EC300 Manual 1020607 - 09 - 03 - CD

INCORPORATED INCORPORATED
TWIN DISC
Installation Installation and Operators Oper ators Manual

Marine Control Control System Model: EC300
Document Number: 1020607
NOTICE Twin Disc, Incorporated makes no warranty or guaranty of any kind, expressed, implied or otherwise, with regard to the information contained within this manual. Twin Disc, Incorporated has developed this manual through research and testing of the information contained therein. Twin Disc, Incorporated assumes no responsibility for any errors that may appear in this manual and shall not be liable under any circumstances for incidental, consequential or punitive damages in connection with, or arising out of, the use of this manual. The information contained within this manual is subject to change without notice.
Document Number 1020607
September 2003
Marine Control System Installation and Operators Manual
TWIN DISC, INCORPORATED EXCLUSIVE LIMITED WARRANTY Marine Electronic Control Systems
A. Twin Disc, Incorporated warrants the aforementioned assembled products and parts (except component products or parts on which written warranties are issued by the respective manufacturers thereof and are furnished to the original customer, as to which Twin Disc, Incorporated makes no warranty and assumes no liability) against defective materials or workmanship for a period of
forty-eight (48) months from the date of original shipment by Twin Disc, Incorporated to the original customer, but not to exceed thirty-six (36) months of service, whichever occurs first . This is the only warranty made by Twin Disc, Incorporated and is in lieu of any and all
other warranties, express or implied, including the warranties of merchantability and fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc, Incorporated. The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc, Incorporateds application engineering. B. In consideration of the Limited Twin Disc General Warranty (hereafter called warranty) and price Twin Disc, Incorporated charges (which reflects Twin Disc, Incorporateds limited liability), the exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable warranty period as specified, or otherwise (including tort liability), shall at the sole option of Twin Disc, Incorporated be either the repair or replacement of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective (or equivalent credit). Under no circumstances, including a failure of the exclusive remedy, shall Twin Disc, Incorporated be liable for economic loss, consequential, punitive or incidental damages. The above warranty and remedy are subject to the following terms and conditions: 1. 2. 3. 4. 5. 6. Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc, Incorporated within sixty (60) days after completion of the in-warranty repair. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse, neglect, improper maintenance or accident. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc, Incorporated. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment to the date placed in service. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product or part with installations properly engineered and in accordance with the practices, methods and instructions approved or provided by Twin Disc, Incorporated. The warranty is void unless all required replacement parts or products are of Twin Disc origin or are Twin Disc authorized replacement parts, and otherwise identical with components of the original equipment. Replacement parts or products not of Twin Disc origin are not warranted by Twin Disc, Incorporated.
C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for injury to persons or property, including without limitation, the original customers and subsequent purchasers employees and property, due to their acts or omissions or the acts or omissions of their agents, and employees in the installation, transportation, maintenance, use and operation of said equipment. D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or expense in the service, repair or replacement of any part or product within the warranty period, except when such cost or expense is authorized in advance in writing by Twin Disc, Incorporated. E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being obligated to incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on a no-charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete unit.
June 24, 2003 TDWP3100
F.
Twin Disc, Incorporated
Table of Contents
Table of Contents
Introduction ................................................................... 11
Preface .................................................................................................................... 11 General Information ............................................................................................... 13 Replacement Parts ................................................................................................. 14 Safety ...................................................................................................................... 15 Source of Service Information .............................................................................. 15 Sectional Contents ................................................................................................ 16 Required Tools ....................................................................................................... 17 Required Supplies ................................................................................................. 18 Additional Materials ............................................................................................... 21 Other Items Which May Be Required .................................................................... 21
Component Installation ................................................ 27

General Installation Guidelines ............................................................................. 27 EC300 Control Installation .................................................................................... 30 Control Head Installation ....................................................................................... 31 Control Head Lever Drag Adjustment .................................................................. 37 Station Doubler Installation ................................................................................... 39 Engine Speed Sensor Installation ........................................................................ 40 Servo Actuator Installation .................................................................................... 44 Push-Pull Cable Installation .................................................................................. 46 Twin Disc Display Installation ............................................................................... 58 Lever Function Switch Installation ....................................................................... 60
Electrical Installation .................................................... 61

Introduction ............................................................................................................ 61 Control Head Harness (J1, J2, or J3) Installation ................................................ 71 Service Connector (J4) .......................................................................................... 86 Engine Control Harness (J5) Installation ............................................................. 86 Engine Room Analog Harness (J6) Installation ................................................... 99 PWM Drivers Harness (J7) Installation ............................................................... 102 Miscellaneous Bridge Signals Harness (J8) Installation ................................... 105 Twin Disc Display Harness (J9) Installation ....................................................... 112 Communication Harness (J10) Installation ........................................................ 115 Servo Actuator Harness (J11) Installation .......................................................... 119 Engine Room Switch Harness (J12) Installation ............................................... 121 EC300 Control Power and Grounding Harness (J13) Installation.................... 124
EC300 Marine Control System Installation Manual #1020607
Table of Contents
Configuration .............................................................. 133

Introduction .......................................................................................................... 133 Configure the Control System ............................................................................ 134 Configure Head Types ......................................................................................... 141 Configure Engine ................................................................................................. 142 Configure Transmission ...................................................................................... 143 Configure Options ............................................................................................... 147 Miscellaneous Configuration Notes ................................................................... 148
System Operation ........................................................ 149

Introduction .......................................................................................................... 149 Basic System Features ........................................................................................ 150 Lever Function in Cruise Mode ........................................................................... 152 Lever Function in Express Mode ........................................................................ 153 Lever Function in Troll Mode .............................................................................. 154 Lever Function in Master Lever Function .......................................................... 155 Lever Function in Phantom Lever Function ...................................................... 156 Mode Select Switch ............................................................................................. 157 Display Features .................................................................................................. 159 Station Transfer .................................................................................................... 160 Manual Mechanical Control ................................................................................. 164 Individual Engine Operations .............................................................................. 165 Engine Synchronization ...................................................................................... 167
Troubleshooting.......................................................... 169
Introduction .......................................................................................................... 169 Diagnostics Test Mode ........................................................................................ 169
Preventative Maintenance .......................................... 189

Periodic Visual Inspection .................................................................................. 189
Table of Contents
Engineering Drawings ................................................ 191

