1. ZF Marine Electronics, L.L.C.

12125 Harbour Reach Drive

Suite B
Mukilteo, WA 98275

ZF Backup
Operation, Installation &
Troubleshooting Manual
MMSB3000-I Rev B 7/08

Copyright
Copyright 2005 ZF Marine Electronics, LLC
All Rights Reserved
No part of this publication may be copied or reproduced in any form, including an electronic
retrieval system or be made available on the Internet, a public network, by satellite, or otherwise
without the prior written permission of ZF Marine Electronics, LLC, 12125 Harbour Reach Drive,
Suite B, Mukilteo, WA 98275.

Legal Information
The information in this manual is believed to be accurate at the time of publication, but no
responsibility, direct or consequential, can be accepted for damage resulting from the use of this
information. ZF Marine Electronics, LLC, reserves the right to make changes to any of its products
without notice.

Preface

Preface
Important:
It is important to keep this manual in a safe place for future reference. The manual contains
answers to questions that may arise during operation or installation of the ZF Marine Electronics
ZF Backup Control System and it options.

Conventional Symbols Used in the Manual

Throughout this manual special attention should be paid to the following symbols.
Warning: Personal Injury may result if these messages are not followed.

Caution: Damage to equipment may occur if these messages are not followed.

Important: Contains essential information about a topic.

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

How to Use the Manual

Warning: Personal Injury may result if this message is disregarded.
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 Electronics
Sales & Service Organization (SSO). For more information on an SSO in your area, please see page
71.

July 25, 2008

Page iii

Table of Contents

Table of Contents
1

INTRODUCTION....................................................................................................... 9

1.1

Attention: Warnings & Cautions .................................................................................................................10

1.2

Features ..........................................................................................................................................................11

1.3

Generic System Drawing...............................................................................................................................12

1.4

Specifications..................................................................................................................................................13

OPERATION ........................................................................................................... 14

2.1
ZF Backup Processor ....................................................................................................................................14
Proportional & Fixed Pauses ...................................................................................................................................14
Time Line for Directional Change...........................................................................................................................15
Start Interlock Relays ..............................................................................................................................................15
Processor LEDs .......................................................................................................................................................16
Deutsch Connectors.................................................................................................................................................17
2.2
ZF Backup Control Panel .............................................................................................................................18
Control Panel LEDs.................................................................................................................................................18
Activating Backup Mode.........................................................................................................................................19
Transmission............................................................................................................................................................19
Exiting Backup Mode..............................................................................................................................................19
2.3
Basic Operation..............................................................................................................................................20
Cruise Mode for Normal Operation.........................................................................................................................20

INSTALLATION ...................................................................................................... 20

3.1
Backup Command Processor (BCP) ............................................................................................................20
Planning the Installation ..........................................................................................................................................21
Installer Supplied Parts and Tools ...........................................................................................................................21
Miscellaneous Parts .................................................................................................................................................21
Selecting the Location for the Processor .................................................................................................................22
Installing the Processor............................................................................................................................................23
Grounding the Processor..........................................................................................................................................23
3.2
ZF Backup Panel ...........................................................................................................................................24
General Information ................................................................................................................................................24
ZF Backup Panel Installation...................................................................................................................................25
DC Power Source ....................................................................................................................................................32
DC Power Cable ......................................................................................................................................................32
3.3
Wire Harness Installation .............................................................................................................................33
General Information ................................................................................................................................................33
Wire Harness Plug Insertion and Extraction............................................................................................................34
Control Panel Wire Harness ....................................................................................................................................34
Power, Start Interlock Wire Harness for Twin Screw Processor .............................................................................35
Clutch Interface Wire Harness.................................................................................................................................37
Throttle Interface Wire Harness ..............................................................................................................................37
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Table of Contents
3.4

Engine Stop Switches.....................................................................................................................................38

DOCK TRIALS........................................................................................................ 39

4.1

Control Panel (Engines Stopped) .................................................................................................................39

4.2

ZF Backup Processor ....................................................................................................................................39

SEA TRIALS ........................................................................................................... 39

5.1

Full Speed Setting ..........................................................................................................................................40

5.2

Sea Trial Reports ...........................................................................................................................................40

5.3

Control System Checks .................................................................................................................................41

PERIODIC CHECKS AND MAINTENANCE........................................................... 45

6.1

Backup Panel..................................................................................................................................................45

6.2

Processor.........................................................................................................................................................45

TROUBLESHOOTING............................................................................................ 45

7.1

Troubleshooting Questions ...........................................................................................................................45

7.2

Generic System Drawing...............................................................................................................................47

7.3

Taking Command ..........................................................................................................................................49

7.4

System Checkout............................................................................................................................................49

7.5
ZF Backup Processor Connector Pin Functions .........................................................................................49
BACKUP PANEL PORT Receptacle......................................................................................................................49
BACKUP PANEL STBD Receptacle......................................................................................................................50
POWER Connector..................................................................................................................................................50
PORT THROTTLE Connector................................................................................................................................50
STBD THROTTLE Connector................................................................................................................................51
PORT CLUTCH Connector ....................................................................................................................................51
STBD CLUTCH Connector ....................................................................................................................................51

APPENDIX A .......................................................................................................... 53

8.1

Deutsch Connector Assembly DT Type ....................................................................................................55

8.2

Grounding (Bonding) ....................................................................................................................................56

8.3

Metal Hull Vessels..........................................................................................................................................58

8.4
References.......................................................................................................................................................59
American Boat & Yacht Council (ABYC) ..............................................................................................................59
Code of Federal Regulations ...................................................................................................................................59
Society of Automotive Engineers ............................................................................................................................59
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Table of Contents
National Marine Manufacturers Association ...........................................................................................................59
Underwriters Laboratories .......................................................................................................................................59
8.5

ZF Backup Part Numbers.............................................................................................................................61

ZF Backup Part Numbers Cont ...........................................................................................................................62

APS Specifications ..................................................................................................................................................63
Materials Provided...................................................................................................................................................63
Installation ...............................................................................................................................................................63
APS Installation Drawings ......................................................................................................................................65
8.6

APS Wiring Options with Backup System ..................................................................................................67

APPENDIX B .......................................................................................................... 69
Sales & Service Organizations ................................................................................................................................71

9.1

Glossary ..........................................................................................................................................................83

9.2

Table of Figures .............................................................................................................................................93

9.3

List of Tables..................................................................................................................................................95

9.4

Index ...............................................................................................................................................................96

9.5

Warranty ........................................................................................................................................................99

9.6

Warranty Registration ................................................................................................................................101

July 25, 2008

Page #vii

Introduction

1 Introduction
The ZF Backup processor provides a twin screw vessel with the minimum controls required to keep it
underway in the event the primary system processor fails or there is a loss of power. It is only
intended to use with systems where throttle and shift control are all electronic. ZF Backup works
with the following twin screw systems:

SmartCommand

Series 9000

MiniCommand

CruiseCommand

The backup system consists of a remote mounted panel and a backup processor. The remote panel
has LEDs (indicator lights) that show gear selection, push buttons for selecting the port and starboard
gears, and potentiometer knobs for commanding port and starboard throttle.
When the backup system is selected, the primary processors command neutral/idle with no station in
control, and the Start Interlock relay is open. ZF Backups gear will be commanded to neutral with
the throttle speed at Idle. The backup processor has a Start Interlock relay for each engine; the relays
are closed in neutral allowing the engines to start.
This manual is intended for use with the ZF Backup Processors in Table 1 below:
Table 1: ZF Backup Processor
ZF Marine
Electronics
Processor Part
No.

Number of
Screws

ENGINE Electronic

CLUTCH
Solenoid

Troll
Solenoid

No. of
Pluggable
Stations
(Max)

3001B

Twin

PWM Throttle

Yes

No

3002B

Twin

Voltage (0.9-4.5V) Throttle

Yes

No

3003B

Twin

Voltage (0.9-1.2-4V) Throttle

Yes

No

3005B

Twin

4-20 mA Throttle

Yes

No

3007B

Twin

Voltage (.5 4.5V) Throttle

Yes

No

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Introduction

1.1 Attention: Warnings & Cautions

Warning: When WELDING on or near the vessel, be sure to
disconnect the Power Harness from the Power Pigtail at
the processor.
Failure to disconnect the power could cause permanent
electrical damage to the processor. The processor must
then be replaced.

Warning: ELECTRO-STATIC DISCHARGE can damage or destroy

the ZF Marine control system. It is extremely important
that personnel working on this equipment be grounded to
the chassis with the Anti-static Wrist Strap provided.

Caution: Do not operate ZF Marine Electronics (ZFME) equipment

with OTHER MANUFACTURERS EQUIPMENT unless
pre-authorized in writing by ZFMEs Engineering
department. ZF Marines equipment is designed to work
with other ZF Marine equipment.

Page #10 of 101

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Introduction

1.2 Features
1. Designed as a backup processor that has a single power supply input for both engines
and gears in a twin screw system.
2. Diesel Engines Only.
3. Operates on either a 12 or 24 VDC power supply.
4. ZF Backup has four options for throttle control of both the port and the starboard
engines:
a. PWM Output (8 92%)
b. Variable Frequency (80 480 Hz)
c. Voltage Output (0.2 4.8 VDC)
d. Current (03.98 20.2 mA
5. Proportional pause on direction changes (ahead to astern or vice versa).
6. ZF Backup has two Start Interlock Relays, one each for the Port and Starboard engines.
7. ZF Backup works with the following twin screw system.
a. SmartCommand No further modifications.
b. Series9000 No further modifications.
c. MiniCommand No further modifications.
d. CruiseCommand Requires jumper modification during installation.
8. Neutral solenoid outputs for both port and starboard are available if required.
9. Interface to backup panel:
a. Switches for gear selection, ahead, astern and neutral for port and starboard
gear, with LEDs in the backup processor to confirm button presses
b. LEDs on the backup panel to show whether the gear is in ahead, astern or
neutral and one that shows whether ZF Backup is active or inactive.
c. There are two potentiometers for port and starboard speed control that output
analog signals, which are read by the backup processors microcontroller unit
(MCU).

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Page #11 of 101

Introduction

1.3 Generic System Drawing

When the vessel has a BACKUP system in addition to the primary system, four alternate APS wiring options are provided. Select the one
that works best on the vessel being equipped with an APS. See page #67.

Figure 1: Generic System Drawing #14091 (See page #67 for APS Wiring Options)
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1.4 Specifications
Table 2: General Specifications Twin Screw Processor
APPLICATION/MARKET

ZF BACKUP IS INTENDED FOR THE PLEASURE CRAFT MARKET.

IT IS NOT INTENDED FOR COMMERCIAL OR PASSENGER
CARRYING APPLICATIONS.

NUMBER OF BACKUP PANELS

ONE (1)

POWER REQUIREMENTS

TWO POWER SOURCES REQUIRED (FOR PORT & STBD)

NOMINAL VOLTAGE INPUT:

12

24 VDC

VOLTAGE RANGE:

9.0

CURRENT RATING

MAXIMUM 5A PER SCREW, TWO 10A CIRCUIT BREAKERS

REQUIRED (ONE PER SCREW)

OR
TO

31.2 VDC

OUTPUTS

CLUTCH SOLENOID

PORT:

(4 TOTAL OUTPUTS)

(2) ON/OFF TYPES FOR AHEAD & ASTERN.

STARBOARD:
(2) ON/OFF TYPES FOR AHEAD & ASTERN.

START INTERLOCK RELAY

(2) RELAY CONTACTS (PORT & STBD), 7A/30V MAXIMUM

(2 TOTAL)

EACH

THROTTLE OPTIONS

(2) PWM, 8 TO 92% DUTY CYCLE. (PORT & STARBOARD)

(2 TOTAL OUTPUTS)
The Processor must be
ordered with a specific
throttle output.

OR (2) 4 TO 20mA (PORT & STBD)

OR (2) 0.2 TO 4.9 VDC (PORT & STBD)
OR (2) FREQUENCY, 0/5 VDC, 120 TO 465 Hz (PORT &
STBD).

ENVIRONMENTAL RATING

IP55 (TEST PENDING)

OPERATING TEMPERATURE

-25 C TO +70 C

STORAGE TEMPERATURE

-40 C TO 85 C

EMC

CE PER EN60945

VIBRATION-RESONANT

2.0 Hz TO 13.2 Hz, 1mm

13.2 Hz

VIBRATION RANDOM

TO

100 Hz, 0.6g (6.9 m/SEC2)

20 Hz

TO

2000 Hz, 1.0g (9.8 m/SEC2)

20 Hz

TO

2000 Hz, 7.5g

ACCELERATION CURVE: FLAT PER IEC 60068 (2) (+64)

8 HOURS PER AXIS EACH OF THREE AXES

Page #13 of 101
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4.65 lbs

WEIGHT

2 Operation
The ZF Backup processor is a redundant system, which is intended to take the place of the
primary propulsion system, in the event the primary system goes down or it has a loss of
power. ZF Backup works with the following primary propulsion systems:

SmartCommand

MiniCommand

Cruise Command

All Electric 9000 Series

2.1 ZF Backup Processor

Figure 2: ZF Backup Processor

Proportional & Fixed Pauses

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.
Important: This pause protects your engine and
transmission from damage.

