Address: Urdesa Central 1A #13184 Costanera
788 Cheung Sha Wan Road Guaaquil – Guayas, Ecuador
Hong Kong, China Phone: (593-4) 238-9306
Phone: 852-27427111 Fax: (593-4) 238-4010
Fax: 852-27427171 Email: zfmarineconsulting@yahoo.com
Email: anthony.yuen@renford.com
Finland
Company: Renford Marine Equipment (Shanghai) Ltd.
Company: Atoy Oy
Contact: Anthony Yuen
Contact: Antti Hiidenheim
Address: 811 Jiaxing Building
Address: PO Box 137
877 Dong Fang Road, Pudong
FIN-00101, Helsinki
Shanghai, China 200122
Finland
Phone: 8621-50589000
Phone: 35-8968271
Fax: 8621-505880007
Fax: 35-896827305
Email: anthony.yuen@renford.com
Email: anttihiidenheimo@atoy.fi
Company: ZF Shanghai Rep. Office

Contact: Tang Zhou Qing, Gong Lan
France
Address: Room 2504, Jiangnan Building Company: ZF France
No. 600 Luban Road Contact: Ronald Gamere
Shanghai, 200023, PR China Address: 3, rue Henri Poincare’
Phone: 0086-21-6301-4338 92167 ANTONY CEDEX, France
Fax: 0086-21-6301-6449 Phone: +33 (01) 40 96 42 74
Email: qiwei.yao@zf.com Fax: +33 (01) 40 96 42 74
Website: www.zf-marine.com Email: Ronald.Gamere@zf.com

Website: www.zf.com/sso/fr
MMC-172 Rev A.8 07/10 Page 226
226 EN 3340.758.001a - 2014-10

Ireland
Germany
Company: ZF Services Great Britain, Ltd
Company: Otto Piening Propeller GMBH
Contact: Adi License
Contact: Mathias Pien
Address: Abbeyfield Road, Lenton
Address: AM Altendeich 83
Nottingham, United Kingdom
D25348 Glückstadt
NG7 2SX, England
Germany
Phone: 44-115-986-9211
Phone: 49-4124-916812
Fax: 44-115-986-9261
Fax: 49-171-4853376
Email: adi.license@zf.com
Email: pein@piening-propeller.de
Website: www.zf-marine.com
Website: www.piening-propeller.de
Italy
Greece
Company: Saim SPA
Company: Amaltheia Marine, Ltd
Contact: Antonio Renzetti, Alessandro Busetto
Contact: Demetris Kyriazis
Address: Via Donizetti, 9/11
Address: 13 Papaflessa Str.
20090 Assago (MI)
143 43 N. Halkidona
Italy
Athens, Greece
Phone: 39-02-488-521
Phone: 30210-25-88-985
Fax: 39-02-45703070
Fax: 30210-25-89-986 alessandro.busetto@saim-group.com;
Email:
Email: amalmar@otenet.gr antonio.renzetti@saim-group.com
Website: www.saim-group.com
Iceland
Japan
Company: Maras ehf
Company: ZF Marine Japan Co. Ltd
Address: Gudmundur Bragasson
Contact: Y. Ikeda, Nobora Kasajima
Akralind 2
Address: Fujikoshi Bldg. 1-10-11 Iriya taito-ku
201 Kopavogur
Tokyo, 110-0013
Iceland
Japan
Phone: 354-555-6444
Phone: 81-03-5808-4521
Fax: 354-565-7230
Fax: 81-03-5808-4531
Email: Gummi@maras.is
Email: mikio.sato@zf.com
MMC-172 Rev A.8 07/10 Page 227
EN 3340.758.001a - 2014-10 227

Korea New Zealand

Company: SE Jung Engineering Co. Company: ZF Services Australia Pty, Ltd
Contact: M.G. Song Contact: Gary Bain, Rodney Lean
Address: #35-4 Namhangdong-1KA Address: Locked Bag 6305
Yeongdogu Blacktown BC
Pusan, Korea NSW, Australia 2148
Phone: 82-51-415-0591 Shipping: 14 Lidco Street
Fax: 82-51-412-6361 Arndell Park, NSW
Email: sjeng88@kornet.net Australia 2148
Phone: 61-02-9679-5555
Mexico Fax: 61-02-9679-5500
Company: Baja Naval, s.a. de c.v. Email: gary.bain@zf.com.au or oesales@zf.com