List of Engineering Drawings ............................................................................. 191 Morse 33 Series Cable Mounting Dimensions ................................................... 193 EC300 Control Mounting Dimensions Sheet 1 (1020676) ................................. 194 EC300 Control Mounting Dimensions Sheet 2 (1020676) ................................. 195 Servo Actuator Mounting Dimensions ............................................................... 196 Twin Disc Display Mounting Dimensions (1018791) ......................................... 197 Control Head Mounting Template ....................................................................... 207 Interface Assembly Mounting Template ............................................................. 209 Selector Assembly Mounting Template .............................................................. 211
Appendix ...................................................................... A-1
Table of Contents
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10
Introduction
Introduction
Preface
The Twin Disc Incorporated product line of electronic Marine Control Systems provides remote operation of engine throttle and transmission engagement. The model EC300 Marine Control System is designed for use with current Electronic Throttle and/or Electric Shift propulsion systems used within the pleasure and work-boat markets. The EC300 Control has many special features which provide flexibility and adaptability for use with the vast majority of engine/transmission combinations including popular options such as Engine Sync, Trolling, Shaft Brake, Mechanical Actuator Output, Transmission Oil Pressure and Oil Temperature Monitoring, Master and Phantom lever function, Alarm Output, and Helm Display. The following installation instructions provide the necessary information on Component Installation, Electrical Installation, Configuration, System Operation and Troubleshooting. Review the entire manual for the options specific to your application, and become familiar with all Customer Supplied materials and tools that may be required. In addition, while the manual is outlined for the general sequence of installation from setup through troubleshooting, a good understanding of all aspects of the installation will help make for a smoother installation process. For most applications, the installation process is as follows: 1. Read and understand this manual. Contact the supplier of the system, your local Twin Disc Distributor, or the Twin Disc Inc. website for help: http://www.twindisc.com Locate desired positions for Control Heads, Controls and general routing of interconnecting harnessing. Identify locations for vessel interconnections such as Ignition, Power Wiring, Electronic Throttle, Electric Shift, Speed Sensing etc. Engine and transmission installation manuals and vessel wiring diagrams may be needed for reference. Purchase/fabricate any necessary Customer Supplied items or tools. Finalize locations of Control Heads and Controls.
2.
3.
4. 5.
11
Introduction
6. 7.
Install harnessing and wiring. Inspect the installation against the manual. Document component part and serial numbers and any particulars regarding wire colors and locations specific to the application. Process initial tests, adjustments and troubleshooting. Process final test/sea-trial.
8. 9.
12
Introduction
General Information
This publication provides the information necessary for the installation of the Twin Disc Model EC300 Control System. This manual is designed to facilitate the installation of the EC300 Control System by the customer. The installer should perform the work as presented in this manual. Twin Disc, Incorporated and its local distributors are available to assist in the installation. The components as supplied with the order meet the codes and standards that were applicable when the order was placed. This instruction manual is prepared to address many of the applicable requirements of the following that are effective on the date that this manual is prepared: American Boat & Yacht Council (ABYC) Direct Current (DC) Electrical Systems on Boats Standard E-9. American Bureau of Shippings (ABS) Rules for Building and Classing Steel Vessels 2002. American Bureau of Shippings (ABS) Rules for Building and Classing Steel Vessels Under 90 Meters (295 Feet) 2001.
However, the customer is responsible for meeting all currently applicable code and standard requirements for the component installation at the time of installation. The following instructions cover typical installation of single- or twin-engine systems with one, two, or three control stations as standard equipment. However, these instructions also cover installation of up to eight engine systems with optional accessories and cables. The EC300 Control System is supplied in response to specific orders for specific applications. Based upon the details of the order, certain features and options that are described in this manual will not be applicable. For specific component information, refer to the system installation drawing supplied for your application.
13
Introduction
Replacement Parts
Parts List
Engineering assembly drawings are provided in appropriate sections of this manual to facilitate ordering spare or replacement parts. Current system drawings are available from Twin Disc Inc. or the nearest authorized Twin Disc Inc. Distributor.
Ordering Parts
WARNING
All replacement parts or products must be of Twin Disc Inc. origin or equal, and otherwise identical with components of the original equipment. Use of any other parts or products will void the warranty and may result in malfunction or accident, causing injury to personnel and/or serious damage to the equipment. Renewal parts and service parts kits may be obtained from any authorized Twin Disc Inc. distributor or service dealer. Twin Disc Incorporated, having stipulated the part number on the units nameplate, absolves itself of any responsibility resulting from any external, internal or installation changes made in the field without the express written approval of Twin Disc Inc.
14
Introduction
Safety
All people installing and operating this unit must employ safe operating practices. Twin Disc Incorporated is not responsible for any personal injury resulting from any unsafe and careless use of hand tools, power tools, lifting equipment, or from any unsafe practices during installation and operation. Because of the possible danger to people or property from accidents that may result from the use of manufactured products, it is important that correct procedures be followed. Products must be used in accordance with the information specified. Proper installation procedures must be used. Proper safety devices, such as guards, may be required as specified in applicable codes. Safety devices are not provided by Twin Disc Incorporated nor are they the responsibility of Twin Disc Incorporated.
Source of Service Information

This manual is current at the time of printing. Changes are made to the manual for advances in technology and improvement in the state of the art when required. All revisions and design improvements are subject to change without notice. Individual product service bulletins are issued to provide Twin Disc distributors with immediate notice of new service information. These service bulletins are distributed to all Twin Disc EC300 Control distributors throughout the United States and many foreign countries. For the latest service information on Twin Disc Inc. products, contact any Twin Disc distributor or service dealer. This can be done on the Twin Disc corporate web site found at [http://www.twindisc.com]. Provide your system drawing number. If necessary, contact the Product Service Department, Twin Disc Incorporated, Racine, Wisconsin 53405-3698, USA by e-mail at service@twindisc.com.
15
Introduction
Sectional Contents
Table 1. Sectional Contents
Section Description
The introduction provides a list of required tools and supplies for installing the system. The lists are representative of requirements for Introduction common installations and may not apply in all cases. Refer to the specific drawings for your system for more detailed information about system installation. Component Installation Electrical Installation Configuration Operating Instructions Troubleshooting The component installation section provides instructions for the location and installation of the physical components supplied with the system. The electrical installation section provides instructions for the connection of the electrical harnesses and wiring required for system operation. The configuration section addresses the system configuration that can be performed by the installer. The operating instructions section addresses basic operating features. The troubleshooting section provides basic information for system troubleshooting. This includes tests available via the optional Twin Disc display.
The engineering drawings section contains a number of installation drawings and templates. This section also contains a copy of the Engineering generic interconnection diagram for the system. This drawing shows Drawings all available options. Specific drawings for each installation are provided separately. Refer to the specific drawings for your system during the installation process.
Note: A number of options are available for use with the EC300 Control System. Not all of the detailed procedures will be needed for any specific application. Crossreferencing is added to assist the user in selecting the correct procedures for use. However, it may be helpful to identify the procedures that are to be used before the start of work. Sub-sections that are not useful may be crossed out or otherwise marked as not applicable. Additionally, checking off progress through the procedures and sections may assist the installer in keeping track of the work that has already been accomplished.
16 EC300 Marine Control System Installation Manual #1020607
Introduction
Note: Dimensions provided in this manual are in mm (in) unless otherwise specified.
Required Tools
Note: Not all installations will require all of the tools itemized below. All of the tools would be required for the most complex installation. Installation may require the following tools: o o o o o o o o o o o o o o o o Electric or pneumatic drill Assorted drill bits Center punch #1 Phillips screwdriver Screwdriver with a 1/8 in. blade Wire terminal crimpers Wire strippers DC voltmeter or multimeter Watch with a seconds hand Tachometer, oscilloscope, or frequency counter for troubleshooting dual engine applications 3/32 in. hex key (Allen) wrench 1/8 in. hex key (Allen) wrench Deutsch crimp tool (P/N HDT 48-00) for 12 to 24 AWG wire sizes Torque wrench capable of measuring 4.52 Nm (40 in-lb) for installing a speed sensor in the flywheel housing and for mounting components File, rasp, or sandpaper to smooth cut surfaces 500 VDC Megohmmeter for testing power wiring as per ABS requirements.
17
Introduction
Required Supplies
This section serves as a guide for your preinstallation parts check. Be sure that you have ordered and received all of the basic components necessary for this system installation. The following section addresses additional parts that may be required depending upon the other options ordered.
Basic System Components

Typical system types and major components needed are listed in Table 2. Table 2. Typical Components for Basic Systems
Basic Systems
Components One (1) Single Lever Control Head One (1) EC300 Control One (1) Port Lever Harness
Single engine with one station
One (1) Power Connector (J13) Kit (see Table 4) One (1) PWM (Valve Coil) Drivers Harness (J7) One (1) Engine Throttle Connector (J5) Kit One (1) Engine Speed Sensor Harness One (1) Miscellaneous Bridge Signals Connector (J8) Kit Two (2) Single Lever Control Heads One (1) EC300 Control Two (2) Port Lever Harnesses
Single engine with two stations
One (1) Power Connector (J13) Kit (see Table 4 ) One (1) PWM (Valve Coil) Drivers Harness (J7) One (1) Engine Throttle Connector (J5) Kit One (1) Engine Speed Sensor Harness One (1) Miscellaneous Bridge Signals Connector (J8) Kit
18
Introduction
Table 2. Typical Components for Basic Systems (continued)

Basic Systems Components One (1) Dual Lever Control Head Two (2) EC300 Controls One (1) EC300 Dual Lever Harness Twin engines with one station One (1) Communication Harness Assembly (J10) (see below) Two (2) Power Connector (J13) Kits (see Table 4) Two (2) PWM (Valve Coil) Drivers Harnesses (J7) Two (2) Engine Throttle Connector (J5) Kits Two (2) Engine Speed Sensor Harnesses Two (2) Miscellaneous Bridge Signals Connector (J8) Kits Two (2) Dual Lever Control Heads Two (2) EC300 Controls Two (2) EC300 Dual Lever Harnesses Twin engines with two stations One (1) Communication Harness Assembly (J10) (see below) Two (2) Power Connector (J13) Kits (see Table 4) Two (2) PWM (Valve Coil) Drivers Harnesses (J7) Two (2) Engine Throttle Connector (J5) Kits Two (2) Engine Speed Sensor Harnesses Two (2) Miscellaneous Bridge Signals Connector (J8) Kits Two (2) Controller Communications Harnesses Communication One (1) Communications Harness Harness Two (2) J1939 T-Connector Receptacles Assembly (J10) * Two (2) Terminating Resistor Plugs * Required for multiple engine systems
19
Introduction
Table 3. Typical Speed Sensor Types