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Sea Trials
The proportional pause feature provides engine deceleration when making a
directional change. The pause is variable and in proportion to:

The Panel Knobs position prior to the reversal, i.e.; the speed of the
vessel.

How long the Knob has been in that position prior to the reversal, i.e.;
the length of time the vessel has been at that speed.

The maximum pause is 5 seconds.

Time Line for Directional Change

1. The Port and/or Starboard Ahead or Astern button(s) are pushed.
2. The vessel begins to slow.
3. There is a (1) second delay before the throttle is at idle
4. The delay timer begins as the vessel continues to slow, up to 5 seconds
(Proportional Pause). The length of the delay depends on how fast the
vessel is going before you command the directional change and how long
the vessel has been traveling at that rate of speed. The maximum delay is 5
seconds. See the Proportional Pause algorithm below:
Note: The Backup Control Processor (BCP) calculates the
proportional pause according to the following algorithm:
APP = 5 x ((S)/30)/M
1. APP = Ahead Proportional in milliseconds
2. S = Sum of last 30 throttle values, sampled at 1 second
intervals.
3. M = Max Throttle Value.
5. The clutch(s) disengage, delay for second, and re-engages in the opposite
gear.
6. You experience another second delay before the throttle begins to rise in
the opposite direction.
7. It will take up to 5 seconds for the throttle to reach the preset level before
the directional change. This time depends on how fast you were traveling
when you made the directional change.
8. This time line is the same whether you are going from Ahead to Astern or
from Astern to Ahead.

Start Interlock Relays

ZF Backup has two Start Interlock Relays, one for each engine (Port and
Starboard).

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Once a stations ZF Backup panel is activated, and all the conditions below are
met the start interlock relay contact closes, allowing the engine to start.

DC power is on.

The Backup Panel is in command.

The Backup Panel is commanding Neutral.

Processor LEDs
The ZF Backup Processor has (18) LEDs defined below.
PORT OUTPUT
1

ZF Backup is active for Port Ahead

ZF Backup is active for Port Astern

ZF Backup is active for Port Neutral

ZF Backup on the Port side is active

STBD OUTPUT (Starboard Output)

5

ZF Backup on the Starboard side is active

ZF Backup is active for Starboard Ahead

ZF Backup is active for Starboard Astern

ZF Backup is active for Starboard Neutral

PORT THR (Port Throttle)

9

ZF Backup has control of the Port engine.

PORT PANEL
10

This LED lights when the Port Ahead switch is pressed on the Backup Panel.

11

This LED lights when the Port Astern switch is pressed on the Backup Panel.

12

This LED lights when the Port Neutral switch is pressed on the Backup Panel.

PWR (Power)
13

These LEDs light when there is power applied to the processor.

14
Page #16 of 101

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The ZF Backup Processor has (18) LEDs defined below.

STBD PANEL (Starboard Panel)
15

This LED lights when the Starboard Ahead switch is pressed on the Backup Panel.

16

This LED lights when the Starboard Astern switch is pressed on the Backup Panel.

17

This LED lights when the Starboard Neutral switch is pressed on the Backup Panel.

STBD THR (Starboard Throttle)

18

ZF Backup has control of the Starboard engine.

Deutsch Connectors
Connectors

Description

Backup Panel Port

This connector goes directly to the ZF Backup panel on the

Port side.

Backup Panel Starboard

This connector goes directly to the ZF Backup panel on the

Starboard side.

Power/Start Interlock

This connector goes directly to the power source, to the Port

main processor, to the starboard main processor, to the Port
Start Interlock and to the Starboard Start Interlock.

Port Throttle

This connector goes to the Port main processor, and to the

Port engine power connector.

Starboard Throttle

This connector goes to the Starboard main processor, and to

the starboard engine power connector.

Port Clutch

This connector goes to the Port main processor, and the Port
gear.

Starboard Clutch

This connector goes to the Starboard main processor, and to

the starboard gear.

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2.2 ZF Backup Control Panel

Figure 3: ZF Backup Control Panel, #14105

Control Panel LEDs

ZF Backup has (6) LEDs on the control panel, which report the state of the gears
and indicate whether the vessel is currently in Ahead, Neutral, or Astern, on the
Port side (left) or Starboard side (right).
ZF Backup Control Panel LEDs

Port
(F) Forward

Indicates ZF Backup is commanding Forward (Ahead) gear for the Port

engine.

(N) Neutral

Indicates ZF Backup is commanding Neutral/Idle gear for the Port engine.

(R) Reverse

Indicates ZF Backup is commanding Reverse (Astern) gear for the Port

engine.

Starboard
(F) Forward

Indicates ZF Backup is commanding Forward (Ahead) gear for the

Starboard engine.

(N) Neutral

Indicates ZF Backup is commanding Neutral/Idle gear for the Starboard

engine.

(R) Reverse

Indicates ZF Backup is commanding Reverse (Astern) gear for the

Starboard engine.

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Activating Backup Mode
When the Neutral Port and/or Neutral Starboard gear button(s) on the ZF
Backup Panel are pressed and held for 2 seconds, ZF Backup is activated. For
each engine placed in backup mode, the following applies:

The Backup Control Processor (BCP) activates the Backup Control Relay.

The BCP activates the Start Interlock Relay, only if the throttle
potentiometers are not at Idle, preventing engine start.

The BCP illuminates the control LED of the engine(s) placed into Backup
Mode. (Example: The Port and/or Starboard Neutral LEDs light up).

When NOT in Backup Mode, the BCP will output Neutral/Idle.

After entering Backup Mode, the BCP will output idle throttle until the
Throttle Control Knob is returned to idle. The Ahead and Astern shift
solenoids are de-energized, commanding neutral.
Note: During this phase of activation clutch controls
are active.

Transmission
When activated, ZF Backup initializes in neutral/idle. The system remains in
neutral/idle until the Throttle Control Knob(s) on the panel are moved to the
minimum throttle speed.
Note: Once the Port and/or Starboard knobs are moved to
the minimum throttle speed, the Start Interlock Relays close
and the clutch control is fully active.
1. ZF Backup is able to independently enter Backup mode for port and/or
starboard engines.
2. ZF Backup will only shift into Ahead or Astern gear from Neutral/Idle.
3. Once the gears have shifted into Ahead or Astern, the appropriate LEDs
light for Ahead or Astern, Port and/or Starboard.
4. When shifting gears from Ahead, the Backup Control Processor (BCP)
pauses in Ahead Idle for the length of the proportional pause before
disengaging the clutch. Five seconds maximum.
5. When shifting gears from Astern, the BCP pauses in Astern Idle for half
the length of the proportional pause before disengaging the clutch. Two
and one half second max.

Exiting Backup Mode

To exit Backup mode on one or both the Port and/or Starboard engines, do the
following:
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On the ZF Backup Panel press and hold the Port and/or Starboard Neutral
button(s) for 5 seconds. ZF Backup exits Backup mode by performing the
following:
a. The Backup Control Processor (BCP) sequences to Neutral/Idle.
b. The BCP deactivates the Backup Control Relay.
c. The BCP deactivates the Start Interlock Relay.
d. Deactivates the Control LED.
Recommendation: If your vessel has two engines, only one ZF
Backup unit is required.
Even if only one of the primary systems goes down (i.e.; Port), ZF
Marine Electronics recommends that ZF Backup be engaged for
both the Port and Starboard engines for ease of operating the
vessel.

2.3 Basic Operation

Cruise Mode for Normal Operation
a. The ZF Backup Control Knob does not have any detents.
b. When in the Ahead gear, ZF Backup commands the throttle speed according
to the position of the throttle knob.
c. Prior to shifting into gear, ZF Backup pauses in gear for the length of the
proportional pause or max of 5 seconds.
d. When shifting into gear, ZF Backup pauses for 500 ms in Idle before
increasing the throttle speed.
e. ZF Marine Electronics recommends that the primary control system (i.e.;
CruiseCommand, MiniCommand, etc.) and the ZF Backup have separate
power sources.

3 Installation
3.1 Backup Command Processor (BCP)
Refer to the Introduction starting on page #9, through Figure 1: Generic System
Drawing #14091 on page #12 for an overview of the installation.
Note: When installing wire harnesses (cables), support the
cables using clamps or straps not more than 18 inches (0.5m)
apart, unless the wire harnesses are contained in a conduit or
wireway. Install each cable so it is protected from physical
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damage. Refer to the ABYC standard E11, Section 11.16.4.1,
7/03.

Planning the Installation

Important: Start the actual installation only when the
locations and lengths of wire harnesses are determined.
The first step when installing a system is to carefully plan the installation. This
includes finding proper mounting locations for the Processor and Control Panel.
The decision is made based on where the power will be sourced and how the
power will be routed to the Processor. Once the locations are decided upon,
lengths of electrical wire harnesses can be determined. Refer to ZF Backup Part
Numbers on page #61.

Installer Supplied Parts and Tools

The mounting hardware is installer supplied.

Miscellaneous Parts
Processor mounting hardware:

July 25, 2008

(4) inch or M6 fasteners (Customer supplied)

Lock Washers (Customer Supplied)

Flat Washers (Supplied with unit)

Grounding (Bond) Stud and Nut, size #6-32

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Figure 4: ZF Backup Processor Dimensions

Selecting the Location for the Processor

The following items must be taken into account when selecting the location for
the Processor:

Page #22 of 101

The Processor is spray proof, but not water proof. Therefore, an area
must be selected that typically stays dry.

The engine room is the preferred location for mounting the Processor.

If the engine room is too small, place the processor in any area where it
is easily accessible, and all of the other criteria listed are met.

Bulkhead mounting is the preferred method due to ease of access for

wiring and adjustments. However, the Processor can be mounted in any
position as long as the LED display and push-buttons are accessible.

The Processor must be installed using the four spacers and grommets
(factory installed in the Processor) and the eight flat washers supplied
with the Processor as shown in Figure 4 - ZF Backup Processor
Dimensions on page #22.

Do not mount the Processor on the engine, transmission, or any other

location that is subject to excessive vibration.
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Sea Trials

Do not mount the Processor to the transom when the vessel is equipped
with a surface piercing drive system (due to vibration concerns).

Locate the Processor away from sources of high heat, such as engine
exhaust manifolds or turbochargers. Allow 4 feet (1,2m) of clearance or
more.

Do not mount the Processor in close proximity to ignition systems,

alternators, generators or any equipment producing strong magnetic
fields. Allow 4 feet (1,2m) or greater clearance.
Warning: Strong magnetic fields can influence the
Processors electronic circuits and void your warranty.

Installing the Processor

1. Place the Processor on the mounting surface and mark the four (4) screw
holes. See Figure 4 ZF Backup Processor Dimensions on page #22.
2. Remove the Processor and drill the screw holes.
3. Secure the Processor to the mounting surface with four 1/4 inch or M6
fasteners using the spacers, grommets, and flat washers supplied with the
Processor and installer furnished fasteners and lock washers.
4. Connect the Processor to the Hull or Grounding Bus by running a 14 AWG
or larger conductor between the Processors grounding threaded male stud
(size #6-32) and the Grounding Bus or Hull (Grounding is optional).

Grounding the Processor

System Grounding (Bonding) contributes to maximum electromagnetic compatibility
(EMC) performance. A threaded male stud (size #6-32) is provided for connection to
the systems grounding system.

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Figure 5: Grounding
Note: Connection to the vessels ground/bond system is not required but is
recommended.

3.2 ZF Backup Panel

General Information

Page #24 of 101

The Backup panel has (2) knobs for adjusting the throttle command, one for
port and one for starboard. Each of these knobs control a potentiometer
which sends an analog signal to the ZF Backup processor.

The Backup panel has (6) buttons, (3) port and (3) starboard, for selecting
the current gear: Ahead, Neutral, or Astern.
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ZF Backup Panel Installation
3.2.1.1 ZF Backup panel Installation Parts and Supplies:

Bezel (to frame ZF Backup Panel top).

Four #6 flat head Philips screws with O rings.

ZF Backup panel housing with pigtail connectors.

Four #2 Black Philips Flat Head Screws.

Mounting plate.
Important: When installing the ZF Backup Panel, be
sure to allow for a minimum cable clearance of five
inches (127mm).

*See Figure 6 - ZF Backup Panel Parts on page #26 for a drawing showing all parts needed for the
ZF Backup Panel.