Jaime Hernandez, Alfredo Soqui, Mario
Contact:
Herrera
Norway
Address: Av. de le Marina, 10
Ensenada, Company: KGK Norge AS
Baja California Norte 22800 Contact: Bjorn Reiersen
Phone: 011 52 646 174 0020 Address: Casper Storms Vei 19
Fax: 011 52 646 174 0028 N-0064 Oslo
Email: diego@bajanaval.com Norway

Phone: 47-22-884-680
Fax: 47-22-720-902
Company: RAL LINE, S.A. DE C.V.
Email: bjorn.reiersen@zf-group.com
Contact: Ing. Ernesto Cadavid
Address: Av. Gran Via Tropical #8
Peru
Fraccionamiento Las Playas
Acapulco, Gro. Mexico Company: PGO International S.A.C
Phone: 744-482-6365 Contact: Pedro Gonzalez – Orbegoso
Fax: 744-482-6365 Address: AV. Arequipa 2450 of 1108
Email: ecadavid@ralline.com.mx Lima 14, Peru

Phone: (51-1) 421-6055
Fax: (51-1) 421-6664
Email: pgorbegoso@perusat.net.pe
MMC-172 Rev A.8 07/10 Page 228
228 EN 3340.758.001a - 2014-10

Russia
Company: ZF South East Asia
Company: ZF Russia
Contact: Sharon Ho
Contact: Anastassia Selverstova
Address: 11, Tuas Drive 1
Address: 71, Marata Street Ste 313
Singapore
St Petersburg
Phone: 6861-0177
Russia 191119
Fax: 6861-9173
Phone: 7-812-324-54-72
Email: sharon.ho@zf-seasia
Fax: 7-812-140-18-15
Email: anastassia.selverstova@zf.sp.ru
South Africa
Company: ZF South Africa Pty, Ltd
Scotland
Contact: Heather Hermann
Company: ZF Services Great Britain, Ltd
Address: PO Box 2098
Contact: Adi License
Kempton Park, 1620 South
Address: Abbeyfield Road, Lenton
Africa
Nottingham, United Kingdom
Shipping: C/O Barlows Power Systems
NG7 2SX England
Cnr Peter Barlow and Kasselss Vlei Rd
Phone: 44-115-986-9211
Phone: 27-11-453-1818
Fax: 44-115-986-9261
Fax: 27-11-453-7506
Email: adi.license@zf.com
Email: heather@zfsa.za
Spain
Singapore
Company: ZF Espana S.A.
Company: Mammoth Enterprises Pte, Ltd
Contact: Maria Valladolid
Contact: Steven Wee
Address: Avda. Fuentemar, 11
Address: PO Box 283
Coslada (Madrid) 28820
Siglap Post Office
Spain
Singapore 914503
Phone: 34 (0) 91485-2695
Shipping: 6-A Waringin Park
Fax: 34 (0) 91485-0036
Singapore 416320
Email: maria.valladolid@zf.com
Phone: 65-6-44-88266
Fax: 65-6-44-89800
Email: mament@singnet.com.sg
MMC-172 Rev A.8 07/10 Page 229
EN 3340.758.001a - 2014-10 229