Single Output Magnetic Pickup Sensors are available with various thread sizes and connectors
TD10102
Dual Output Magnetic Pickup* Sensors are available with various thread sizes and connectors
TD10003
Tachometer Generator with Drive Tang
* One sensor is required for each engine. One output can be used for EC300 input and the other output can be used for instrumentation. The dual-output pickup can be installed in place of existing pickups if both are electrically compatible.
One (1) engine speed signal generator or sensor is required per engine. Note: All engines must use speed signal generators of the same type, model, and part number. Table 4. Hook-Up Wire Color Codes as per ABYC Standard E-9
Color Code Yellow with red stripe Purple Yellow (preferred) or Black Red Green with Yellow stripe (preferred) or Green
20
Function Neutral Start Relay Contacts (J5 pins 9 & 10) Ignition Switch (J8 pin 1) Battery negative (-) (J13 pin 3) Battery positive (+) (J13 pin 1) Auxilliary Battery positive (+) (J13 pin 2) DC Grounding Conductors or Bonding Only
Introduction
Additional Materials
Installation requires the following supplies that are not furnished with the basic control system: Note: Use 6.35 mm (0.25 in) maximum fastener diameter to mount the control(s). o o Brackets, fasteners, and other hardware for mounting the components Wire terminal lugs, cable ties, cable clamps, insulating materials, and other electrical hardware (Refer to General Installation Guidelines for more information about the electrical hardware requirements.) Note: Table 4 provides color code requirements for those vessels subject to American Boat & Yacht Council (ABYC) Standard E-9 requirements. o Hook-Up Wire, stranded copper (19 strands or more); 14 AWG (15 amps max.) unless otherwise specified; rated for 50 VDC, conforming to UL 1426 Cables for Boats or other applicable standards; marked with type/ style, voltage, size, and dry temperature rating; color coded as shown in Table 4.
Other Items Which May Be Required

One or more of the following components may be required depending upon the options ordered.
Installations Requiring Four to Six Control Stations

o Station Doubler _____ One (1) Station Doubler is required for installations with four (4) control stations. _____ Two (2) Station Doublers are required for installations with five (5) control stations. _____ Three (3) Station Doublers are required for installations with six (6) control stations.
21
Introduction
o o
Control Head to Station Doubler Harness, length must be specified, one (1) harness per Control Head Station Doubler to Control Harness, length must be specified, one (1) harness required per Station Doubler Note: Use 6.35 mm (0.25 in) maximum fastener diameter to mount the Station Doubler(s).
Brackets and hardware for mounting the Station Doubler(s)
Substituting Split Single Lever Control Heads for a Dual Lever Control Head in Twin Engine Installations
o o o o Port Single Lever Control Head, one (1) required for each Dual Lever Control Head being replaced Starboard Single Lever Control Head, one (1) required for each Dual Lever Control Head being replaced Port Single Lever Harness, length must be specified, one (1) required per split lever station Starboard Single Lever Harness, length must be specified, one (1) required per split lever station
22
Introduction
Installations With a Servo Actuator Option

Note: Each EC300 Control System supports only one Servo Actuator for mechanical control. This Servo Actuator may be used to control a mechanical throttle, a mechanical gear selector, or a mechanical trolling valve with push-pull cable. Note: The maximum diameter for fasteners to mount the Servo Actuator is 6.35 mm (0.25 in). o o o o o Servo Actuator (12 VDC or 24 VDC must be specified), one (1) for each EC300 Control using a mechanical control output Brackets and hardware for mounting the Servo Actuator Servo Actuator Harness (J11), length must be specified, one (1) for each EC300 Control using a mechanical control output Brackets and hardware for mounting and connecting the Servo Actuator Harness Push-Pull Cable, Morse 33 Series RED JAKET Supreme or equivalent, one (1) required for each mechanically operated control, length of cable depends on distance between components and routing of cables Note: Isolated and Non-Isolated quick-disconnect ball joint and clamp kits for Morse 33 series push-pull cables are available from Twin Disc. See Push-Pull Cable Installation Kits for Conductive Vessels and Push-Pull Cable Installation Kits for Nonconductive Vessels. One kit will accommodate one end of one cable. (For example, a mechanical troll control in a twin engine installation would require two (2) kits to mount and connect the cables to the two Servo Actuators.) The kits do not include mounting brackets needed to secure and clamp the push-pull cable to the engine or transmission. Note: Morse 33 series cable mounting dimensions are given in the Engineering Drawings section to aid in bracket fabrication. o Brackets and hardware for mounting the push-pull cable
23
Introduction
Installation In Starter Solenoid Circuits Greater Than 5 Amps

o Relay, Normally Open (NO) Single Pole Single Throw (SPST), coil voltage rating equal to the starter solenoid voltage, contact current rating greater than the starter solenoid current, one (1) required per control, customer supplied
Push-Pull Cable Installation on Nonconductive Vessels

o Insulated push-pull cable mounting hardware may be necessary to satisfy bonding or isolation requirements, especially if the engine block is not grounded. Single and Dual Nylon Installation Kits are available. Consult Twin Disc Incorporated or a local distributor for further information or to order insulated push-pull cable mounting hardware
Master or Phantom Switch Installations

Note: Switches and controls must be marked to indicate the usage. Most switch manufacturers provide legend plates for their switches. o Toggle switch, DC Current rating greater than 0.5 amps, one (1) required if either switch is used
24
Introduction
Twin Disc Display Installations

o o Twin Disc Display, at least one (1) required for each EC300 Control Twin Disc Display Harness Assembly (J9), length must be specified, one (1) required per display
Installations With Engine Room Analog Sensor Inputs Or Transmission Output Speed Sensor Input
o o Engine Room Analog Harness (J6), length must be specified, one (1) required per EC300 Control Connector Kits for customer supplied cables are available from Twin Disc Inc. to make connections at Control End (J6)
Installations With Engine Room Switch Contact Inputs

o Engine Room Switch Harness (J12), length must be specified, one (1) required per EC300 Control
Maximum Electrical Harness Lengths
CAUTION
Do not add additional wire to any harness. Longer harnesses may require thicker conductors. Wiring Harnesses for the EC300 Control System have specified maximum lengths that must be considered when mounting the Controls, Servo Actuators and Station Doublers. Harnesses are available in varying lengths in 0.6 m (2 ft) increments. Specific information will be needed about the length of the boat, the number of stations, and the nature of any options.
25
Introduction
26
Component Installation
General Installation Guidelines

EC300 Control Systems should be mounted near the engines in a location reasonably free from direct splash and spray, and protected from mechanical abuse. When selecting the location for mounting the components, consideration should be given to any push-pull cable routing in order to avoid sharp bends or excessive lengths. The mounting surface should be flat, or shimmed so that the control enclosure is secured without distortion to the bottom plate. Controls should not be mounted on the engines unless they are protected by a heat shield and mounted to a vibration-damped plate. Ensure a suitable location is chosen for mounting the EC300 Control(s), Control Head(s), Twin Disc Display(s), and any other components. Choose a location that meets the following criteria: q q q q q q q q q q It is not on any drivetrain component. It is away from heat sources. It is clear of service and access areas. It is away from AC power and high current conductors. It is protected from submersion or splash. It will not provide a step for personnel. It is a minimum of 1 m (3.3 ft) away from alternators, generators, communications equipment, and associated leads. It is away from high vibration. It provides easy access for routing, connecting, and adjusting the pushpull cable, if used. It is convenient for accessing the electrical connections.
27
Control equipment and instrumentation are to be so placed or protected as to minimize the likelihood of sustaining damage from the condensation of moisture, accumulation of dust, oil vapors, steam, dripping liquids, or from activities around their location.
There are other factors to consider when choosing a mounting location for the EC300 Controls and Servo Actuators. Push-pull cable installation should meet the following criteria: q q q q q Cables should be minimum length possible. Any bends should have the maximum possible bend radius. Refer to cable manufacturers specifications. Cables must be located away from hot surfaces. Cables must be clear of service or access areas. Cables must be Morse Series 33 RED JAKET Supreme or equivalent.
Electrical wiring and routing should meet the following criteria: q q q q q q q Wiring must be minimum practical length. Wiring must be located away from high current conductors and devices. Wiring must be located away from hot surfaces. Wiring must be clear of service and access areas. Wiring should be at least 1 m (3.3 ft) away from communications equipment, antennas, and associated leads. Wiring should be at least 1 m (3.3 ft) away from alternators, generators, and ignition systems. Wiring should have drip loops where required, especially at the controls.
28
Use the correct fasteners and mounting hardware as follows: q q q Use any fasteners and mounting hardware as supplied from Twin Disc Incorporated with the component. Use stainless steel fasteners unless otherwise specified. Use lock washers as specified, but only use them once. Install new lock washers, if required.
29
EC300 Control Installation

Note: The EC300 Control can be mounted in any orientation on a flat surface.
TD10009
Figure 1. Preferred Mounting Arrangement for EC300 Control
1.
Locate a solid, flat surface where the three enclosure mounting feet contact and are parallel to the mounting surface. Note: All mounting hardware must be corrosion resistant.
2.
If required, fabricate brackets, shims, or spacers in order to provide a flat surface. Note: Refer to the EC300 Control Mounting Dimensions drawing (1020676) in Engineering Drawings.
3.
Mark and drill three (3) mounting holes for the 6.35 mm (0.25 in) mounting hardware. Note: Place lock washers under the mounting screw heads.
4. 5.
Mount the control using three (3) sets of fasteners and lock washers. Tighten fasteners up to 1.13 Nm (10 in-lb) maximum.
Electrical Installation contains wiring instructions for the EC300 Control System.
30
Control Head Installation