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#2 X .18" LNG
BLACK FLATHEAD
SCREW
4 PLACES

TOP

BEZEL

#6 X 1" LONG, SELF-SEAL

FLAT HEAD SCREW
4 PLACES

HOUSING

#4 X 1" LONG
PAN HEAD SCREW
4 PLACES

MOUNTING PLATE

LIST OF MATERIALS

DWG: 14134-1

Figure 6: ZF Backup Panel Parts

Page #26 of 101

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3.2.1.2 Mounting Plate
Use the mounting plate as a template for the hole to be cut in the
console and for marking placement of screws.
1. Holding the mounting plate upside down, so that the pem nuts
are facing upward, place it on the console where you want the
ZF Backup Panel to be.
2. Trace the interior shape of the mounting plate on the console.
3. Mark (through the holes) each of the points where the eight
screws are to be placed.
4. Cut a hole through the console following the pattern of the
template.
5. Drill holes at the eight screw points.
NOTE: PEM NUTS
THIS SIDE

TOP

MOUNTING
PLATE

STEP 1
Using the mounting plate as a
template, trace opening and mark
(8) hole centerlines for screws.
STEP 2
Cut opening following traced
pattern.

B
CONSOLE

A
B

STEP 3

B
A

Drill (4) .152 AND (4) .128

holes as shown.

.128 (3,26mm) THRU

(#30 DRILL)
4 PLACES
DESIGNATED "A"

.152 (4,32mm) THRU

(#24 DRILL)
4 PLACES
DESIGNATED "B"

DWG: 14134-5

Figure 7: Use Mounting Plate as Template for Cutting and

Drilling
Once the hole is cut and the screw holes drilled, secure the mounting plate as follows and as shown
in Figure 8 - Attaching Mounting Plate on page #28.
1. Flip the mounting plate so the pem nuts are facing downward.
2. Manipulate the mounting plate through the hole and hold the plate in place.
3. Screw in the four #4 Philips pan head screws to secure the plate under the console.

July 25, 2008

Page #27 of 101

Sea Trials

TOP
STEP 4
Flip mounting plate so pem nuts are
facing downward.

CONSOLE

STEP 5
Manipulate mounting plate through
the cut out hole.
STEP 6
Screw the (4) #6 x 1.00 pan head
screws through console to secure
plate underneath.

NOTE: PEM NUTS ARE

ON OPPOSITE SIDE.
MOUNTING
PLATE

DWG: 14134-6

Figure 8: Attaching Mounting Plate

3.2.1.3 ZF Backup Panel Housing

Fit the ZF Backup Panel housing into the opening as follows in the
steps below and/or as shown in Figure 9 - ZF Backup Panel Housing
Installation on page #29:
1. Insert the ZF Backup Panel through the opening, making sure
that it sinks onto the heads of the pan head screws so the panel
rests flat on the console surface.
2. In each corner, screw in one of the #6 Philips flat head screws
to secure the ZF Backup Panel to the console and the mounting
plate underneath.

Page #28 of 101

July 25, 2008

Sea Trials

TOP

STEP 7
Using the (4) #6 x
1.00 long flat head
screws, secure
housing to mounting
plate.

DWG: 14134-2

Figure 9: ZF Backup Panel Housing Installation

July 25, 2008

Page #29 of 101

Sea Trials
3.2.1.4 Bezel
The bezel is the black aluminum frame that gives the ZF Backup Panel
its finished look. Use four #2 black Philips flat head screw to secure
the Bezel to the housing top plate.

TOP

FRONT BEZEL

DWG: 14134-3

Page #30 of 101

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Sea Trials
3.2.1.5 ZF Backup Panel Cables
The ZF Backup Panel processor cables can be attached at any time
after the opening in the console is made, either before or after the ZF
Backup panel housing is completely installed. Attach the cables as
directed below and as shown in Figure 10 - Cable Connections on page
#31.

Starboard pigtail cable to the cable connector from ZF

Backup Panel Starboard on ZF Backup Processor.

Port pigtail cable to the cable connector from ZF Backup

Panel Port on ZF Backup Processor.

Note: If you choose to attach the cables just after the hole
in the console is cut, and before the housing is screwed
down, reach through the hole and grasp the cable end
connector (they should be visible through the newly-cut
opening).

PORT PIGTAIL
ASSEMBLY

STBD PIGTAIL
ASSEMBLY

DWG: 14134-4

Figure 10: Cable Connections

July 25, 2008

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Sea Trials
DC Power Source
Warning: When connecting the Power Wire Harnesses to the
primary processor (i.e.; CruiseCommand, MiniCommand) and to
ZF Backup, be sure the power if OFF.
One of the most important (and often overlooked) items for proper operation of
your primary control system and your backup system is a clean, dedicated and
reliable source of DC Power to each.
The wiring used to supply power from the power sources (batteries) through the
various components (fuses, distribution panel, relays, etc.) to the primary
processor and the backup unit must be sized for a voltage drop of 10% or less
using 5 amps as the maximum current draw. Refer to ABYC Standard E-11,
Table XI to determine the appropriate wire gauge for the necessary conductor
length.
The APS power source(s) are protected by two 30 Ampere fast acting fuses. The
power from the APS to the primary processor and from the APS to the backup
processor is protected by two 10 Ampere trip-free thermal circuit breakers with
manual On/Off actuation. In addition to the protection provided, the circuit
breakers can be used to turn power on and off to the primary system or the
backup system.
For installations where the distance between the power source and the primary
processor, or the power source and the backup processor exceed 30/40 feet for
12/24 volt systems respectively, power relays can be installed between the
power source and the processors. The power relays must be properly selected
to avoid an excessive voltage drop across the contacts. Use relays with silver or
gold contacts.

DC Power Cable
3.2.1.6 Installation without Power Relays
a. Refer to Figure 17 -Drawing 11488F-3, Twin Screw with Two
APS and Alternate Remote Switch on page #66.
b. Within the Power Harness, run the cable labeled POWER to the
ZF Backup 10 Ampere Circuit Breaker.
c. Terminate the red conductor at the Circuit Breaker and the black
conductor to a DC Common (--).
d. Run a conductor from the circuit breaker to the output of the
APS. Insert 30 Ampere in-line fuses in both the port and
starboard (red) conductors.
e. From the APS, run one conductor to the port power source and
another to the starboard power source.

Page #32 of 101

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Sea Trials
3.2.1.7 Installation with Power Relays
a. Refer to Figure 16 - Drawing 11488F-1 Notes Page on page #65.
b. Within the Power Harness, run the cables labeled POWER to the
port and starboard Power Relays Normally Open (N.O.) contact
and terminate the red conductor. Terminate the Black conductor
to a DC Common (--).
c. From the opposite side of the N.O. contact, run a conductor to
each of the 10 Ampere Circuit Breakers and terminate.
d. Run conductors from the opposite side of the port and starboard
Circuit Breakers to the output of the APS.
e. From the APS, run one conductor to the port power source and
another to the starboard power source. Insert 30 Ampere in-line
fuses in both of the conductors.

3.3 Wire Harness Installation

General Information
Please consult Figure 1 - Generic System Drawing #14091 on page #12 showing
how all components (primary and backup systems) are wired. In addition all
wire harnesses are clearly marked as to where each end is to be plugged.
See Table 12 - ZF Backup Part Numbers on page #61 for a list of wire harnesses
and their part numbers:

One Power/Start Interlock wire harness.

Two Clutch wire harnesses.

Two Throttle wire harnesses.

Two Control Panel wire harnesses.

Warning: After installation every connector must have either a
wire harness or plug connected to it in order to prevent damage
or Processor failure. Do not leave any of the connector pins
exposed to the environment.

When connecting (or disconnecting) wire harnesses to the Processor, ensure

that the release button(s) on the plug connector are depressed and held until the
plug is fully connected or disconnected.

July 25, 2008

Page #33 of 101

Sea Trials
Figure 11: Harness Plug Connectors (from left, picture 1 & 2)

Figure 12: Processor Connector and Harness Plug Keying (from left, picture 3)

Wire Harness Plug Insertion and Extraction

One style of plug and connector are used on the ZF Backup Processor, and are
inserted as follows:

Prior to inserting the wire harness plugs, pay close attention to the color,
number of pins and the keying of the plug. The plug is designed to be
inserted one way only into the connector, but can be incorrectly forced
together in the opposite orientation.

When connecting the plugs, ensure that the locking mechanisms are
depressed and held until the plug is fully connected or disconnected. If
this rule is not followed, damage to the plug could result.

Important: The wire harness between the Control Panel and the Processor must be
uninterrupted. This harness can NEVER be spliced.

Control Panel Wire Harness

3.3.1.1 General Information
The Control Panel Wire Harnesses are available in various lengths
from 10 to 60 (3,0 18,3 meters).

3.3.1.2 Installation
a. At the Processor, insert the plugs into the Control Panel
connectors (Port and Starboard).
b. Run the cable to the location where the Control Panel is installed.
Insert the wire harness plugs into the control Panels appropriate
Port and Starboard pigtails.
c. Ensure that the wire harness has a Strain Relief close to the
Control Panel to relieve the strain on the connections.

Page #34 of 101

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Sea Trials
d. Repeat steps (a) through (c) on the opposite side (port or
starboard).

Power, Start Interlock Wire Harness for Twin Screw Processor

This Wire Harness has one plug at the ZF Backup processor end, which is
inserted in the Processors POWER connector. This plug has three cables
connected to it for the primary systems Port, and Starboard power/start
interlock, and the ZF Backup processors power.
The opposite end of the ZF Backup power cable has no connector and needs to
be terminated by the installer to a power source for ZF Backup. See Figure 1:
on page #12.
Caution: The most common source of trouble is loose wiring
connections.

Verify wiring connectors are properly crimped and cannot be

pulled out.

Crimps and connections must be made to conductor wire,

NOT to the wire insulation.

Verify all wire connections are secure.

Warning: Not using the Start Interlock circuit could result in starting
the engine with the transmissions clutch engaged, causing the vessel to
surge ahead or astern unexpectedly. This could result in damage to the
vessel and surrounding area, and/or personal injury or death.

Note: The ZF Backup systems Start Interlock relay has a N.O contact.
This contact only closes, allowing the engine to start when:

DC power is on.

The Backup Panel is in command.

The Backup Panel is commanding Neutral.

Caution: With the exception of the Power, and Backup Panel wire
harnesses, all other harnesses (port and starboard) have a maximum 20
(6,10m) routing length.
Therefore, the backup processor must be located in close proximity to
the main processor.

July 25, 2008

Page #35 of 101

Sea Trials
All of the cables in the Wire Harnesses are the same length. Therefore, order the
appropriate lengths for ZF Backup connectors.
Wire Harnesses available from ZF Marine Electronics are in lengths of 10
(3,0m), 20 (6,1 m) and 30 (9,14m). ZF Marine Electronics part numbers are:

P/N MI4402-10 (ten feet)

P/N MI4402-20 (twenty feet)

P/N MI4402-30 (thirty feet)

Caution: The Processor is designed for a maximum of 5 amperes per
side (port and starboard), and a maximum of 30 VDC for the start signal
current. Current higher than the amperes and VDC specified will
damage the interlock circuit.

Figure 13: Typical Start Interlock Connections

1. Run the cable labeled START INTERLOCK to the Engines Starter
Solenoid (or other appropriate engine start circuit).
2. Disconnect the Starter Switch wire from the Solenoid.
3. Strip back the appropriate amount of PVC jacketing and conductor
insulation.
4. Connect one of the conductors to the Solenoids Starter Switch terminal.
Page #36 of 101

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Sea Trials
5. Connect the second wire to the Starter Switch wire.

Clutch Interface Wire Harness

3.3.1.3 General Information
The Clutch wire harness plugs into the Processor.

Two wire harnesses are required: one each for the Port Clutch
and Stbd Clutch connections on the Processor.

Each Wire Harness has multiple cables for interfacing with the
main propulsion processor and the clutch connector.

3.3.1.4 Installation
a. Insert the Port Clutch Wire Harness on the Primary Processor into
the Port Clutch connector on the ZF Backup Processor.
b. Insert the Stbd Clutch Wire Harness on the Primary Processor into
the Stbd Clutch connector on the ZF Backup Processor.

Throttle Interface Wire Harness

3.3.1.5 General Information

Two Wire Harnesses are required for the ZF Backup Processor:

one each for the Port Throttle and Stbd Throttle connectors.

There are 4 types of Throttle Wire Harnesses available: Voltage,

Current, PWM (Pulse Width Modulation), and Frequency.

The Throttle wire harnesses are supplied with plugs at both ends.

3.3.1.6 Installation
Important: Ensure all Processors (primary and backup) are
using the same kind of wire harness.
The ZF Backup Processor connects directly to the primary propulsion
processor using a throttle interface Wire Harness.
a. Connect the plug end of the Throttle Wire Harness on the Port
Primary Processor into the Port Throttle connector on the ZF
Backup Processor.
b. Connect the plug end of the Starboard Wire Harness on the
Starboard Primary Processor into the Starboard Throttle
connector on the ZF Backup Processor.
c. Run the cable to the appropriate engine interface. (Example:
Port to Port, Starboard to Starboard.).
d. Refer to the engine documentation for termination points at
the engine interface.
July 25, 2008

Page #37 of 101

Sea Trials

3.4 Engine Stop Switches

An engine stop switch must be located in close proximity to the ZF Backup Panel
and capable of stopping the engine at any RPM.
The Installer supplies the Stop Switches. Refer to the installation instructions
supplied with the switch and the engine installation instructions for manufacturers
recommendations.
Warning: An Engine Stop Switch at each remote Station/Backup
Panel (primary/backup system) is an absolute requirement. Refer to
CFR 46, SEC. 62.35-5 and ABYC P-24.5.8.