Sweden Thailand
Company: KG Knutsson AB Company: ZF Thailand Co. Ltd
Contact: Karl-Henry Pragsten Contact: Reungpoj V
Address: Tansmissions Divisionen Address: 159/33 Soi Vipawasee 64
Hammarbracken 8 Vipawasee-Rangsit Road
S-191 81 Sollentuna Laksi, Bangkok 10210 Thailand
Sweden Phone: 66-2-521-6520
Phone: 46-08-923-312 Fax: 66-2-521-6523
Fax: 46-08-929-599 Email: tanapath@bkk.loxinfo.th
Email: zf-marine@kgk.se
Website: www.kgk.se The Netherlands (Holland)
Company: ADS/van Stigt
Switzerland Contact: Ton Hekman, Rob van der Linde
Company: Marine Parts Technic Address: Avelingen – West 30
Contact: Fabian Kraemer NL-4202 MS Gorinchem
Address: Pfaffikerstrasse 6 The Netherlands
CH-8604 Volketswil Phone: 31-0-183-650000
Zurich, Switzerland Fax: 31-0—183-650001
Phone: 41-1997-4090 Email: Ton.Hekman@vanstigt.com
Fax: 41-1997-4094 Website: info@vanstigt.com
info@marineparts.ch;
Email:
fabian.kraemer@marineparts.ch
Website: www.marineparts.ch U.A.E.
Company: ZF Middle East, LLC
Taiwan Contact: M. Narasimhan (Narsi), A.T. Moorthy
Company: Asia Diesel electric Corp Address: PO Box 26093
Contact: Mike Ou Sharjah, U.A.E.
Address: 8F-1, No. 34, Min Chuan 1s. Road Shipping: #502 Golden Tower Building
Kaohsiung, Taiwan. #80205 Sharjah, U.A.E.
Phone: 886-7-3331191 Phone: 971-6-5747074
Fax: 886-7-3346808 Fax: 971-6-5747174

thiru.moorthy@zf-marine.com;
Email: ade.taiwan@msa.hinet.net Email:
narasimhan.manian@zf-marine.com
Website: www.asiadiesel.com.tw Website: www.zf.com
MMC-172 Rev A.8 07/10 Page 230
230 EN 3340.758.001a - 2014-10

United Kingdom
Company: ZF Marine Propulsion Systems Miramar –West
Company: Atlantis Marine Power, Ltd Coast
Contact: Peter Middleton, Paul Lakey Contact: Kevin Zwicker
Address: Western wood Way Address: 12125 Harbour Reach Drive Ste B
Language Science Park Mukilteo,WA 98275
Plymouth, Devon, PL7 5BG Phone: 425-583-1900
5BG England Fax: 425-493-1569
Phone: 44-1752-208810 Email: kevin.zwicker@zf.com
Fax: 44-1752-208811 Website: www.zf.com

paul.lakey@atlantismarine.co.uk;
Email:
peter@atlantismarine.com Venezuela
Website: www.atlantismarine.co.uk
Company: Sistemas de Propulsion C.A.
Address: AV 67a Entre 149By 150
USA
2 Etapa Zona Industrial
ZF Marine Propulsion Systems Miramar – US
Company: Maracaibo, Venezuela
Headquarters
Contact: A.J. Halavacs Phone: 58-261-736-0747
Address: 15351 SW 29th Street, Ste 300 Fax: 58-261-736-0746
Miramar, FL 33027 Email: spd@sistemaspropulsion.com
Phone: 954-441-4040
Fax: 954-441-4140
Email: aj.halavacs@zf.com
Website: www.zf.com
ZF Marine Propulsion Systems Miramar, LLC –

Company:
Gulf Coast
Contact: Mike Gauthreaux
Address: 161 James Drive West
Suite 120
St Rose, LA 70087
Phone: 504-443-0501
Fax: 504-443-0504
Email: mike.gauthreaux@zf.com
Website: www.zf.com
MMC-172 Rev A.8 07/10 Page 231
EN 3340.758.001a - 2014-10 231

232 EN 3340.758.001a - 2014-10

MMC-165 Warranty ZF Marine Propulsion Systems Miramar, LLC
APPENDIX B - SALES AND SERVICE 12125
INFORMATION
Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
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 warranties
of any kind, including warranties of merchantability and fitness for a particular purpose. Under no circumstances shall ZF be liable for any incidental or consequential damages
sustained 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 not
authorize 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 on
how 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 the
duration of this express warranty. This warranty gives you legal rights, and you may have other rights that may vary from State to State.
MMC-165 Rev G.1 04/09 Page 233
EN 3340.758.001a - 2014-10 233