A control station is a location from which the boat can be operated. A control station will consist of one or more Control Heads. Each control station requires the installation of a Control Head and associated wiring harnesses. The control station may consist of a single or dual lever Control Head, multiple Control Heads, or side mount Control Head Assembly. There are separate instructions for the single/dual lever Control Head and the side mount Control Head Assembly. Note: Only EC300 Control Heads will work with the EC300 Control. The older EC200 Control Heads are not compatible. Note: Chrome plated Control Heads should be polished periodically using a chrome polish to help retard corrosion.
Single/Dual Lever Control Head

The Control Head may be either a single or dual lever version. This installation procedure applies to both versions.
STBD LEVER PORT LEVER
NEUTRAL INDICATOR LED (2 PLACES)

IN IS N ER IO . IFT SIT ON SH PO OR S AR AL AT ES GE UTRINDIC L PR NE EN OL EX TR WH C
R
B ST D
STATION SELECT BUTTON
N SY E UIS CR
MODE SELECT SWITCH STATION SELECT INDICATOR LED (2 PLACES)

TD10010
RT PO
N IO AT T ST LEC SE
TW
D IN
ISC
P0
RC WE
M OM
0 30 EC ER D AN
TD10103
Figure 2. Front View of Dual Lever Control Head With Levers in Neutral Position
31
Note: If this is a new installation, ensure that all required components are properly located before cutting the first hole. Other components that may require installation include a display, an ignition switch or instrumentation gauges. Note: At least 25.4 mm (1 in) of clearance is required at both ends of the lever travel for the operators hands (see Figure 3). Clearance must be provided beneath the Control Head to accommodate the base, an electrical connector and a harness. The Control Head should be installed at least 1 m (3.3 ft) away from any communications equipment and associated leads.
TD10011
Figure 3. Side View of Control Head With Lever Clearance Shown
1.
Select a mounting location that is flat, readily accessible, permanent, and solid. Note: The template is direction specific. Ensure that the ahead direction on the template is pointing toward the bow in order to ensure that the forward motion of the lever is directed ahead.
32
2. 3. 4. 5.
Cut out the Control Head Mounting Template in Engineering Drawings and tape it in the desired location. Make sure this position provides clearance for the operators hands over the full range of lever travel. Center punch the four (4) mounting holes and scribe the base cutout outline. Remove the template. Note: The hole cannot be smaller than shown on the template and must be properly aligned with the mounting holes.
6. 7. 8. 9. 10. 11. 12.
Drill and cut the holes using the template markings. Check the hole locations with the template. Remove any splinters or sharp edges from the holes. Carefully place the Control Head in the hole. Check the fit of holes. Remove the Control Head from the cutout. If required, correct the fit. Note: Drag adjustment is provided at each lever. Proper adjustment is necessary to ensure that the lever remains in the intended position without operator assistance.
13.
Set drag per Control Head Lever Drag Adjustment.
33
Side Mount Control Head Assembly (Binnacle/Console Station)

The side mount Control Head Assembly consists of a Lever, Interface Assembly, Interface harness and Selector Assembly. The lever may be supplied by Twin Disc or other sources. Specific lever attachment instructions should be supplied with the lever and the lever must be capable of attaching to the 15.87 mm (0 .625 in) diameter shaft of the Interface Assembly. The Interface Assembly comes with a mounting plate for sandwiching the console wall between the assembly and the mounting plate. The Selector Assembly mounts directly to the surface of the console. 1. Locate a position on the side of the console which provides the operator with unrestricted access to the lever(s), while providing full range (70 degrees either side of neutral) of lever motion. Locate a position on the top or front surface of the console which provides unrestricted access to the Selector Assembly indicators and Mode Select Switch. Confirm that the desired location will allow the Interface Harness to reach between the Interface Assembly and the Selector Assembly.
2.
TD10200
Figure 4. Side Mount Control Head Assembly
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3.
Cut out the Interface Assembly Mounting Template and Selector Assembly Mounting Template in Engineering Drawings and tape in the selected positions. Note that for twin engine applications, the Starboard Interface Assembly is rotated 90 degrees from the Port Interface Assembly. See Figure 4. Using the templates, mark all necessary holes and cutouts. Drill and cut the holes using the template markings. Check the hole locations with the template. Remove any splinters or sharp edges from the holes. Check the fit of the holes by carefully inserting the Interface and Selector assemblies. Correct the fit as necessary.
4. 5. 6. 7. 8. 9.
TD10201
Figure 5. Interface Mounting 10. 11. Install the Selector Assembly using the gasket and stainless steel hardware provided with the unit. Install the Interface Assembly/Assemblies using the mounting plate and stainless hardware provided.
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12. 13.
Connect the Interface Harness between the Interface Assembly and the Selector Assembly and secure/strain relieve as necessary. Attach the Lever to the 15.87 mm (0 .625 in) diameter shaft of the Interface Assembly, following the instructions provided with the lever.
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Control Head Lever Drag Adjustment
TD10013
Figure 6. Drag Adjustment Screws for Single/Dual Lever Control Head
Figure 7. Drag Adjustment Screws for Side Mount Control Head Assembly Note: 0.45 to 0.91 kg (1 to 2 lb) average drag is normally desirable. 1. Insert an 1/8 in. hex key wrench into the base opening for each lever. See Figure 6. Note: See Figure 7 to access side mount lever drag adjustment screw.
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2.
Tighten the drag adjustment screw(s) until the desired drag is obtained over the full lever travel. Note: All fastening hardware must be corrosion resistant. Note: The type of fastener to be used depends on material used for the support. Each Control Head is supplied with stainless steel 38 mm (1.5 in) screws suitable for mounting in a dash up to 19 mm (0.75 in) thick. Use the appropriate fastener for the specific installation.
3. 4.
Install and mount the Control Head using the supplied gasket and four (4) oval head #10 screws or equivalent. Torque the fasteners to 1.13 Nm (10 in-lb) maximum.
Control Head Harness (J1, J2, or J3) Installation addresses Control Head harness wiring installation.
38
Station Doubler Installation

Station Doublers are used for installations requiring four (4) to six (6) Control Heads per control. One (1) Station Doubler is required if four (4) Control Heads are used. Two (2) are required for five (5) Control Heads. Three (3) are required for six (6) Control Heads.
TD10012
Figure 8. Station Doubler Top and Side Views 1. Locate a solid, flat surface where the mounting pads contact and are parallel to the mounting surface. Note: All mounting hardware must be corrosion resistant. 2. If required, fabricate brackets, shims or spacers in order to provide a flat surface. Mark and drill four (4) mounting holes for the 6.35 mm (0.25 in.) mounting hardware. Note: Place lock washers under the mounting screw heads. 4. Mount the Station Doubler using four (4) sets of fasteners and lock washers. Tighten the fasteners to 1.13 Nm (10 in-lb) maximum.
3.
5.
Multiple Station Dual Lever Control Head Wiring Installation addresses Station Doubler harness installation.
39
Engine Speed Sensor Installation

Installations with options such as engine syncronization (Sync Mode), Express Mode, and Troll Mode (with speed feedback) require engine speed sensors. There are many types of sensors available. Many will work with the EC300 Control System. This section outlines the installation of the sensors available from Twin Disc. Contact Twin Disc Incorporated or the nearest distributor for the possible use of other sensors. The following speed signal generators are covered: q q Speed Sensor including the use of a dual output Speed Sensor Tachometer Signal Generator
Speed Sensor Installation

Note: Newer Twin Disc Incorporated transmissions have integrated input speed sensors as a standard option. The Speed Sensor is a cylindrical-threaded component that screws into each engine flywheel housing. It is triggered by the crown of the ring gear teeth on the engine flywheel when the engine is running. See Figure 10. The Speed Sensor produces an output signal with a frequency of one pulse per gear tooth. The EC300 Control software converts the individual pulse signals into revolutions per minute (rpm). The number of teeth on the gear must be known in order for the software to be properly configured.
TD10015
Figure 9. View of Typical Single and Dual Output Speed Sensors
40
Note: Single output Speed Sensors are preferred. See Figure 9. Dual output Speed Sensors are acceptable if the outputs are electrically isolated from each other and have the required electrical characteristics.
TD10014
Figure 10. View of Mounting Hole in Flywheel Housing for the Speed Sensor Note: Some engines have pre-drilled and plugged sensor mounting plates that may eliminate the need to drill into the flywheel housing. Consult the engine manufacturer if a mounting hole must be added. Note: Some engines have Speed Sensors already installed in the flywheel housings for the engine tachometers. An existing single output sensor may be replaced with a dual output sensor in order to eliminate the need to add any holes. Note: The number of teeth on the flywheel must be known. If required, count the teeth. 1. Bump the engine starter until the crown (top) of a gear tooth is visible in the center of the hole. See Figure 10.
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CAUTION
Do not use too much oil. Dirt will collect on the sensing face and make the Speed Sensor malfunction. 2. 3. 4. Coat the Speed Sensor threads with a very thin film of oil. Install the Speed Sensor in the hole finger-tight against the ring gear. Back out the Speed Sensor one-half turn and tighten the lock nut to 4.52 Nm (40 in-lb) maximum against the flywheel housing while holding the Speed Sensor body in place. If using a dual-output Speed Sensor, reconnect the original signal cable to one of the sensor outputs.
5.
Cable installation is completed in Electrical Installation.
Tach Signal Generator Installation