Page #38 of 101

July 25, 2008

Sea Trials

4 Dock Trials
Warning: It is imperative that the information provided in the previous
sections be read and followed precisely, prior to attempting a Dock
Trial.
If any of the following tests fail, consult Troubleshooting on page #45, or
consult a technician from ZF Marine Electronics Sales & Service
Organizations on page #71.

Note: During the course of the Dock Trial and Sea Trials, fill out the
Sea Trial Report on page #40.

4.1 Control Panel (Engines Stopped)

Warning: Do not start the engines at this time as injuries could
occur.

4.2 ZF Backup Processor

If any of the tests above fail, verify that connections from the ZF Backup processor
to the Backup Panel are secure, and that the power and engine connections to the
ZF Backup Processor are correctly seated.
a. Turn the ZF Backup Processors DC power OFF. Verify that the engines will
not start.
b. Turn ZF Backup Processors DC power On. Verify that the engines will not
start.
c. Place the Control Panel in Neutral/Idle by pressing the Neutral buttons on
the Port and Starboard sides. Verify that the engines will start.

5 Sea Trials
Warning: It is imperative that the information provided in the previous
Sections be read and followed precisely, prior to attempting a Sea Trial.
If any of the following tests fail, discontinue the Sea Trial immediately
and return to the Dock Trials. Consult Troubleshooting on page #45, or
consult a technician from ZF Marine Electronics Sales & Service
Organization (SSO).

July 25, 2008

Page #39 of 101

Sea Trials
For more information on an SSO in your area, please see page 71.

Note: In a Twin Screw Application, the following tests must be

performed on all engines/transmissions. During the course of the Dock
Trials and Sea Trials, fill out the Sea Trial Report starting on page #40.

5.1 Full Speed Setting

a. Warm-up the engine(s) and transmission(s) and slowly move into open water.
b. Gradually turn the Port and Starboard Throttle knobs to full speed (maximum
setting).
c. For twin screw applications, check that matching Idle, Mid-range and Full speed
Throttle Knobs cause equal RPM in both engines.

5.2 Sea Trial Reports

The purpose of this Sea Trial Report is to provide a convenient checklist and record
of installation, setup, dock trial, and sea trial performance of the ZF Marine
Electronics Propulsion Control System. Please enter ALL of the information.
We recommend that this form remain aboard the vessel, and a copy be sent to ZF
Marine Electronics, 12125 Harbour Reach Drive, Suite B., Mukilteo, WA 98275,
along with the Warranty Registration which is located at the end of this manual.
Table 3: Vessel Information
VESSEL INFORMATION
Vessel Name:

Hull #

Vessel Type:

Dwg No.:

Installing Yard/Project
Manager:

Tel:

Owner(s)
Representative:

Tel:

Engine Data:

Make

Model:

Trial Date

HP(KW):
RPM:

Propeller Data:

No. of Screws

Propeller Type:

Fixed:
Other:

Gear Data:
Page #40 of 101

Make:

Model:

Ratio:
July 25, 2008

Sea Trials

VESSEL INFORMATION

No of Remote
Stations:

Locations:

5.3 Control System Checks

Make the following checks prior to applying power to the Processor.
Table 4: Processor
BACKUP PROCESSOR

YES NO

Is the Backup Processor subject to excessive heat? (Above 70 degrees

C)?

YES NO

Is the Backup Processor at least 4 feet (1,2m) from a strong magnetic

field?

YES NO

Is the Backup Processor accessible for checkout, adjustments, and

maintenance?

YES NO

Is the Backup Processor grounded?

YES NO

Are all Electric Cables for the Backup Processor supported every 18
inches (45,72cm)?

YES NO

Are the electrical cable connections between the Backup Processor

and the Backup Panel tight?

YES NO

Is the Backup Processors Start Interlock Circuit being used? If NO,

what type of start interlock is being utilized?

YES NO

Is there an Engine Stop Switch installed at the Backup Panel?

YES NO

Do gears operate in the correct direction?

YES NO

Table 5: Wire Harness Lengths

BACKUP PROCESSOR

LENGTH IN FEET

Backup Panel Port Wire Harness

Backup Panel Starboard Wire Harness
Power Wire Harness

July 25, 2008

Page #41 of 101

Sea Trials

BACKUP PROCESSOR

LENGTH IN FEET

Port Throttle Wire Harness

Starboard Throttle Wire Harness
Port Clutch Wire Harness
Starboard Clutch Wire Harness
Table 6: Power Supply
BACKUP PROCESSOR

ANSWER

What is the source of Backup Processor power and how is it charged?

Is there a backup power supply? APS or other. If Yes, explain.

YES / NO

Are the power cables for ZF Backup protected by 10 Ampere Circuit

Breakers?

YES / NO

What is the Voltage when not being charged?

Battery_____________
VDC
Processor __________
VDC

Table 7: Dock Trials

BACKUP PROCESSOR
What is the Voltage when connected to Shore Power?

ANSWER
Battery_____________
VDC
Processor __________
VDC

What is the Voltage when the engines are running?

Battery_____________
VDC
Processor __________
VDC

BACKUP PROCESSOR
Does the engine start when the Backup Control System is turned
OFF?
Page #42 of 101

ANSWER
YES / NO

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Sea Trials

BACKUP PROCESSOR

ANSWER

Does the engine Stop Switch at the Backup Panel function

regardless of RPM?

YES / NO

What is the Minimum RPM?

RPM______

What is the Maximum RPM?

RPM______

Does the vessel surge forward when you push the Forward (F)
button(s) on the Backup Panel

YES / NO

Warning: Do not start the engine to turn on engine electronics!

Table 8: Record at Dock Trials (Requires Use of Field Service Test Unit)
BACKUP PROCESSOR

TYPE OF POWER

Throttle in Neutral (Cummins

Quantum only)

VDC, mA, Hz, or %

Throttle Minimum,

VDC, mA, Hz, or %

Throttle Maximum

VDC, mA, Hz, or %

PORT

STBD

Table 9: Record During Sea Trials (Requires Use of Field Service Test Unit)
BACKUP PROCESSOR

PORT

STBD

Engine Idle RPM

RPM:_______

RPM:_______

Shaft Idle RPM (Calculate the Shaft Idle RPM as follows:

(Engine Idle RPM/Gear Ratio)

RPM:_______

RPM________

Full Throttle RPM

RPM:_______

RPM________

July 25, 2008

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Sea Trials

Comments (Please Use Additional Space as Needed)

General Installation Condition

Any Irregularities

Is the Installation and Troubleshooting Manual on board?

Is a copy of this completed Report placed in the Installation and Troubleshooting Manual on board?

INSPECTOR __________________________________________ DATE _______________

MAIL A COMPLETED COPY TO:
ZF MARINE ELECTRONICS, LLC. 12125 HARBOUR REACH DRIVE, STE B, MUKILTEO, WA 98275
OR FAX TO: SERVICE DEPARTMENT 425-493-1569

Page #44 of 101

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Troubleshooting

6 Periodic Checks and Maintenance

As a general rule, you should check at least once every quarter that you can start your backup
system.

6.1 Backup Panel

Disconnect the Deutsch connectors and check the pins and sockets for signs of
moisture and corrosion.

6.2 Processor
Un-plug and inspect all Deutsch connectors and check the pins and sockets for signs
of moisture or corrosion.

7 Troubleshooting
The ZF Marine Electronics ZF Backup Control System (twin screw only) has two sets of
electronics, one for each engine/transmission combination, in one enclosure, and is typically
mounted in the engine room. There is one Control Panel to operate the backup system.
In the event that a malfunction occurs, review the appropriate system diagram and become
familiar with the various components, their functions and locations on the vessel.

7.1 Troubleshooting Questions

QUESTIONS

ANSWERS
Backup System / Backup Mode

No Engine Speed
When I switch over to ZF Backup, what can I do
if there is no engine speed command at the
engine?

1. Make sure all of the connections to and

from the ZF Backup Processor and Panel
are secure. The connections include:
a. Throttle

No Clutch Command

b. Clutch

What can I do when there is no Clutch

Command at the gear?

c. Power

No Start Interlock
What can I do when there is no Start Interlock
Signal?

Backup Panel Does Not Take Command

Page #45 of 101

July 25, 2008

2. When checking a connector, also make

sure the plug is not corroded.
3. When checking a Deutsch connector,
make sure the pin-outs are correct. For
information on pin-outs for ZF Backup,
see ZF Backup Processor Connector Pin
Functions on page #49.
Make sure that the wire harnesses between the
ZF Backup panel and processor are inserted

Troubleshooting
QUESTIONS
What can I do if the Backup Panel does not take
control?

Page #46 of 101

ANSWERS
properly.

July 25, 2008

Troubleshooting

7.2 Generic System Drawing

When the vessel has a BACKUP system in addition to the primary system, four alternate APS wiring options are provided. Select
the one that works best on the vessel being equipped with an APS. See page #67.

Figure 14: Generic System Drawing #14091, Relevant to Troubleshooting (See page #67 for APS Wiring Options)
Page #47 of 101

July 25, 2008

Troubleshooting

Table 10: ZFBU Panel Pigtail, #14093-1

July 25, 2008

Table 11: ZFBU Panel Wire Harness #14022

Page #48 of 101

Troubleshooting

7.3 Taking Command

Once a stations ZF Backup panel is activated, and all the conditions below are met,
the start interlock relay contact closes, allowing the engine to start.

DC power is on.

The Backup Panel is in command.

The Backup Panel is commanding Neutral.

7.4 System Checkout

1. In Normal mode, verify operation of primary control system: Throttle, clutch,
start interlock, and all other modes of operation (e.g., cruise, troll, or Autotroll
modes, etc.).
2. Take control at Backup panel.
3. Verify clutch commands, (port and starboard, ahead, astern, and neutral).
4. Verify throttle command (port and starboard, idle to full speed).
5. Verify start interlock output.

7.5 ZF Backup Processor Connector Pin Functions

BACKUP PANEL PORT Receptacle
Pin

Function

1
2
3
4
5
6
7
8
9
1
11
12

DC Return for Switches (-)

Port Ahead Switch Input
Port Astern Switch Input
Port Neutral Switch Input
NC
Port Ahead LED Output
Port Astern LED Output
Port Neutral LED Output
NC
DC Return for Potentiometer (-)
Port Potentiometer Wiper Input
+5V for Potentiometer

July 25, 2008

P/N 3301B-XX Wire Harness Control Panel

to Processor, ZF Back-Up / Dwg #14022,
page #3 of 4.

Page #49 of 101

Troubleshooting

BACKUP PANEL STBD Receptacle

Pin

Function

1
2
3
4
5
6
7
8
9
10
11
12

DC Return for Switches (-)

Starboard Ahead Switch Input
Starboard Astern Switch Input
Starboard Neutral Switch Input
NC
Starboard Ahead LED Output
Starboard Astern LED Output
Starboard Neutral LED Output
NC
DC Return for Potentiometer (-)
Starboard Potentiometer Wiper Input
+5V for Potentiometer

P/N 3301B-XX Wire Harness Control Panel

to Processor, ZF Back-Up / Dwg #14022,
page #3.

POWER Connector

Pin

Function

1
2
3
4
5
6
7
8
9
10
11
12

Ships Battery Positive

Ships Battery Return
Start Interlock, Port
Start Interlock, Port
Port Backup Select
Port Backup Select
Start Interlock, Starboard
Start Interlock, Starboard
Starboard Backup Select
Starboard Backup Select
NC
NC

PORT THROTTLE Connector

Page #50 of 101

Pin

Function

1
2
3
4
5
6
7
8

IN Port Throttle +
OUT Port Throttle +
OUT Port Throttle Isolated Return
IN Port Throttle Isolated Return
IN Port Low Current Port Start Interlock Relay -OUT Low Current Port Start Interlock Relay -OUT Low Current Port Start Interlock Relay +
IN Port Low Current Port Start Interlock Relay +
July 25, 2008

Troubleshooting

STBD THROTTLE Connector

Pin

Function

1
2
3
4
5
6
7
8

IN Starboard Throttle +
OUT Starboard Throttle +
OUT Starboard Throttle Isolated Return
IN Starboard Throttle Isolated Return
IN Starboard Low Current Stbd Start Interlock Relay -OUT Low Current Stbd Start Interlock Relay-OUT Low Current Stbd Start Interlock Relay+
IN Starboard Low Current Stbd Start Interlock Relay +

PORT CLUTCH Connector

Pin

Function

1
2
3
4
5
6
7
8
9
10
11
12

IN Port Astern +
IN Port Ahead Return
OUT Port Astern +
IN Port Astern Return
OUT Port Troll Command +
IN Port Troll Command +
IN Port Troll on/off +
OUT Port Ahead Return
OUT Port Troll on/off +
OUT Port Astern Return
OUT Port Ahead +
IN Port Ahead +

STBD CLUTCH Connector

July 25, 2008

Pin

Function

1
2
3
4
5
6
7
8
9
10
11
12

IN Starboard Astern +
IN Starboard Ahead Return
OUT Starboard Astern +
IN Starboard Astern Return
OUT Starboard Troll Command +
IN Starboard Troll Command +
IN Starboard Troll on/off +
OUT Starboard Ahead Return
OUT Starboard Troll on/off +
OUT Starboard Astern Return
OUT Starboard Ahead +
IN Starboard Ahead +

Page #51 of 101

Appendix A

8 Appendix A

July 25, 2008

Page #53 of 101

Appendix A Metal Hull Vessels

8.1 Deutsch Connector Assembly DT Type

Step 1: Contact Removal
1.

