Complete Guide for On site Maintenance and Troubleshooting of ZF ClearCommand 9000 Series Ship Propulsion Control System

Adjust the maximum pressure of L3 drag to 20.0-100.0% to 70-80% when the shaft speed is idle

Quick search for auditory alarm codes and on-site response

The ClearCommand system prompts the type of fault through different beeps emitted by the console. The following are the six most common auditory alarms on site and their meanings:

3.1 Slow Repetitive Sound (approximately once per second)

Timing of occurrence: When the system is first powered on or suddenly appears during operation.

meaning:

When powered on normally: The system initialization is complete, but there is no console to obtain command authority.

Sudden occurrence during operation: The processor voltage drops instantly below 8VDC and then recovers.

Troubleshooting steps:

Check the battery voltage (>12.4V for 12V systems and>24.8V for 24V systems).

Measure the difference between the voltage at the processor end and the voltage at the battery end. For 12V systems, it should not exceed 1.2V, and for 24V systems, it should not exceed 2.4V.

If using an automatic power selector (APS), an additional 0.7V diode voltage drop needs to be included.

Check all power terminals, circuit breakers, and grounding wires for looseness or corrosion.

3.2 One long and three short notes

Meaning: The control lever signal of the current command console exceeds the valid range (below 0.6VDC or above 4.4VDC).

Troubleshooting method:

Enter the diagnostic menu H0 and check the corresponding A/D count value on the console.

The normal idle/neutral position should have an A/D count value of 485~505.

If the A/D value is greater than 910, the cause of the fault is that the potentiometer signal is too high - check whether the 5V reference voltage circuit (blue wire) or green wire (signal wire) is open circuit.

If the A/D value is less than 100, the cause of the fault is low signal - check if the green wire (signal wire) is open or if the potentiometer ground (yellow wire) is disconnected.

3.3 Continuous long sound (non-stop)

Meaning: The Transfer Button has been stuck for more than 12 seconds.

Countermeasures:

Attempt to obtain command authority from another console, the long sound will stop.

Unable to obtain command authority again before repairing the faulty console.

Enter the diagnostic menu H0 and check if the status display of the transfer button for the corresponding station is "1".

3.4 Three second long tone

Meaning (one of the three):

The transfer button on the current console is stuck.

If equipped, the system has entered backup mode.

If equipped with an integrated solenoid drag, the drag solenoid valve may have an open or short circuit.

Solution: Refer to the error code displayed on the LED for further judgment.

3.5 One long and one short tone (clutch servo or solenoid valve)

Servo type (clutch): Abnormal feedback potentiometer signal. Error code 63 (feedback too high) or 64 (feedback too low). Check the orange (ground) and green (signal) lines.

Electromagnetic valve model: clutch solenoid valve failure. Error codes 1-6 correspond to reverse short circuit, reverse open circuit, forward short circuit, forward open circuit, etc. This alarm can only be generated after enabling the H2 driver fault detection function.

3.6 One long and two short notes (throttle servo or drag servo)

Throttle servo: The throttle feedback potentiometer signal is abnormal. Error code 66 (feedback too high) or 67 (feedback too low).

Dragging servo: The dragging feedback potentiometer signal is abnormal.

3.7 One long and two short high-speed repetitive sound (servo card lag sound)

Meaning: The throttle servo (or drag servo, clutch servo) cannot reach the commanded position. Error codes 65 (throttle servo stuck) and 62 (clutch servo stuck).

Troubleshooting steps:

Disconnect the push-pull cable from the engine/transmission rocker arm.

Observe whether the feedback A/D value changes with the instruction in the diagnostic menu.

If there is still a stuck sound after disconnection, check if the power supply voltage of the processor is normal, otherwise it may be a processor failure.

If the stuck sound disappears after disconnection, the problem is that the push-pull cable is stuck or the rocker arm resistance is too high.

Deep analysis of typical error codes

4.1 Console related errors (error codes 13~42)

The main reasons and solutions for the meaning of error codes

Check the red (+5V) and blue (reference circuit) lines for high N signal and missing 5V reference voltage or open circuit of potentiometer on console 13-22; Check the jumper wires between starboard console terminals 3 and 5, and port terminals 3 and 7

Check the continuity of the green wire if the signal line (green) of the 23~32 console N signal is too low or if the potentiometer grounding is disconnected; Check if the yellow wire (grounding) is disconnected

33-42 Console N Transfer Button Stuck Button Physical Stuck or Line Short Circuit Cleaning Button; Check if there is a short circuit between the orange wire (button signal) and the ground wire

4.2 Communication and power supply errors (error codes 43~61)

The main reasons and solutions for the meaning of error codes

43-49 CAN communication protocol error: The serial communication cable is too long (>120 feet) or improperly shielded to shorten the length of the serial cable; Ensure that only one end of the shielded wire is grounded