Tach signal generators will also work with the EC300 Control System. The tach signal generator must be capable of generating an AC signal with a frequency that is proportional to speed. Use a generator that provides the highest frequency possible. A minimum of 15 cycles per crankshaft revolution is required. Twin Disc, Incorporated has a 30 pulse per revolution tach signal generator available. The output amplitude of the tach signal generator must be a minimum of 1.5 volts RMS AC.
TD10017
Figure 11. View of Tach Signal Generator
42
Note: Mechanical drive components that are necessary to convert an existing tach sender drive to a dual tach sender drive must be ordered from the accessory supplier identified on the existing tach sender.
CAUTION
The tach signal generator output used for the EC300 Marine Control System cannot be used to provide signals to other devices on the vessel. The signal generator output used must be connected directly to the EC300 Control. Install the tach signal generator as per the manufacturers instructions. Reference Engine Control Harness Installation for Cable Installation. Note: The number of pulses per revolution must be known in order for the EC300 control software to be properly configured.
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Servo Actuator Installation

Marine control systems can have different combinations of electronic and mechanical controls for operation of the throttle, gear shifter, and trolling valve. The EC300 Control System supports one servo actuated device per control. The Servo Actuator can be mounted in any orientation on a flat surface. See Figure 12. The Servo Actuator (12 VDC or 24 VDC) should be located within the reach of the supplied harness and as close to the engine/transmission as practical.
TD10019
Figure 12. Preferred Mounting Arrangement for Servo Actuator The Servo Actuator will accommodate a total push-pull cable stroke of 41 to 84 mm (1.6 to 3.3 in). It will provide a maximum of 24 kg (53 lb) force at the innermost point on the lever and a maximum of 11.3 kg (25 lb) at the outermost point on the lever. 1. Locate a solid, flat surface where the mounting rails contact and are parallel to the mounting surface. Note: Refer to Servo Actuator Dimensional Drawing in Engineering Drawings for mounting dimensions. Note: Use 6.35 mm (0.25 in) diameter fasteners.
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Note: All mounting hardware must be corrosion resistant. 2. If required, fabricate brackets, shims or spacers in order to provide a flat surface. Mark and drill the four mounting holes for the 6.35 mm (0.25 in) mounting hardware. Note: Place lock washers under the mounting screw heads. 4. 5. Mount the Servo Actuator using four sets of fasteners and lock washers. Install the push-pull cable. See Push-Pull Cable Installation.
3.
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Push-Pull Cable Installation

Introduction
Correct push-pull cable installation will aid in trouble-free operation and maintenance of the control system. Different installation kits are available. Using quick-disconnect ball joints will aid in push-pull cable adjustment. This section contains the following sub-sections: q q q q Push-Pull Cable Installation Kits for Conductive Vessels Push-Pull Cable Installation Kits for Nonconductive Vessels Push-Pull Cable Installation Guidelines Push-Pull Cable Installation
Push-Pull Cable Installation Kits for Conductive Vessels

Quick-disconnect ball joint kits or terminal eye pins with cable clamps for Morse 33 series push-pull cables are available from Twin Disc Incorporated. See Figure 13 and Figure 14. The dual kit accommodates one end of two cables. The single kit accommodates one end of one cable. Each Servo Actuator requires a single kit to connect the cable to the Servo Actuator. Refer to Morse 33 Series Cable Mounting Dimensions in Engineering Drawings for additional information.
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TD10053
Figure 13. Installing Cable Clamp on Servo Actuator for Conductive Vessels
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TD10054
Figure 14. Installing Ball Joint Assembly for Conductive Vessels
Push-Pull Cable Installation Kits for Nonconductive Vessels

There is a possibility that high-powered electronic equipment used on vessels built in glass reinforced plastic (fiberglass), wood, or other nonconductive material can produce radio frequency interference to these controls. A major source of interference can be eliminated by insuring there are no bond connections which loop through the engine block or transmission via pushpull cables.
CAUTION
If isolation components are used on any component of the EC300 Control System, they must be used on all components.
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For nonconductive vessels, isolating installation kits with cable clamps and terminal eye pins must be used to isolate the Servo Actuator from push-pull cables. See Figure 15 and Figure 16. One kit is required to attach the cable to each Servo Actuator. Consult Twin Disc Incorporated or a local distributor about any substitutions or alterations. Refer to Morse 33 Series Cable Mounting Dimensions in Engineering Drawings for additional information.
Figure 15. Installing Cable Clamp on Servo Actuator for Nonconductive Vessels
TD10023
Figure 16. Installing Terminal Eye Pin for Nonconductive Vessels
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Push-Pull Cable Installation Guidelines

Push-pull cable installation should meet the following guidelines: q q q q q Cables must be Morse 33 Series RED JAKET Supreme or equivalent. A minimal number of bends should be used. Bends should use the maximum possible radius where bends are required. Cables should not be routed near hot surfaces. Cables should not be routed in service or access areas.
Push-Pull Cable Installation