2.

3.

Remove wedgelock using

needlenose pliers or a hook
shaped wire. Pull wedge
straight out.
To remove the contacts,
gently pull wire backwards,
while at the same time
releasing the locking finger
by moving it away from the
contact with a screwdriver.
Hold the rear seal in place,
as removing the contact
may displace the seal

Step 3: Contact Crimping

Step 2: Wire Stripping - Solid Contacts

Contact Part
Wire Gauge
Strip Length
Number
Range
(inches)
0460-202-20141

20 AWG

0462-201-20141

20 AWG

.156-.218
.156-.218

0460-202-16141
0462-201-16141

16, 18 & 20 AWG

16, 18 & 20 AWG

.250-.312
.250-.312

0460-215-16141
0462-209-16141

14 AWG
14 AWG

.250-.312
.250-.312

0460-204-12141
0462-203-12141

12 & 14 AWG
12 & 14 AWG

.222-.284
.222-.284

0460-204-08141
0462-203-08141

8 & 10 AWG
8 & 10 AWG

.430-.492
.430-.492

0460-204-0490
0462-203-04141

6 AWG
6 AWG

.430-.492
.430-.492

Step 4: Contact Insertion

Use Crimp Tool #HDT48-00

1.

Strip insulation from wire.

(See Step 2.)

2.

Raise selector knob and

rotate until arrow is aligned
with wire size to be
crimped.

3.

Loosen locknut, turn

adjusting screw in until it
stops.

4.

Insert contact with barrel

up. Turn adjusting screw
counter-clockwise until
contact is flush with
indentor cover. Tighten
locknut.

5.

Insert wire into contact.

Contact must be centered
between indicators. Close
handles until crimp cycle is
completed.

6.

Release handles and remove

crimped contact.

1.

Grasp crimped contact

approximately (25,2 mm) one
inch behind the contact barrel.

2.

Hold connector with rear

grommet facing you.

3.

Push contact straight into

connector grommet until a click
is felt. A slight tug will confirm
that contact is properly locked in
place.

4.

Once all contacts are in place,

insert wedgelock with arrow
pointing toward exterior locking
mechanism. The wedgelock will
snap into place. Rectangular
wedges are not oriented. They
may go in either way. Note: The
receptacle is shown. Use the
same procedure for the plug.

7. Inspect terminal to ensure

that all strands are in crimp
barrel. Note: Tool must be
readjusted for each
type/size of contact. Use
HDT04-08 for size 8 and 4
contacts.

July 25, 2008

Page #55 of 101

Appendix A - References

8.2 Grounding (Bonding)

Grounding (Bonding) should be done according to ABYC Section E-11 and Code of Federal
Regulations 46 CFR 111.05
Each grounding system must have only one point of connection to ground regardless of the
number of power sources operating in parallel in the system.
A vessels 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 mA
under the most unfavorable conditions.
4. Welding systems with hull return, except vessels subject to 46 CFR Subchapter D.
Grounding conductors should be green or green with a yellow stripe.
References:

CFR Sec. 111.05-11, Sec. 111.05-13

ABYC E-11; 11.4, 11.5.2.2, 11.18

See drawing on next page.

Page #56 of 101

July 25, 2008

Appendix A References

Figure 15: Grounding*

* Diagram is used courtesy of American Boat and Yacht Council

All parts of figure except processor and processor connection

July 25, 2008

2003 American Boat and Yacht Council

Page #57 of 101

Appendix A - References

8.3 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.

Page #58 of 101

July 25, 2008

Appendix A References

8.4 References
American Boat & Yacht Council (ABYC)
Address: 3069 Solomons Island Road, Edgewater, MD 21037-1416, www.abycinc.org.

American Boat & Yacht Council (ABYC)

E-11

AC and DC Electrical Systems on Boats.

E-11.6.2

Wiring Identification on Boats.

H-2.6

(Gasoline Engines) or H32.5.5 (Diesel Engines) Ambient Temp. 50

degree C.

P-24

Electric/Electronic Propulsion Controls

Code of Federal Regulations

Additional Information & Address: Obtained from the Superintendent of Documents,
United States Information, POB 371 954, Pittsburgh, PA 15250-7954

Code of Federal Regulations

33CFR 183 Subpart I

Electrical Systems

33CFR 183.410

Ignition Protection

33CFR 183.415

Grounding

33CFR 183.425

Conductors: General

33CFR 183.430

Conductors in Circuit of Less than 50 Volts

33CFR 183.445

Conductors: Protection

46CFR 111.01

15(b) Ambient Temp. Machinery Spaces 50 degrees

C

46CFR 111.05

System Grounds

Society of Automotive Engineers

Address: 400 Commonwealth Drive, Warrendale, PA 15096, www.sae.org.

Society of Automotive Engineers

J1171

External Ignition Protection

J1428

Marine Circuit Breakers

J378

Marine Engine Wiring

National Marine Manufacturers Association

Address: 401 North Michigan Avenue, Chicago, IL 60611

Underwriters Laboratories
Address: Marine Department, POB 13995, 12 Laboratory Drive, Research Triangle
Park, NC 27709, www.ul.com.
July 25, 2008

Page #59 of 101

Appendix A ZF Backup Part Numbers

8.5 ZF Backup Part Numbers

Table 12: ZF Backup Part Numbers
ASSIGNED
P/N

DESCRIPTION

Commercial Processors for 9000 Series

(One required per Twin Screw)
3001BC

Processor ZF Backup, PWM (CAT), 9000 Twin

3002BC

Processor ZF Backup, 0.9-4.5V, (CENTRY), 9000 Twin

3003BC

Processor ZF Backup, 0.9-1.2-4V, (QUANTUM), 9000 Twin

3005BC

Processor ZF Backup, 4-20mA, (MTU or MAN), 9000 Twin

3007BC

Processor ZF Backup, 0.5-4.5V, (JOHN DEERE), 9000 Twin

Pleasure Craft Processors for 9000 and SmartCommand

(One required per Twin Screw)
3001BP
3002BP
3003BP
3005BP
3007BP

Processor ZF Backup, PWM (CAT), 9000/SmartC, Twin

Processor ZF Backup, 0.9-4.5V, (CENTRY), 9000/SmartC,
Twin
Processor ZF Backup, 0.9-1.2-4V, (QUANTUM),
9000/SmartC, Twin
Processor ZF Backup, 4-20m, (MTU or MAN) 9000/SmartC,
Twin
Processor ZF Backup, 0.5-4.5V. (JOHN DEERE)
9000/SmartC, Twin

Control Panels (One required per Twin Screw)

3200B

Control Panel 3000 Series, ZF Backup, Twin Screw

Wire Harness for Backup Panel (Two required for Twin Screw)
3301B-XX

Wire Harness Control Panel to Processor, ZF Backup.

Wire Harness for Power\Start Interlock\Backup for Interfacing to

SmartCommand (Two required for Twin Screw)
3401B-XX

Wire Harness PWR\S.I.\B.U. Interface to SmartCommand,

Wire Harness for Power\Start Interlock\Backup for Interfacing to 9000

Series (Two required for Twin Screw)
3403B-XX

Wire Harness PWR\S.I\B.U. Interface to Clear, ZF Backup

Wire Harness - Clutch Interface for 9000 Series and SmartCommand

(Two required for Twin Screw)
3501B-XX

Wire Harness Clutch Interface to Clear\Smart, ZF Backup.

Wire Harness Throttle, PWM (Two required per Twin Screw)

3601B-XX

July 25, 2008

Wire Harness PWM Throttle Interface, ZF Backup

Page #61 of 101

Appendix A ZF Backup Part Numbers

ZF Backup Part Numbers Cont

Table 13: ZF Backup Part Numbers
ASSIGNED
P/N

DESCRIPTION

Wire Harness Throttle, Voltage (Two required for Twin Screw)

3602B-XX

Wire Harness Throttle, Voltage Interface, ZF Backup

Wire Harness Throttle, 4-20mA (Two required for Twin Screw)

3603B-XX

Wire Harness 4-20mA throttle Interface, ZF Backup

Wire Harness Throttle, 4-20mA w/Neutral Interlock

(Two required for Twin Screw)
3605B-XX

July 25, 2008

Wire Harness 4-20mA, Throttle,Neutral Interlock, ZF backup

Page #62 of 101

Appendix A ZF Backup Part Numbers

The APS (Automatic Power Selector), Part #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 Electronics Propulsion Control
System.
The APS is rated for loads up to 70 Amps on 12-24 volt systems. The unit is ruggedly
constructed with heavy-duty wiring studs and epoxy-potted components in an
anodized aluminum case.

APS Specifications
APS Specifications

Descriptions

Model
Maximum Load Current
Operating Temperature

Voltage Drop
Dimensions

13505
70 amps
-40 degrees C to +80 degrees C; derate
linearly from 100% @ 50 degrees C to
70% @ 80 degrees C.
0.7 VDC @ 50% load; 0.9 VDC @full
load.
3.25 x 4.5 x 3.1 (8,3 x 11,4 x 7,9 cm)

Materials Provided
The single APS is supplied with a hardware packet containing (6) hex nuts, (3)
lock washers, (4) self-tapping mounting screws, and (1) instruction diagram.
Note: Not all of the hardware is used in the installation;
some spares are provided. Nut size is M-6.
The Twin APS is supplied with (2) single APS hardware packets.

Installation
Refer to the installation drawing #14091, Figure 14 - Generic System Drawing
#14091, Relevant to Troubleshooting (See page #67 for APS Wiring Options) on
page #47.
Shut off all charging sources and disconnect the negative (ground) side of each
battery which will be wired to the APS.
1. 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 (container) of the APS is electrically isolated from the internal
diodes, so mounting on either a metal or non-metal surface is
acceptable.
July 25, 2008

Page #63 of 101

Appendix A - ZF Backup Part Numbers

2. Complete the wiring as indicated on the drawing in Figure 17 - Drawing

11488F-3, Twin Screw with Two APS and Alternate Remote Switch on
page #66.
3. Reconnect the negative battery posts.
Important: 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.

Page #64 of 101

July 25, 2008

Appendix A APS Installation Drawings

APS Installation Drawings

Figure 16: Drawing 11488F-1 Notes Page

Page #65 of 101

July 25, 2008

Appendix A APS Installation Drawings

Continue: APS Installation Drawings

Figure 17: Drawing 11488F-3, Twin Screw with Two APS and Alternate Remote Switch

Page #66 of 101

July 25, 2008

Appendix A APS Installation Drawings

8.6 APS Wiring Options with Backup System

When the vessel has a BACKUP system in addition to the primary system, four
alternate APS wiring options are provided. Select the one that works best on the
vessel being equipped with an APS.

Figure 18: APS Wiring Options

July 25, 2008

Page #67 of 101

Appendix B

9 Appendix B

July 25, 2008

Page #69 of 101

ZFMarineElectronics,LLC
12125 Harbour Reach Drive
Mukilteo, WA 98275 USA
800-546-5455 / 425-583-1900

MMC-172 Rev A 2-08

Fax: 425-493-15690

Sales & Service Organizations

Factory Authorized Sales & Service Centers International

ARGENTINA

CHILI

3205
Carlos Dorian
Freidlander
Trimer S.A.
T: 54-11-4580-0444
(mail) PO Box 772
F: 54-114580-0440
Attn: Mariano Castroverde
1000 Buenos Aires, Argentina
(shipping) Fray J.S.M. de Oro 2030-40
1425 Buenos Aires, Argentina
Pleasure Craft

trimer@trimer.com.ar

Transmsiones Marinas S.A.