234 EN 3340.758.001a - 2014-10

MMC-163 Warranty Registration ZF Marine Propulsion Systems Miramar, LLC
APPENDIX B - SALES AND SERVICE 12125
INFORMATION
Harbour Reach Dr Ste B
Mukilteo, WA 98275
P - 425-583-1900
F - 425-493-1569
www.zf.com
Warranty Registration
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
ZF Marine Propulsion Systems Miramar, LLC. Product First Seen At:
Boat Show Dealer Magazine Friend
MMC-163 Rev C.1 04/09 Page 235
EN 3340.758.001a - 2014-10 235

236 EN 3340.758.001a - 2014-10
APPENDIX C - SYSTEM DRAWINGS
Appendix C
13 Appendix C - System Drawings
EN 3340.758.001a - 2014-10 237

238 EN 3340.758.001a - 2014-10

EN 3340.758.001a - 2014-10 239

240 EN 3340.758.001a - 2014-10

EN 3340.758.001a - 2014-10 241

Drawing 13170 SmartCommand Twin Screw System Drawing
242 EN 3340.758.001a - 2014-10

EN 3340.758.001a - 2014-10 243

244 EN 3340.758.001a - 2014-10

EN 3340.758.001a - 2014-10 245

ZF Padova S.r.l.
Via Penghe, 48
I - 35030 Caselle di Selvazzano (PD)
ITALY
Phone +39 049 8299 311
Fax +39 049 8299 550
www.zf.com
EN 3340.758.001a - 2014-10

ZF Smartcommand User Manual

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INSTALLATION, OPERATION

MMSC5000 - SMARTCOMMAND USER MANUAL

MARINE PROPULSION SYSTEMS

Released by After Sales dept.

SmartCommand User Manual ........................................................ 1

3.4 Engine Stop Switch .........................................................................................................................41

5 Set Up Procedures ............................................................................. 61

7 Sea Trials: Adjustments and Tests Underway ................................. 103

9 Periodic Checks and Maintenance .................................................. 123

10 Troubleshooting ............................................................................... 125

11 Appendix A - System Components and Specifications.................... 179

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

MMSC5000 Rev B 01/13 Page 6

MMSC5000 Rev B 01/13 Page 7

Figure 10-5: Processor Display in Run Mode................................................................................................... 135

MMSC5000 Rev B 01/13 Page 8

MMSC5000 Rev B 01/13 Page 9

Table ENG-289-13: Sport Fish Mode Functions (Sport Fish) ............................................................................. 89

MMSC5000 Rev B 01/13 Page 11

MMSC5000 Rev B 01/13 Page 13

Conventional Symbols Used in the Manual

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.

MMSC5000 Rev B 01/13 Page 15

How to Use the Manual

MMSC5000 Rev B 01/13 Page 16

1.1 SmartCommand System

MMSC5000 Rev B 01/13 Page 17

1.1.2 Advanced Control Modes

mode maintains a constant propeller RPM while you have a

MMSC5000 Rev B 01/13 Page 18

2.2 Take Control

Note: Only one station has control at any time.

MMSC5000 Rev B 01/13 Page 19

Figure 2-1: Take Control at a Station

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

2.3 Basic Operation

MMSC5000 Rev B 01/13 Page 20

Figure 2-2: Control Head Detents

2.4 Engine Start Interlock

2.5 Proportional Pause

MMSC5000 Rev B 01/13 Page 21

2.6 Station Transfer at Neutral

2.7 Station Transfer on the Fly

To transfer control from one station to another:

MMSC5000 Rev B 01/13 Page 22

2.8 Warm Up Mode (Throttle Only)

Figure 2-3: Warm Up LED

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

2.8.1 Entering Warm Up Mode

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

To put the system in Warm Up mode:

MMSC5000 Rev B 01/13 Page 23

2.8.2 Exiting Warm-up mode

2.9 High / Low Idle

2.10 Twin Screw Synchronization

2.10.1 Setting Up Synchronization on the Processor

MMSC5000 Rev B 01/13 Page 24

2.10.2 Disabling and Enabling Synchronization from the Control Head