This section describes how to install the push-pull cable for a mechanically shifted transmission, for a mechanically controlled throttle, and for a mechanically controlled troll actuator.
TD10024
Figure 17. Servo Actuator Push-Pull Cable Installation
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The transmissions gear select actuator is a three-position device: 45 degree left, center, and 45 degree right. See Figure 18. The control will drive the Servo Actuator to these positions as commanded by ahead, neutral, or astern commands from the operators lever. The push-pull cable positions the gear select actuator in the desired position.
TD10210
Figure 18. Transmission Gear Select Actuator
The engines throttle actuator is a two-position device with continuous control between the two end positions. The nominal end positions are at 45 degrees left and 45 degrees right. See Figure 19. The control will drive the Servo Actuator between these positions as commanded by the lever position at the Control Head. The push-pull cable positions the throttle actuator in the corresponding position.
TD10211
Figure 19. Engine Throttle Actuator
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The transmissions troll valve actuator is a two-position device with nominal positions at 45 degree left and 45 degree right rotation. See Figure 20. The Control will drive the Servo Actuator to these positions as commanded by lever position at the Control Head. The push-pull cable positions the troll valve in the desired position.
TD10212
Figure 20. Transmission Troll Valve Actuator
Note: Neither the engines nor the transmissions push-pull clamp and bracket are supplied. Note: This process should be read and understood prior to installation of Servo Actuator and related components, to ensure all component mounting positions are located properly and all necessary materials are available for complete installation. 1. Fabricate push-pull cable mounting bracket as needed, to attach/clamp the cable to the engine or transmission. The critical dimension is 7.25 inches from centerline of clamp mounting holes to centerline of engine/ transmission lever. See Figure 21. Secure bracket to engine/ transmission.
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TD10213
Figure 21. Push-Pull Cable Mounting Bracket
CAUTION
Bracket must be located to allow the most direct and unrestricted movement of push-pull cable. Bends, kinks, and tight or multiple radii will cause premature wear and undesirable engine/transmission response. 2. The Servo Actuator end of the push-pull cable may be adjusted for a range of travel from 1.5-3.5 in. Loosely attach the cable at the engine/ transmission using a mounting hole which allows for a cable travel within the 1.5-3.5 in range. In rare instances, modifications to the engine/ transmission lever are required to meet this range of travel. (For example: If the travel is less than the 1.5 in, then the engine/transmission lever may need to be lengthened, or an additional hole added to the existing lever.) Loosely attach the other end of the push-pull cable to the Servo Actuator. Confirm that the cable travel is within the 1.5-3.5 in range and tighten the engine/transmission end. (Leave the Servo Actuator end loose for the following steps of alignment.)
CAUTION
To make final adjustments/alignment of the push-pull cable, the following steps must be completed with power applied to a functioning control system. All power wiring and Control System checks should be made prior to proceeding with the following steps. These steps must NOT be done with power off, as this will create misalignment of the pushpull cable and the Servo Actuator. Disconnect the quick connect on the push-pull cable from the Servo Actuator lever.
EC300 Marine Control System Installation Manual #1020607 53
3.
The Control Head levers and Mode Select Switch will have to be manipulated for the following activities. Power up the Control System and take command of the Control Head. Use the Control Head closest to where the Servo Actuator is located, or have one person command the Control Head while another monitors and adjusts the push-pull cable at the Servo Actuator.
Engine Servo Actuator (Throttle): A: Position Control Head lever for Idle/Neutral. The Servo Actuator lever will move to the idle position. B: Position engine lever to Idle. The attached push-pull cable will move accordingly. C: Make note of the push-pull cable position at the Servo Actuator end, comparing the location of the cable end to the Servo Actuator lever. Using a piece of tape and pen/marker, mark the Servo Actuator with the position of the cable end. D: Repeat with the Control Head lever in Full Throttle position. The Servo Actuator lever will move to the full throttle position. Transmission Servo Actuator (FWD/NEU/REV): A: Position Control Head lever for Forward Detent. The Servo Actuator lever will move to the Forward position. B: Position the transmission lever to Forward Detent. The attached push-pull cable will move accordingly. C: Make note of the push-pull cable position at the Servo Actuator end, comparing the location of the cable to the Servo Actuator lever. Using a piece of tape and pen/marker, mark the Servo Actuator with the position of the cable end. D: Repeat with the Control Head lever in the Reverse Detent. The Servo Actuator will move to the Reverse position. Note: When you adjust the push-pull cable travel for Forward and Reverse positions, Neutral will automatically be centered. However, you cannot adjust the push-pull cable for Neutral and then assume the Forward and Reverse positions will be aligned.
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Transmission Servo Actuator (TROLL): A: Position Control Head lever for Neutral Detent and the Mode Select Switch to TROLL. The Servo Actuator will move to the Full Slip/Troll position. B: Position the transmission trolling lever to Full Slip/Troll. The attached push-pull cable will move accordingly. C: Make note of the push-pull cable position at the Servo Actuator end, comparing the location of the cable end to the Servo Actuator lever. Using a piece of tape and pen/marker, mark the Servo Actuator with the position of the cable end. D: Repeat with the Control Head Mode Select Switch in CRUISE. The Servo Actuator will move to the Lockup/Cruise position. 4. Compare your marks of the positions of the push-pull cable to the Servo Actuator, with the following diagrams. Use these diagrams and the associated instructions to adjust/align the cable attachment at the Servo Actuator lever. As adjustments are made, repeat step 3 to confirm results of adjustments. Several adjustments and checks may be necessary before achieving final alignment. Final alignment should be when the Servo Actuator lever is unrestricted to move to its positions, while moving the engine/transmission lever to its proper positions without bottoming out against the engine/transmission end stops. When final alignment is complete, make sure all related clamps and hardware are tight. A: When the travel of the Servo Actuator lever is wider than the travel of the push-pull cable, adjust by moving the attachment for the cable on the Servo Actuator lever down towards the shaft of the actuator. See Figure 22.
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TD10214
Figure 22. Adjustment of Cable Attachment B: When the travel of the Servo Actuator lever is narrower than the travel of the push-pull cable, adjust by moving the attachment for the cable on the Servo Actuator lever up and away from the shaft of the actuator. See Figure 23.
TD10215
Figure 23. Adjustment of Cable Attachment
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C: When the travel of the Servo Actuator lever and push-pull cable matches closely, however the cable will not reach to attach to the Servo Actuator Lever at both ends of travel, move the cable clamp inwards towards the actuator lever. See Figure 24.
TD10216
Figure 24. Adjustment of Cable Clamp - Short D: When the travel of the Servo Actuator lever and push-pull cable matches closely; however, the cable overshoots the Servo Actuator lever at both ends of travel, moving the cable clamp outwards away from the actuator lever. See Figure 25.
TD10217
Figure 25. Adjustment of Cable Clamp - Overshoot Note: Electrical harness installation for the Servo Actuator is completed in Electrical Installation.
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Twin Disc Display Installation
TD10025
Figure 26. Twin Disc Display Note: Ensure that all items are located for installation on the dash or control panel before cutting the first hole. Note: One (1) display is provided as an option for each EC300 Control. Multiple displays may be provided to support multiple control stations. Note: The Twin Disc Display is designed to mount from the front through a 3.2 to 19 mm (0.125 to 0.75 in) thick panel or dash. See Twin Disc Display Mounting Dimensions (1018791) in Engineering Drawings. The mounting bracket is installed from the rear. Wiring should be connected while the display is accessible. 1. 2. 3. 4. 5. 6. Locate a position on the dash or control panel for the display. Using the appropriate cutting tools, cut a 54 mm (2.125 in) hole. Round off any sharp edges and remove any burrs. Remove the mounting bracket and nuts from the rear of the display. Ensure that the display will fit in the hole. Install gasket on display.(See Twin Disc Display Harness (J9) installation for wiring instructions.)
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7. 8. 9.
Insert the display in the dash or control panel. Attach the mounting bracket and tighten the nuts until the display is firmly secured in the dash. If applicable, repeat steps 1 through 8 for each additional display.
Twin Disc Display Harness (J9) Installation addresses display harness wiring installation.
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Lever Function Switch Installation

The lever function toggle switch is used in certain applications for the EC300 Control System. The switch can be used to enable Master Lever or Phantom lever modes depending upon the selected options. This instruction provides information related to the installation of a typical toggle switch. Refer to the manufacturers literature for any custom switch installation requirements. Note: Ensure that all items are located for installation on the dash or control panel before cutting the first hole. Note: The typical toggle switch is designed to mount from the rear of the panel or dash. The mounting nut is installed from the front.
TD10026
Figure 27. Typical Enable Toggle Switch 1. 2. 3. 4. 5. 6. Locate a position on the dash or control panel for the switch. Using the appropriate cutting tools, cut a mounting hole of the required size. Round off any sharp edges and remove any burrs. Remove the mounting nut from the front of the switch. Insert the switch and any legend plate in the dash or control panel. Install and tighten the nut until the switch is firmly contacting the dash or panel.
Lever Function Switch Wiring addresses Miscellaneous Bridge Signals Connector Kit (J8) wiring installation.
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Electrical Installation
Introduction
Harnesses and Connectors
The EC300 Control System is provided with prefabricated cable harnesses with pre-installed connectors in order to reduce installation time and errors. In some cases, only the EC300 end of the harness has a pre-installed connector. In other cases, the EC300 connector is supplied by Twin Disc Incorporated and the cable and far-end connectors are supplied by the customer. Note the following when making connections: q The installer must provide suitable wire cable and crimping tools, Deutsch crimp tool (P/N HDT 48-00). Use all tools and materials in accordance with manufacturers instructions. See Required Tools and Table 4. The installer must follow the print provided for the system. Cables should never be installed in a manner which puts strain on the connector or which results in more than 610 mm (24 in) of excess length. A service loop or drip leg should be provided in each cable at the EC300 Control. Service loops should be tied down so that they do not move freely when the boat is in motion. Excess motion can cause the wiring to fatigue and break. The connectors have a resilient insert that seals to the insulation of each wire in the connector. Do not attempt to fit two wires into any of the connector positions. Sealing plugs are provided for unused positions of the connector in order to insure the sealed nature of the connected cable assembly. Do not discard these white plastic plugs since they must be inserted into the unused positions. For harness kits that require field termination by the installer, tape and secure the ends of any unused wires. Note: Harnesses supplied by Twin Disc Inc. will not include any unused wires.
q q q
To connect a harness to an EC300 Control, align the harness plug with the EC300 Controls receptacle and push the plug in until it snaps in place.
Electrical Isolation
CAUTION
When making the electrical connections described in this section, ensure that the associated power source is turned off. Ensure that the EC300 Control Power and Grounding Harness (J13) connector is disconnected before proceeding with the installation of wiring.
Power Wiring Requirements