Hernandarias 3656
B7603GNH Mar Del Plata
Argentina

Ing. Daniel Canoura

Tele/Fax: (54-223) 4807174

TM@tmgroup.com.ar

Commercial Craft

www.tmgroup.com

AUSTRALIA
6948
ZF Australia Pty, Ltd.
(mail) Locked Bag 6305
Blacktown BC NSW 2148
Australia
(shipping) 14 Lidco Street
Arndell Park, NSW 2148
Australia

Gary Bain
T: 61- (0)2-9679-5555
F: 61-(0)2-9679-5500

gary.bain@zf.com.au
www.zf.com.au

BRAZIL
7000
Richard Bergamini
ZF do Brazil S.A.
T: 5515-235-2301
Avenida Conda Zepplin, 1935
F: 5515-235-2233
CEP 18103-0000 Sorocaba, Brazil
richard.bergamini@zf.com
www.zf-marine.com

July 25, 2008

Christian Rogers Nickelmann

Equipamiento Marino Ltda
T: (56-2) 4158737
Rafael Correa 1268 Vitacura
F: (56-2) 9-9975059
Santiago, Chili
equipamiento.marino@gmail.com

CHINA
CO0102

Paul Chow

Foilborne Engineering, Ltd.

T: 852-2687-2988
Unit A 7-9, 13/F Veristrong.
F: 852-2687-1996
34-36 Au Pui Wan Street / FO-Tan,
Shatin, N.T.
Hong Kong, China
paulchow@foilborne.biz.com.hk
5224

Anthony Yuen

Renford Marine Equipment (China) Ltd.

501 Laws Commercial Plaza
T: 852-27427111
788 Cheung Sha Wan Road
F: 852-27427171
Hong Kong, China
anthony.yuen@renford.com
5224
Anthony Yuen
Renford Marine Equipment (Shanghai) Ltd
811 Jiaxing Building
T: 8621-50589000
877 Dong Fang Road, Pudong
F: 8621-505880007
Shanghai, China
anthony.yuen@renford.com

6953
Tang Zhou Qing, Gong Lan
ZF Shanghai Rep. Office
T: 0086-21-6301-4338
Room 2504, Jiangnan Building
F: 0086-21-6301-6449
No. 600 Luban Road
Shanghai, 200023, PR China
qiwei.yao@zf.com
www.zf-marine.com

Page #71 of 101

DENMARK

GREECE

7257
Michael Johansson, Frank Kiessling
ZF Danmark APS
T: 45-7022-6243
Taastrupgaardsvej 8-10
F: 45-7022-2643
Taastrup, DK-2630, Denmark
michael.johansson@zf.com
frank.kiessling@zf.com
www.zf-marine.com

ECUADOR
Pedro Aspiazu
ZF Marines Consulting
T: (593-4) 238-9306
Urdesa Central 1A #13184 Costanera F: (593-4) 238-4010
Guaaquil Guayas, Ecuador
zfmarineconsulting@yahoo.com

2386
Amaltheia Marine, Ltd.
13 Papaflessa Str.
143 43 N. Halkidona
Athens, Greece

amalmar@otenet.gr

ICELAND
CO0133
Maras ehf
Akralind 2
7230
201 Kopavogur,
Iceland
Gummi@maras.is

Gudmundur Bragasson
T: 354-555-6444
F: 354-565-

IRELAND

FINLAND
7487
Atoy Oy
PO Box 137
FIN-00101, Helsinki
Finland

Demetris Kyriazis
T: 30210-25-88-985
F: 30210-25-89-986

Antti Hiidenheimo
T: 35-8968271
F: 35-896827305
anttihiidenheimo@atoy.fi

7326

Adi License

ZF Great Britain, Ltd.

Abbeyfield Road, Lenton
Nottingham, United Kingdom
NG7 2SX, England

FRANCE
2190
Seimi
(mail) B.P. 30307
Brest Cedex, France 29603
(shipping) Z.I.P. Du Moulon Blanc
Rue Alain Colas
Brest Cedex, France 29200

3590
Vidal Diffusion Marine
(mail) B.P. 97
Toulon Cedex 9, France
(shipping) Z.I. Toulon-Est
Toulon Cedex 9, France

Laurent Gautier
T: 33-2-98-46-11-02
F: 33-2-98-43-37-49

laurent@seimi.com
info@seimi.com
www.seimi.com
David Elderkin
T: 33-494-08-68-20
F: 33-494-08-26-59

d.elderkin@vidalmarine.com
www.vidalmarine.com

GERMANY
7636
Otto Peining GMBH
Piening Propeller
AM Altendeich 83
D25348 Glckstadt
Germany

Page #72 of 101

T: 44-115-986-9211
F: 44-115-986-9261
adi.license@zf.com
www.zf-marine.com

ITALY
7093
Busetto Saim SPA
Via Donizetti, 9/11
20090 Assago (MI)
Italy

Antonio Renzetti, Alessandro

T: 39-02-488-521
F: 39-02-45703070

antonio.renzetti@saim-group.com
alessandro.busetto@saim-group.com
www.saim-group.com

JAPAN
7253
Y. Ikeda, Nobora Kasajima
ZF Marine Japan Co. Ltd
T: 81-03-5808-4521
Fujikoshi Bldg. 1-10-11 Iriya taito-ku
Tokyo, 110-0013
F: 81-03-5808-4531
Japan
mikio.sato@zf.com
www.zf-marine.com

KOREA
Mathias Pien
T: 49-4124-916812
F: 49-171-4853376

pein@piening-propeller.de
www.piening-propeller.de

1415
SE Jung Engineering Co.
#35-4 Namhangdong-1KA
Yeongdogu
Pusan, Korea

July 25, 2008

M.G. Song
T: 82-51-415-0591
F: 82-51-412-6361
sjeng88@kornet.net

SINGAPORE

THE NETHERLANDS (HOLLAND)

7252

Ton Hekman, Rob van der Linde

ADS/van Stigt
Avelingen West 30
NL-4202 MS Gorinchem
The Netherlands

T: 31-0-183-650000
F: 31-0183-650001
Ton.Hekman@vanstigt.com
info@vanstigt.com

NEW ZEALAND
6948
ZF Australia Pty, Ltd..
(mail) Locked Bag 6305.
Blacktown BC
NSW, Australia
2148
(shipping) 14 Lidco Street
Arndell Park, NSW
Australia
2148

Gary Bain
T: 61-02-9679-5555
F: 61-02-9679-5500

7045
ZF South East Asia
11, Tuas Drive 1
Singapore

Sharon Ho
T: 6861-0177
F: 6861-9173
sharon.ho@zf-seasia

SOUTH AFRICA
gary.bain@zf.com

NORWAY
7029
KGK Norge AS
Casper Storms Vei 19
N-0064 Oslo,
Norway

157
Steven
Wee
Mammoth Enterprises Pte, Ltd.
T: 65-6-44-88266
(mail) PO Box 283
F: 65-6-44-89800
Siglap Post Office
Singapore
914503,
(shipping) 6-A Waringin Park
Singapore
416320
mament@singnet.com.sg

Bjorn Reiersen
T: 47-22-884-680
F: 47-22-720-902
bjorn.reiersen@zf-group.com

7261
Heather Hermann
ZF South Africa Pty, Ltd
T: 27-11-453-1818
(mail) PO Box 2098
F: 27-11-453-7506
Kempton Park, 1620 South
Africa
(shipping) C/O Barlows Power Systems
Cnr Peter Barlow and Kasselss Vlei Rd
heather@zfsa.za

SPAIN

PERU
7000
Pedro Gonzalez - Orbegoso
PGO International S.A.C
T: (51-1) 421-6055
AV. Arequipa 2450 of 1108
F: (51-1) 421-6664
Lima 14, Peru
pgorbegoso@perusat.net.pe

5556
ZF Espana S.A.
Avda. Fuentermar
Coslada (Madrid) 28820
Spain

maria.valladolid@zf.com
www.zf-marine.com

RUSSIA
7313
ZF Transmissia 000
Suite 313
71, Marata Street
St Petersburg
Russia 191119

Anastassia Selverstova
T: 7-812-324-54-72
F: 7-812-140-18-15

anastassia.selverstova@zf.sp.ru

SCOTLAND
7326
ZF Great Britain, Ltd.
Abbeyfield Road, Lenton
Nottingham, United Kingdom
NG7 2SX
England

July 25, 2008

Maria Valladolid
T: 34-91-4852-699
F: 34-91-6733931

SWEDEN
7234
KG Knutsson AB
Tansmissions Divisionen
Hammarbracken 8,
S-191 81 Sollentuna
Sweden

Adi License
T: 44-115-986-9211
F: 44-115-986-9261

adi.license@zf.com
www.zf-marine.com

Page #73 of 101

Karl-Henry Pragsten
T: 46-08-923-312
F: 46-08-929-599

zf-marine@kgk.se
www.kgk.se

SWITZERLAND
C00111
Marine Parts Technic
Pfaffikerstrasse 6
CH-8604 Volketswil,
Zurich, Switzerland

UNITED KINGDOM (ENGLAND)

Fabian Kraemer
T: 41-1997-4090
F : 41-1997-4094

fabian.kraemer@marineparts.ch
info@marineparts.ch
www.marineparts.ch

TAIWAN
5355
Asia Diesel electric Corp.
20th Floor
34 Min chuan 1st Road
Kaohsuing, R.O.C Taiwan

Mike Ou
T: 886-7-333-1191
F: 886-7-334-6808

ade.taiwan@msa.hinet.net

6932
Lakey

Peter Middleton, Paul

Atlantis Marine Power, Ltd.

T: 44-1752-208810
Western wood Way
F: 44-1752-208811
Language Science Park
Plymouth, Devon, PL7 5BG
5BG England
peter@atlantismarine.com
paul.lakey@atlantismarine.co.uk
www.atlantismarine.co.uk

USA
6427
ZF Marine US Headquarters
3131 SW 42nd Street
Ft Lauderdale, FL 33312

A.J. Halavacs
T: 954-581-4040
F: 954-581-4078
aj.halavacs@zf.com
www.zf-marine.com

THAILAND
7283
ZF Thailand Co. Ltd
159/33 Soi Vipawasee 64
Vipawasee-Rangsit Road
Laksi, Bangkok 10210
Thailand

Reungpoj V
T: 66-2-521-6520
F: 66-2-521-6523

ZF Marine, LLC Gulf Coast

161 James Drive West
Suite 120
St Rose, LA 70087

tanapath@bkk.loxinfo.th

TURKEY
7223
Georg Weinstabl
Niveko Makina Dis Ticaret kollektif Sti
Lorenz severin Moritz Weinstabl ve T: 90-212-287-27-80
Ortaklan
F: 90-212-287-65-71
Hasan Yelmen Cad No. 15,
TR-34957 Tuzla Instanbul Deri
Serbest Bolgesi, Turkey

georg@niveko.com

U.A.E.

ZF Marine West Coast

12125 Harbour Reach Drive
Mukilteo,WA 98275

Mike Gauthreaux
T: 504-443-0501
F: 504-443-0504
mike.gauthreaux@zf.com
www.zf-marine.com
Bud Bloom, Kevin Zwicker
T: 425-583-1900
F: 425-493-1579
bud.bloom@zf.com
kevin.zwicker@zf.com
www.zf-marine.com

VENEZUELA
Sistemas de Propulsion C.A.
T: 58-261-736-0747
AV 67a Entre 149By 150
F: 58-261-736-0746
2 Etapa Zona Industrial
Maracaibo, Venezuela
spd@sistemaspropulsion.com

7030
M. Narasimhan (Narsi), A.T. Moorthy
ZF Middle East, LLC
T: 971-6-5747074
(mail) PO Box 26093
F: 971-6-5747174
Sharjah, U.A.E.
(shipping) #502 Golden Tower Building
Sharjah
narasimhan.manian@zf-marine.com
U.A.E.
thiru.moorthy@zf-marine.com
www.zf-marine.com

Page #74 of 101

July 25, 2008

Appendix B Sales & Service Organizations North America

July 25, 2008

Page #75 of 101

Appendix B Sales & Service Organizations North America

Page #76 of 101

July 25, 2008

Appendix B Sales & Service Organizations North America

July 25, 2008

Page #77 of 101

Appendix B Sales & Service Organizations North America

Page #78 of 101

July 25, 2008

Appendix B Sales & Service Organizations North America

July 25, 2008

Page #79 of 101

Appendix B Sales & Service Organizations North America

Page #80 of 101

July 25, 2008

Appendix B Sales & Service Organizations North America

July 25, 2008

Page #81 of 101

Appendix B Sales & Service Organizations North America

Page #82 of 101

July 25, 2008

Appendix B Glossary

9.1 Glossary
Glossary Word

Definition

12 or 24 VDC Power
Supply

12 to 24 Volts Direct Current Power Supply.

ABYC

American Boat and Yacht Council

Adjacent

Near or close; especially adjoining.

Ahead Command

A command to the transmission to activate the forward gear.

All Electric 9000

Series

The All Electric 9000 Series are some of the Primary Propulsion
systems that can be used with ZF Backup. The other primary
systems are SmartCommand, MiniCommand and CruiseCommand.

Ampere (A)

The Ampere, often shortened to amp, is a unit of electric current,

or amount of electric charge per second.

Analog Signal

A signal continuously variable in both time and amplitude.