The following criteria must be met when installing power distribution wiring for US installations: q Low voltage conductors must comply with SAE standards J1127 Battery Cable or J1128 Low Tension Primary Cable. The insulation temperature rating must meet the requirements of SAE J378 Marine Engine Wiring or UL 1426 Cables for Boats. Electric cables must be constructed of stranded copper conductors, thermoplastic, elastomeric or other insulation, moisture-resistant jackets, and, where applicable, armor and outer-sheathing are to be in accordance with IEC Publication 60092-353, IEEE 1580-2001 or other marine standards acceptable to the American Bureau of Shipping (ABS). All electrical cables for power circuits are to have insulation suitable for a conductor temperature of not less than 60C (140F). Maximum current carrying capacities of cables conforming to IEC Publication 60092-353 are to be in accordance with the values given in 4-8-3/Table 6 of ABS Rules for Building and Classing Steel Vessels 2002. These values are applicable for cables installed double-banked on cable trays, in cable conduits or cable pipes. The values, however, are to be reduced for installations where there is an absence of free air circulation around the cables. See 4-8-2/7.7.1 and Note 4 of 4-8-3/Table 6 in the ABS document.
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Electric cables are to be flame retardant and must comply with the following requirements, as applicable: _____ Cables constructed to IEC Publication 60092 standards are to comply with the flammability criteria of IEC Publication 60332-3, Category A/F or A/F/R. _____ Cables constructed to IEEE 1580-2001 are to comply with the flammability criteria contained therein. _____ Cables constructed to other standards, where accepted by ABS, are to comply with the flammability criteria of IEC Publication 60332-3, category A/F or A/F/R (depending on the intended installation), or other acceptable standards. _____ Flame retardant marine cables which have not passed the bunched cable flammability criteria as per IEC Publication 603323 may be considered, provided that the cable is treated with approved flame retardant material or the installation is provided with approved fire stop arrangements.
Battery positive and negative power wires must be 14 American Wire Gauge (AWG) minimum (15 amps max.); stranded copper (19 strands or more); rated for 50 VDC, conforming to UL 1426 Cables for Boats or other applicable standards; should not be more than 3.6 m (12 ft) long; should be marked with type/style, voltage, size, and dry temperature rating; and should be color coded as shown in Table 5. Table 5. Power Wire Color Codes as per ABYC Standard E-9
Color Code Function Battery negative (-) (J13 pin 3) Battery positive (+) (J13 pin 1) Auxiliary Battery positive (+) (J13 pin 2) DC Grounding conductors or bonding only
Yellow (preferred) or Black Red Green with Yellow Stripe (preferred) or Green
Note: A fuse or circuit breaker is required at the battery or power distribution point for cable protection. The EC300 Control is internally protected. q Approved fuses or manual-reset trip-free circuit breakers must be used for the EC300 Control System power distribution wiring as per the applicable codes or standards.
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q q
A 15A fuse and fuse holder are supplied in the Power Connector Kit (J13). All fuses must meet the general provisions of Article 240 of the National Electrical Code or IEC 92-202, as appropriate, and have an interrupting rating sufficient to interrupt the maximum asymmetrical RMS short-circuit current at the point of application. Each fuse must provide for ready access to test the condition of the fuse. Unless otherwise permitted, the fuse or circuit breaker must be located within 178 mm (7 in) of the point at which the power conductor is connected. If the wire is continually sheathed or enclosed and if connected directly to a battery terminal, the distance may be up to 1,829 mm (72 in). If connecting downstream of the battery terminal the circuit protection must be within 1,016 mm (40 in) of the connection. Power distribution wiring must be insulated. Caps or boots are required at all terminals in order to prevent accidental shorts. Special requirements apply to vessels with gasoline, liquid petroleum gas (LPG), or Marine Compressed Natural Gas (CNG) engines or to vessels with hazardous areas. Power routing and wiring must meet all applicable codes and standards. Circuit components may have to be rated as Ignition Protected as per SAE J1171 External Ignition Protection of Marine Electrical Devices, UL 1500 Ignition Protection Test to Marine Products, and the electrical system requirements for boats in Title 33 CFR 183.410(a). The main power wires to the power/interface connector (battery + and battery -) must be routed directly to the battery or a primary distribution panel within 1 m (3.3 ft) of the battery, but not the starter feed. Do not connect the EC300 Controls battery + or - power input directly to the engine or any of its electrical components. Connect the control power wires to the battery for the engine controlled by the EC300 Control. Port engine controls should be connected to the port battery. Starboard engine controls should be connected to the starboard battery. Use a good quality connector to connect the power wires to the battery or bus bar and check the wires to be sure they are secure. Do not use simple spring-loaded connectors.
q q
q q
64
DC Distribution must be a two-wire system. Battery return wiring must be routed to the battery and not to the bonding system or the metallic hull. The negative side of the battery must be connected to ground if the system is to be grounded. The electrical load added by the EC300 Control System is not large. Current is limited to 15 amps at either 12 or 24 VDC. However, in some circumstances, this may require an increase in the capacity of the power distribution system, larger batteries, and/or larger grounding conductors. The customer is responsible for meeting the applicable code and standard requirements.
Neutral Start Interlock Wiring Requirements

All EC300 Control Systems include a Neutral Start Interlock feature for prevention of start-in-gear situations. The Neutral Start Interlock is a relay contact inside of the EC300 Control which is normally located in the engine room. The relay contact only closes when the system ignition is turned on, a Control Head is selected, and the lever for the selected Control Head is placed in the neutral position. Normally, the boat wiring routes the start command wire from the key switch or engine control panel through the EC300 Controls Neutral Start Interlock. If a bypass or override switch is desired, contact Twin Disc Incorporated or a local distributor for information related to specific installation requirements. Damage or injury that is caused by improper installation is not the responsibility of Twin Disc Incorporated or its distributors. The following criteria must be met when installing neutral start interlock wiring: q q These wires must be 14 AWG stranded copper. Neutral start interlock wiring must be connected to prevent the engine from starting with the gear selector out of the neutral position. If a hard wired transmission neutral switch is available, route the engine start signal through the switch. Route the wire from the ignition switch to the starter relay through the interlock contact connections provided via Engine Throttle Connector (J5). If more than 5 amps are required for the neutral start interlock circuit, a transfer relay must be installed using the diagram provided on the system installation drawing.
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Routing Requirements
The following criteria must be met when routing electrical wiring: q q Wiring must be the minimum practical length. Wire bend radii should be at least eight wire-diameters unless otherwise permitted.
CAUTION
Keep the EC300 system wires away from antenna wires and AC power wires. Do not route the EC300 control wires in the same trough or conduit as antenna or AC power wires. q Wiring must be located away from high current conductors and devices. Wiring must be at least 1 m (3.3 ft) away from communications equipment, antennas and associated leads. Wiring must be at least 1 m (3.3 ft) away from alternators, generators, and ignition systems. Wiring must be located away from hot surfaces or high-risk fire areas. Wiring must be clear of service areas, access areas, or other spaces where it may be exposed to mechanical damage. Where this cannot be avoided, special measures are to be made for effective protection of wiring. Wiring should have drip loops at each connection point as required to minimize water drainage toward the connector. Do not splice or substitute different types of wire into the harnesses. Increased length may require increased wire size. Any splices must meet the requirements of the applicable standards or specifications. Wiring is to be secured in such a manner that stresses are not transmitted to the connector terminal. Wiring and harnesses must be supported or secured every 406 mm (16 in) maximum with the appropriate hardware except if the wiring is enclosed in rigid duct, conduit, or other enclosure. The distance between cable supports are to be suitably chosen according to the type of cable
q q
q q q q q
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and the degree of vibration the installation is likely to be subjected to. For horizontal runs where cables are laid on tray plates, individual support brackets or hanger ladders, the distance between the fixing points may be up to 914 mm (36 in), provided that there are supports with maximum spacing as specified above. Increased support will be required for cable runs on weather decks where forces from sea water washing over the deck is expected. Alternatively, cable support systems complying with a recognized standard other than IEC 60092-352 may be used where the installed cables also comply with that standard. Specifically, cable support systems meeting the requirements of IEEE 1580-2001 may be used where IEEE 1580-2001 cables are installed. q Metallic cable clamps or supports are required if the failure of the support could cause a hazardous condition in the engine room, machinery rooms, or passageways. Clamps and supports shall not have sharp edges or rough surfaces that could damage the insulation. Special protective measures such as tape or other wrapping are required for metallic clamps or supports. Clips, saddles, and straps are to have surface area sufficiently wide and shaped that the cables are fixed tight without their covering being damaged. Non-metallic clamps and supports must be resistant to oil, gasoline, and water and shall have a temperature range of -34 to 121C (-30 to 250F). They shall be flame retardant in accordance with IEC Publication 60092-101. Where used for cables that are not routed on top of horizontal cable trays, suitable metal clips or straps are to be added at regular intervals not exceeding 2 m (6.6 ft) in order to prevent the release of cables during a fire. Do not use wire staples, as staples can damage the insulation and allow the conductor to break under stress. Where cables pass through watertight or fire-rated bulkheads or decks, the penetrations are to be made through the use of approved stuffing tubes, transit devices, or pourable materials in order to maintain the watertight or firetight integrity of the bulkheads or decks. These devices or materials must not damage the cable. Where cable conduit pipe or equivalent is carried through decks or bulkheads, arrangements are to be made to maintain the integrity of the water or gas tightness of the structure.
q q
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Cables are not to be installed behind, or imbedded in, structural insulation. They may, however, pass through such insulation at right angles. Cable conduit or recesses integral with B or C class fire-walls may be used for installing cables if the fire-walls are of an approved type and the installation prevents the propagation of smoke through the conduit. When cables pass through non-watertight bulkheads, decks or structural members, the length of the bearing surface for the cable is to be at least 6.4 mm (0.25 in). All burrs and sharp edges are to be removed. No cable is allowed to penetrate the collision bulkhead. The rated temperature of the cables insulating material is to be at least 10C (18F) higher than the maximum ambient temperature likely to be in the space where the cable is installed. To avoid possible signal interference, signal cables occupying the same wireway or conduit with power cables are to be effectively shielded.
q q
Bonding Requirements
The EC300 Control must be bonded. If used, the Station Doubler and the Servo Actuator must also be bonded. Note: Insulated push-pull cable mounting hardware may be necessary to satisfy bond/isolation requirements, especially if the engine block is not grounded to the battery negative. See Push-Pull Cable Installation Kits for Nonconductive Vessels. The following criteria must be met when making bonding connections: q The EC300 Control must be directly bonded to battery negative, bond rails, or hull plates. If the engine is grounded to the battery negative terminal, then the EC300 Controls bond connection should also be to the battery negative. If the vessel or engine has an independent bonding system, then the control should be bonded to the independent bonding system.
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Bond wires must be connected to one of the unpainted mounting surfaces of the EC300 Control, the Station Doubler, and/or the Servo Actuator. Any paint must be removed in order to make the bonding connection. The bond wire must be terminated with a ring lug that fits the fastener used to mount the component. The bonding conductor must be 14 AWG stranded copper wire with insulation that is colored green with yellow stripe (preferred) or green.
Wiring Connections
The following criteria must be met when making wiring connections: q All electrical connections must be made within waterproof enclosures or shall be watertight. Connections must be watertight if they can be immersed in water. Wiring connections must not damage the conductor. Metals used for connections shall be corrosion resistant. Terminal lugs shall be ring lug or captive spade styles and shall be sized to match the terminal and the conductor. Shanks shall be insulated unless used on a grounded conductor. Crimp lugs must be of equal or greater current rating than the wire. Cables stripped of insulation are to be sealed using heat shrink tubing in combination with insulating compound or sealing devices. Crimps must be made with a tool designed to operate with the lug/ contact. Crimps shall be able to hold 13.6 kg (30 lb) for one minute. Aluminum or unplated steel shall not be used for fasteners. Twist-on connectors, such as wire nuts, shall not be used. Solder may not be the only means of connection between two or more conductors or between a conductor and a connector.
q q q
q q q q q
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Any friction connectors or soldered connectors at components must meet the component manufacturers requirements as well as the applicable standards. No more than four conductors may be terminated at any single stud. Wires shall have sufficient freedom of movement to allow for removal, dressing, and tension relief. To avoid electromagnetic noise caused by circulating currents, the conductive shield and cable armor of signal cables is to be grounded only at one end of the cable.
q q q
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Control Head Harness (J1, J2, or J3) Installation