Anodize

To coat a metal, for example, aluminum, with a protective or

decorative oxide by making the metal the anode of an electrolytic
cell.

APS

see Automatic Power Selector.

Astern Command

A command to the transmission to activate the reverse gear.

Automatic Power
Selector

The Automatic Power Selector (APS) is a solid state device which

enables installation of a seamless, redundant power system for
critical electronic loads.

BCP

Backup Control Processor

Bonding

see System Grounding

Break-Out Box

see Field Service Test Unit

Bulkhead

An upright partition (wall), ceiling, or floor separating

compartments on a vessel.

Cables

A cable is one, two or more wires bound together typically in a

common protective jacket or sheath. The individual wires inside the
jacket may be covered or insulated.

Cathodic Protection

Cathodic Protection (CP) is a technique to control the corrosion of a

metal surface by making that surface the cathode (an electrode
through which positive electric current flows out of a polarized
electrical device) of an electrochemical cell.

July 25, 2008

Page #83 of 101

Appendix B Glossary

Glossary Word

Definition

Circuit Breaker

A Circuit Breaker is an automatically-operated electrical switch

designed to protect an electrical circuit from damage caused by
overload or short circuit.
Unlike a fuse, which operates once, and then has to be replaced, a
Circuit Breaker can be reset (either manually or automatically) to
resume normal operation.

Clutch

A device typically comprised of one or more friction discs, which

allow the engines output to be connected or disconnected from the
transmission.

Command Signal

The signal which the Control Panel outputs to the Backup

Processor, which in turn is converted to the appropriate outputs to
the engine and transmission.

Conduit

A protective cover for cables.

Connector
Designations

Name given to identify a specific connector.

Contact

Active component of electric switch or electrical connector.

Control Knob

The Port & Starboard Control Knobs on the ZF Backup Panel that
control throttle speed.
ZF Backup initializes in Neutral/Idle and remains in Neutral/Idle
until the Control Knobs are moved to the minimum throttle speed.

Control Panel

The panel from which the vessel operator controls ZF Backup.

CruiseCommand

CruiseCommand is one of the Primary Propulsion systems that can

be used with ZF Backup. The other primary systems are
SmartCommand, MiniCommand and the All Electric 9000 Series.

Current

Current is an electrical term which represents the flow of electrons

through a conductor and is measured in amperes.

DC Common

A common ground.

DC Grounding
Systems

In electrical engineering, something that is connected to the earth or

at the voltage defined as zero (in the U.S. is called ground; in the
UK, called Earth.

Diesel Engine

Engine that runs on diesel fuel.

Digital Signal

A signal which is comprised of highs (1) and lows (0).

Dimensions

A Dimension is a parameter or measurement required to define the

characteristics of an object (length, width and height, 3D; size and

Page #84 of 101

July 25, 2008

Appendix B Glossary
Glossary Word

Definition
shape, 2D)

Diodes

In electronics, a Diode is a component that restricts the directional

flow of charge carriers. Essentially, a diode allows an electric
current to flow in one direction, but blocks it in the opposite
direction.
Thus, the diode can be thought of as an electronic version of a
Check Valve (a device for automatically limiting flow in a piping
system to a single direction.). Circuits that require current flow in
only one direction typically include one or more diodes in the
circuit design.

ECM

Engine Control Module

Electrical Conductor

Any metal that easily permits the flow of electrical current.

EMC

Electromagnetic Compatibility

Field Service Test

Unit

Referred to as a Break Out Box, this unit reads the output of the
wires in a cable.

Footprint

The physical size required to mount a device.

Forward

Relative direction, where forward is the opposite of reverse.

Fuse

A device used in electrical systems to protect against over-current. A

fuse can only be used once.

Gear

A gear is a component within a transmission device that transmits

rotational force to another gear or device. A gear is different from a
pulley in that a gear is a round wheel which has linkages ("teeth" or
"cogs") that mesh with other gear teeth, allowing force to be fully
transferred without slippage.
Depending on their construction and arrangement, geared devices
can transmit forces at different speeds, torques, or in a different
direction, from the power source. Gears are a very useful simple
machine.

Governor

A device used on diesel engines to control the fuel and air mixture.

Hertz (Hz)

A unit of frequency equal to one cycle per second.

Idle

The engines minimum RPM.

Ingress Protection
(IP Rating)

The Ingress Protection (IP) rating scheme is an internationallyrecognized system of denoting the degree of protection afforded by
various products against:
a. access to hazardous particles

July 25, 2008

Page #85 of 101

Appendix B Glossary

Glossary Word

Definition
b. harmful ingress of water
It is a very simple system comprising two numbers, the first
referring to access to particles, and the second to water ingress.

Protection Against Foreign Solid Matter

#

Protection Against

Explanation

None

People are not protected against

accidental contact with charged or
moving parts.
Machines are not protected against
penetration of solid foreign matter.

Page #86 of 101

Penetration by large
solid matter

Protects large surfaces from

accidental contact with charged or
moving parts inside the machine,
such as contact with hands but does
not protect against voluntary contact
with these parts. Protects machine
against penetration by solid matter
with diameter > 50mm.

Penetration by
medium sized solid
matters

Protects fingers from accidental

contact with charged or moving
parts inside the machine. Protects
against penetration by solid matter
with diameter > 12mm.

Penetration by small
solid matter

Protects tools, conductors, and

similar objects with a thickness >
2.5mm from contact from charged
or moving parts inside the machine.
Protects against penetration by solid
matters with a diameter > 2.5mm.

Penetration by very
small solid matter

> 1 mm from contact or moving

parts inside the machine. Prevents
solid bodies with a diameter > 1mm
such as small tools and wires from
entering the machine.

Dust Deposits

Completely protects from contact

with charged or moving parts inside
the machine. Protects against dust
deposits. The quantity of dust
July 25, 2008

Appendix B Glossary
Glossary Word

Definition
allowed to enter the machine is
reduced to ensure the machine
functions properly.
6

Dust Particles

Completely protects from contact

with charged or moving parts inside
the machine. Totally prevents dust
from entering machine.

Protection Against Water Penetration

July 25, 2008

Protection Against

Explanation

No Protection

No particular protection.

Water Drops Moving

in a Perpendicular
Direction

Water drops that fall

perpendicularly must not damage
the machine.

Water Drops Moving

in an Oblique
Direction

Water drops that fall at any angle up

15% from the vertical must not
damage the machine.

Dripping Water

Water that falls at any angle up 60%

from the vertical must not damage
the machine.

Spraying Water

Protection against water sprayed

from any direction against the
machine must not cause damage.

Jets of Water

Jets of water launched from any

direction against the machine must
not cause damage.

Flooding

Water that penetrates the machine

because of temporary flooding, such
as rough sea, must not damage the
machine.

Immersion

When the machine is immersed for

a predetermined time, water must
not enter in such quantities as to
cause damage.

Submersion

When the machine is submerged at

a predetermined pressure for an
undetermined period of time, water
must not enter the machine in such
quantities as to cause damage.
Page #87 of 101

Appendix B Glossary

Glossary Word

Definition

Insulation

Electrical insulation, materials used to inhibit the conduction of

electricity.

LEDs

See Light Emitting Diodes

Light Emitting
Diodes

ZF Marine Electronics uses Light Emitting Diodes (LEDs)

throughout their product line to indicate specific functions and/or
operations.
ZF favors this kind of indicator because of its low current
requirements and visibility in the daylight.

Max

ZF Backups highest operational engine RPM.

MCU

Micro Controller Unit.

Milliampere (mA)

1/1000th of an Ampere.

Min

ZF Backups lowest operational engine RPM.

MiniCommand

MiniCommand is one of the Primary Propulsion systems that can be

used with ZF Backup. The other primary systems are
SmartCommand, CruiseCommand and the All Electric 9000 Series.

Multimeter

A Multimeter or a Multitester is an electronic measuring instrument

that combines several functions in one unit. The most basic
instruments include an ammeter, voltmeter, and ohmmeter.
A multimeter can be a handheld device useful for basic fault
finding, or a field service work or bench instrument which can
measure to a very high degree of accuracy.
Such an instrument will commonly be found in a calibration lab and
can be used to characterize resistance and voltage standards or
adjust and verify the performance of multi-function calibrators.

N.C.

Normally Closed

N.O.

Normally Open

Neutral

When the ahead or astern clutches are not engaged.

Pigtail

A cable that has a connector at one end, and loose wires on the
other.

Pin Assignments

Labels used to identify individual wires.

Port

While facing forward (front), the Left side of vessel.

Potentiometer

Control Head command voltage.

Page #88 of 101

July 25, 2008

Appendix B Glossary
Glossary Word

Definition

Wiper Voltage
Power Connector

Connector that supplies power to the ZF Backup system.

Power Source

A source of power such as a battery or APS.

Primary Mode

In reference to ZF Backup, Primary Mode is when the primary

control system (SmartCommand, Series 9000, MiniCommand or
CruiseCommand) is in control.

Primary System

In reference to ZF Backup, the Primary System would be

SmartCommand, Series 9000, MiniCommand, or CruiseCommand.
If the primary system fails, then the backup system (ZF Backup) can
take control of the vessel.

Processor

Proportional Pause

The device which takes inputs from the Control Panel and outputs
the appropriate signals at the correct time to the engines and
transmissions.
1. ZF Backup will only shift into Ahead or Astern gear from
Neutral/Idle.
2. When a shift is commanded from Ahead to Astern:
a.

Before disengaging the clutch, the backup propulsion

system pauses in gear for the value of the calculated
proportional pause or a maximum pause of (5)
seconds.

b.

The gear(s) shift to Neutral.

c.

The backup propulsion system pauses in Neutral/Idle

for 500 ms before shifting into Astern.

3. When a shift is commanded from Astern to Ahead:

a.

Before disengaging the clutch, the backup propulsion

system pauses in gear for half the time that it pauses
when going from Ahead to Astern or a maximum
pause of 2 seconds.

b.

The gear(s) shift to Neutral.

c.

The backup propulsion system pauses in Neutral/Idle

for 500 ms before shifting into Ahead.

4. Once the gears have shifted into Ahead or Astern, the

appropriate LEDs light for Ahead or Astern, Port or Starboard.
Pulse Width
Modulated (PWM)
July 25, 2008

The type of electronic signal used by Caterpillar engines for speed

control. PWM is the ratio of On time to Total time.
Page #89 of 101

Appendix B Glossary

Glossary Word

Definition

PWM

see Pulse Width Modulation

Redundancy

Redundancy in general terms refers to the quality or state of being

redundant, that is exceeding what is necessary or normal, or
duplication.
Specifically in Engineering, it means serving as a duplicate in case
the Primary Propulsion System stops working.

Relay

An electrical actuator that allows a relatively small electrical voltage

or current to control a large voltage or current.

Reverse

Causing movement in the opposite direction.

RPM

Revolutions Per Minute.

Screw

Propeller

ZF Backup

The ZF Backup processor provides a twin screw vessel with the

minimum controls required to keep it underway in the event that
the primary system processor fails.

SmartCommand

SmartCommand is one of the Primary Propulsion systems that can

be used with ZF Backup. The other primary systems are
MiniCommand, CruiseCommand and the All Electric 9000 Series.

Solenoid

A device which takes an electrical input and converts that input to a

mechanical output. Solenoids are used to engage the clutch in some
marine transmissions.

Solid State

Solid State relates to semiconductor materials, components and

related devices; as distinct from older technologies such as vacuum
tubes.

Starboard

While facing forward (front), the right side of the vessel.

Start Interlock

A device which prevents the engine from being started.

Throttle

The Throttle controls the speed of the engine. ZF Backup has four
options for throttle control:

Transmission

Page #90 of 101

PWM Output

(8 92% )

Variable Frequency

(80 480 Hz

Voltage Output

(0.2 4.8 VDC)

Current

(03.98 20.2 mA

The device which take the engines horsepower and torque and
connects them to the propeller via the output shaft.
July 25, 2008

Appendix B Glossary
Glossary Word

Definition

Transom

The material which forms the stern of a square ended boat.

Twin Screw
Configuration

When a system is programmed to control two engines and

transmissions.

VDC

see Voltage Direct Current.

Vessel

A general term for all kinds of craft designed for transportation on

water, such as ships or boats.

Voltage Direct
Current

A measure of electrical potential difference which has current

flowing in one direction and is substantially constant in value.

Voltage Drop

One of the most important (and often overlooked) items for proper
operation of your control system or backup system is a clean,
dedicated, and reliable source of DC Power.
The wiring used to supply power from the power source (battery)
through the various components (fuses, distribution panel, relays,
etc.) to the Processors must be sized for a voltage drop of 10% or
less using 5 amps as the maximum current draw.
Refer to ABYC Standard E-11, Table XI to determine the appropriate
wire gauge for the necessary conductor length.
It is critical to design and wire the Control System in a manner
which provides the cleanest power sources available. This can be
accomplished by using an APS (Automatic Power Selector) which
connect two separate power sources (batteries) to the Processor.

Voltmeter

A Voltmeter is an instrument used for measuring the electrical

potential difference between two points in an electric circuit.

Warm Up

Mode of Operation which allows the operator to increase the

engines RPM while the clutch remains in neutral.

Wire/Cable Harness

A Wire/Cable Harness is a string of cables which transmit signals

(information) or operating currents (energy). The cables are bound
together by clamps, cable ties, or sleeves.
Insulated wires------Cables---------Wire/Cable Harness

Wireway

July 25, 2008

A wiring duct for your wire containment needs. This prevents the
wire from being stepped on, or tripped over. It protects the wire
from internal and external damage.

Page #91 of 101

Appendix B Table of Figures

9.2 Table of Figures

Figure 1: Generic System Drawing #14091 (See page #62 for APS Wiring Options) ....................... 12
Figure 2: ZF Backup Processor........................................................................................................... 14
Figure 3: ZF Backup Control Panel, #14105 ...................................................................................... 18
Figure 4: ZF Backup Processor Dimensions....................................................................................... 22
Figure 5: Grounding............................................................................................................................ 24
Figure 6: ZF Backup Panel Parts ........................................................................................................ 26
Figure 7: Use Mounting Plate as Template for Cutting and Drilling ................................................. 27
Figure 8: Attaching Mounting Plate ................................................................................................... 28
Figure 9: ZF Backup Panel Housing Installation ............................................................................... 29
Figure 10: Cable Connections ............................................................................................................ 31
Figure 11: Harness Plug Connectors (from left, picture 1 & 2) .......................................................... 34
Figure 12: Processor Connector and Harness Plug Keying (from left, picture 3).............................. 34
Figure 13: Typical Start Interlock Connections ................................................................................. 36
Figure 14: Generic System Drawing #14091, Relevant to Troubleshooting (See page #62 for APS
Wiring Options) ................................................................................................................................... 47
Figure 15: Grounding*........................................................................................................................ 57
Figure 16: Drawing 11488F-1 Notes Page .......................................................................................... 65
Figure 17: Drawing 11488F-3, Twin Screw with Two APS and Alternate Remote Switch ............. 66
Figure 18: APS Wiring Options ........................................................................................................... 67

July 25, 2008

Page #93 of 101

Appendix B List of Tables

9.3 List of Tables

Table 1: ZF Backup Processor .......................................................................................................................... 9
Table 2: General Specifications Twin Screw Processor.............................................................................. 13
Table 3: Vessel Information ............................................................................................................................ 40
Table 4: Processor ........................................................................................................................................... 41
Table 5: Wire Harness Lengths....................................................................................................................... 41
Table 6: Power Supply .................................................................................................................................... 42
Table 7: Dock Trials ........................................................................................................................................ 42
Table 8: Record at Dock (Requires Use of Field Service Test Unit) .............................................................. 43
Table 9: Record During Sea Trials (Requires Use of Field Service Test Unit) .............................................. 43
Table 10: SB Panel Pigtail, #14093-1

Table 11: SB Panel Wire Harness #14092........................ 48

Table 12: ZF Backup Part Numbers ............................................................................................................... 61

July 25, 2008

Page #95 of 101

Appendix B

9.4 Index
12 or 24 VDC power supply ...........................................11
ABYC .............................................................................87
ahead command ..............................................................87
all electric 9000 series.....................................................87
ampere (A)......................................................................87
analog signal ...................................................................87
anodize............................................................................87
APS.................................................................................87
installation...................................................................68
installation drawings ...................................................70
materials provided.......................................................68
specifications...............................................................68
Wiring Options with Backup System..........................72
APS to backup processor
protected by.................................................................35
APS to primary processor
protected by.................................................................35
astern command ..............................................................87
automatic power selector ................................................87
backup command
processor .....................................................................23
backup mode
activating.....................................................................20
both engines ................................................................21
exiting .........................................................................21
backup panel
buttons.........................................................................27
knobs ...........................................................................27
BCP.................................................................................87
bonding ...........................................................................87
break-out-box..................................................................87
bulkhead..........................................................................87
cables ..............................................................................87
cathodic protection..........................................................87
circuit breaker .................................................................88
circuit breakers
power on/off to backup processor ...............................35
power on/off to primary processor(s)..........................35
clutch ..............................................................................88
clutch interface wire harness
installation...................................................................40
command signal ..............................................................88
conduit ............................................................................88
connector designations....................................................88
connector pin functions...................................................56
J10-port solenoids .......................................................57
J11-starboard solenoids...............................................57
J12-port throttle, low current, start interlock relay......58
J13-starboard throttle, low current, start interlock relay
.................................................................................58
J2-starboard backup panel...........................................56
J3-power......................................................................56
Page #96 of 101

J5-port backup panel ...................................................57

J6-BDM ......................................................................57
connector pins exposed...................................................36
contact ............................................................................88
control knob....................................................................88
control panel ...................................................................88
6 LEDs ........................................................................19
cruise mode
normal operation .........................................................21
CruiseCommand .............................................................88
current.............................................................................88
DC common....................................................................88
DC grounding systems....................................................88
DC power source ............................................................34
clean, dedicated and reliable .......................................34
deutsch connector assembly - DT type ...........................61
deutsch connectors..........................................................18
diesel engine ...................................................................88
diesel engines only..........................................................11
digital signal ...................................................................88
dimensions......................................................................88
diodes..............................................................................89
directional change...........................................................16
timeline .......................................................................16
dock trial
type of power ..............................................................48
dock trial report
backup processor.........................................................47
dock trials .......................................................................43
control panel................................................................43
processor .....................................................................43
ECM ...............................................................................89
electrical conductor.........................................................89
electromagnetic compatibility ........................................25
EMC .........................................................................25, 89
engine stop switches .......................................................41
enter backup mode
for each engine ............................................................20
features ...........................................................................11
field service test unit.......................................................89
fixed pause......................................................................16
footprint ..........................................................................89
forward ...........................................................................89
fuse .................................................................................89
gear .................................................................................89
glossary...........................................................................87
governor..........................................................................89
grounding (bonding) .......................................................62
hertz (Hz)........................................................................89
how ZF Backup initializes ..............................................20
idle ..................................................................................89
ingress protection (IP rating) ..........................................89
July 25, 2008

Appendix B Index
installation
wire harnesses .............................................................36
with power relays ........................................................35
without power relays ...................................................35
insulation ........................................................................92
interlock circuit
damage ........................................................................39
LEDs...............................................................................92
control panel................................................................19
processor .....................................................................17
light emitting diodes .......................................................92
list of tables.....................................................................99
max .................................................................................92
MCU ...............................................................................92
metal hull vessels............................................................65
milliampere (mA) ...........................................................92
min ..................................................................................92
MiniCommand................................................................92
mounting locations
control panel................................................................23
processor .....................................................................23
multimeter.......................................................................92
N.C..................................................................................92
N.O. ................................................................................92
neutral .............................................................................92
neutral solenoid outputs ..................................................11
panel installation.............................................................27
parts and tools
flat washers .................................................................23
grounding bond stud and nut.......................................23
installer supplied .........................................................23
lock washers................................................................23
M6 fasteners................................................................23
pause
in proportion to............................................................16
variable........................................................................16
periodic checks and maintenance....................................51
backup panel ...............................................................51
processor .....................................................................51
pigtail ..............................................................................92
pin assignments...............................................................92
pleasure craft...................................................................11
port..................................................................................92
potentiometer wiper voltage ...........................................92
power connector..............................................................93
power relays
silver or gold contacts .................................................35
voltage drop.................................................................35
power source...................................................................93
primary mode..................................................................93
primary propulsion system..............................................15
primary system ...............................................................93
backup system selected .................................................9
processor fails ...............................................................9
primary/backup systems
separate power sources................................................21
processor.........................................................................93
July 25, 2008

do not mount ...............................................................25

grounding ....................................................................25
high heat......................................................................25
installing......................................................................25
location...................................................................... See
maximum amperes per side.........................................39
preferred location ..................................................24, 25
strong magnetic fields .................................................25
surface piercing drive system......................................25
vibration ......................................................................25
proportional pause ..............................................11, 16, 93
ahead gear .............................................................20, 21
astern gear ...................................................................20
protection against foreign solid matter ...........................89
dust deposits................................................................89
dust particles ...............................................................89
none.............................................................................89
penetration by large solid matter.................................89
penetration by medium sized solid matters .................89
penetration by very small solid matter ........................89
protection against water penetration ...............................89
dripping water .............................................................89
flooding.......................................................................89
immersion ...................................................................89
jets of water.................................................................89
no protection ...............................................................89
spraying water.............................................................89
submersion ..................................................................89
water drops moving in a perpendicular direction........89
water drops moving in an oblique direction................89
pulse width modulated (PWM).......................................93
PWM ..............................................................................94
redundancy .....................................................................94
redundant system ............................................................15
references........................................................................66
american boat & yacht council (ABYC) .....................66
code of federal regulations ..........................................66
national marine manufacturers association .................66
society of automotive engineers..................................66
underwriters laboratories.............................................66
relay ................................................................................94
reverse ............................................................................94
RPM................................................................................94
sales & service organization (SSO) .......................... iii, 75
international ................................................................75
north america ..............................................................79
SB throttle control
current .........................................................................11
PWM Output...............................................................11
variable frequency.......................................................11
voltage output..............................................................11
screw...............................................................................94
sea trial
backup processor RPM ...............................................48
full speed setting .........................................................45
sea trial report .................................................................45
backup processor.........................................................46
Page #97 of 101

Appendix B - Index
backup processor power supply ..................................47
backup processor wire harness lengths .......................47
vessel information .......................................................45
shift from neutral/idle .....................................................20
single power supply ........................................................11
ZF Backup ......................................................................94
panel............................................................................27
panel pigtail.................................................................55
part numbers................................................................67
power off .....................................................................34
processor dimensions ..................................................24
works with...............................................................9, 11
ZF Backup processors.......................................................9
4-20 mA throttle............................................................9
frequency throttle ..........................................................9
PWM throttle.................................................................9
voltage throttle ..............................................................9
SmartCommand ..............................................................94
solenoid...........................................................................94
solid state ........................................................................94
speed
throttle knob ................................................................21
spray proof......................................................................24
starboard .........................................................................94
start interlock ..................................................................94
start interlock circuit
not using......................................................................38
start interlock connections
typical..........................................................................39
start interlock relay ...................................................11, 17
closed ......................................................................9, 20
engine start ..................................................................17
when it closes ..............................................................38
start signal current
maximum VDC ...........................................................39
symbols used in manual
caution......................................................................... iii
important ..................................................................... iii
note.............................................................................. iii
warning........................................................................ iii
system checkout..............................................................56
table of figures ................................................................97
taking command..............................................................56
throttle.............................................................................94
throttle interface wire harness
installation...................................................................40
throttle wire harnesses
plugs at both ends........................................................40
throttle wire harnesses available
current .........................................................................40
frequency.....................................................................40
PWM (pulse width modulation ...................................40
voltage.........................................................................40
transmission ..............................................................20, 94

Page #98 of 101

transom ...........................................................................95
troubleshooting ...............................................................53
troubleshooting questions
backup panel does not take command.........................53
no clutch command .....................................................53
no engine speed...........................................................53
no start interlock .........................................................53
twin screw configuration ................................................95
twin screw system...........................................................11
VDC................................................................................95
vessel ..............................................................................95
voltage direct current ......................................................95
voltage drop ....................................................................95
10% or less..................................................................34
voltmeter.........................................................................95
warm-up..........................................................................95
warranty........................................................................103
warranty registration.....................................................105
water proof......................................................................24
wire harness
clutch...........................................................................36
clutch interface............................................................40
color ............................................................................37
control panel................................................................36
control panel lengths ...................................................37
incorrectly forced together ..........................................37
insertion and extraction...............................................37
keying of plug .............................................................37
lengths.........................................................................39
loose wiring.................................................................38
number of pins ............................................................37
power/start interlock .............................................36, 38
primary and backup systems .......................................36
release button ..............................................................36
strain relief ..................................................................37
ten feet.........................................................................39
thirty feet.....................................................................39
throttle .........................................................................36
twenty feet...................................................................39
wire harness between control panel and processor
uninterrupted ...............................................................37
wire harnesses
lengths determined ......................................................23
maximum length .........................................................38
primary and backup systems .......................................40
support ........................................................................23
wire/cable harness...........................................................95
wireway ..........................................................................95
works with
9000 series ........................................................9, 11, 15
CruiseCommand ...............................................9, 11, 15
MiniCommand ..................................................9, 11, 15
SmartCommand ................................................9, 11, 15

July 25, 2008

Appendix B Warranty

9.5 Warranty

12125 Harbour Reach Drive

Mukilteo, WA 98275

ZF Marine Electronics, LLC

July 25, 2008

Telephone: (425) 583-1900

Telefax: (425) 493-1569

Page #99 of 101

Appendix B Warranty Registration

9.6 Warranty Registration

July 25, 2008

Page #101 of 101