This section contains the following sub-sections: q q q q q q q Control Head Harness Routing Guidelines Multi-Station Single Lever Control Head Wiring Installation Multi-Station Dual Lever Control Head Wiring Installation Multi-Station Dual Lever Control Head Wiring Installation Using Station Doublers Split Single Lever Control Heads in Twin Engine Installations Without Station Doublers Control Head Wiring for Master Switch Applications Without Station Doublers Control Head Wiring for Phantom Switch Applications Without Station Doublers
Control Head Harness Routing Guidelines

Follow these guidelines when routing the Control Head harnesses: q q q q q q q q q Keep clear of service and access areas. Avoid hot surfaces. Avoid AC power and high current conductors. Avoid potential pinch or abrasion points. Use vertical or overhead surfaces for attachment if possible. Do not route across deck. Ensure that harnesses can be properly supported along their length. Arrange harnesses so that drip-loops are formed. Route harnesses at least 1 m (3.3 ft) away from communications equipment and associated leads.
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Multi-Station Single Lever Control Head Wiring Installation

This section is applicable to single engine applications with up to three Single Lever Control Heads.
TD10028
Figure 28. Single Engine Single Lever Control Head Wiring Each single lever harness is a single cable designed to connect to the Control Head at one end and to the EC300 Controls J1, J2, or J3 connector at the other end. Use Connector J1 if only one Single Lever Control Head is used. Use Connectors J1 and J2 if two Single Lever Control Heads are used. The most often used or the main Single Lever Control Head should be connected to Connector J1. Note: The Control Head may be removed from the dash if this facilitates making the connection. If it is removed, then reinstall it after the connections have been made.
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Note: The Control Head may be removed from the dash if this facilitates making the connection. If it is removed, then reinstall it after the connections have been made. Note: Provide enough length in the harness to allow removal of the Control Head in the future. Note: For each Control Head connector, align the large connector key with the large keyway and push the connector into place. Then, turn the connectors collar until engagement snap is felt. 1. 2. 3. 4. 5. 6. 7. Connect the circular connector end of the Control Head harness to the Control Station 1 Single Lever Control Head. Ensure that the Single Lever Control Head is firmly mounted. Route the Control Head harness to the EC300 Control. Connect the Control Head Harnesss plug at the J1 receptacle of the EC300 Control. If applicable, repeat Steps 1 through 4 for connecting the Control Station 2 Single Lever Control Head at the J2 receptacle of each EC300 Control. If applicable, repeat Steps 1 through 4 for connecting the Control Station 3 Single Lever Control Head at the J3 receptacle of each EC300 Control. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Multi-Station Dual Lever Control Head Wiring Installation

This section is applicable to dual engine applications with up to three Dual Lever Control Heads.
TD10029
Figure 29. Dual Engine Dual Lever Control Head Wiring Note: Each dual lever harness consists of two separate cables joined together at the Control Head end. On the other end, one cable end is marked PORT and the other cable end is marked STARBOARD. The cable end(s) marked PORT must route to the port control. The STARBOARD cable end(s) must route to the starboard control. Use receptacle J1 at both controls if only one Dual Lever Control Head is used. Use receptacles J1 and J2 if two Dual Lever Control Heads are used. Use the same J number receptacles from each Dual Lever Control Head at both the port and the starboard controls. The most often used or the main Dual Lever Control Head should be connected to the J1 receptacle of each EC300 Control.
Note: The Control Head may be removed from the dash if this facilitates making the connection. If it is removed, then reinstall it after the connections have been made. Note: Provide enough length in the harness to allow removal of the Control Head in the future. Note: For each Control Head connector, align the large connector key with the large keyway and push the connector into place. Then, turn the connectors collar until engagement snap is felt. 1. 2. 3. 4. 5. 6. 7. 8. 9. Connect the circular connector end of the dual lever harness to the Control Station 1 Dual Lever Control Head. Ensure that the Dual Lever Control Head is firmly mounted. Route the cable marked PORT to the EC300 Port Control. Plug the PORT cable into the J1 receptacle of the EC300 Port Control. Route the cable marked STARBOARD to the EC300 Starboard Control. Plug the STARBOARD cable into the J1 receptacle of the EC300 Starboard Control. If applicable, repeat steps 1 through 6 for connecting the Control Station 2 Dual Lever Control Head to the J2 receptacle of each EC300 Control. If applicable, repeat steps 1 through 6 for connecting the Control Station 3 Dual Lever Control Head to the J3 receptacle of each EC300 Control. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: The EC300 Controls communication harness assembly is shown in the Communication Harness (J10) Installation section of this manual.
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Multi-Station Dual Lever Control Head Wiring Installation Using Station Doublers
This section is applicable to multiple engine applications with more than three (3) Dual Lever Control Heads per EC300 Control. Up to six Control Heads can be used through the use of Station Doublers. Each Station Doubler combines the signals from two separate Control Heads and routes the combined signals to each of the EC300 Controls (J1, J2, or J3). Note: Station Doublers may also be used on single-engine Single Lever Control Head applications if more than three Control Heads are required. Single Lever Control Head station-to-doubler harnesses are used in place of the dual lever station-to-doubler harnesses. A port station-todoubler harness is used with a Port Control Head. A starboard station-to-doubler harness is used with a Starboard Control Head.
TD10055
Figure 30. Station Doubler Connection Using Dual Lever Control Heads
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Note: The Station Doubler Harnesses route between the Control Heads and the Station receptacles on the Station Doubler. The Dual Lever Harness routes between the CONTROL connector on the Station Doubler and the EC300 Control. Note: The Control Head may be removed from the dash if this facilitates making the connection. If it is removed, then reinstall it after the connections have been made. Note: Provide enough length in the harness to allow removal of the Control Head in the future. Note: For each Control Head connector, align the large connector key with the large keyway and push the connector into place. Then, turn the connectors collar until engagement snap is felt. 1. 2. 3. 4. 5. 6. 7. 8. 9. Connect the circular connector end of a station-to-doubler harness to the Control Station 1 Dual Lever Control Head. Ensure that the Control Station 1 Dual Lever Control Head is firmly mounted. Route the Control Station 1 station-to-doubler harness to the Station Doubler. Plug the cable marked PORT into the receptacle marked STATION A on the side of the Station Doubler marked PORT. Plug the cable marked STARBOARD into the receptacle marked STATION A on the side of the Station Doubler marked STBD. Connect the circular connector end of a station-to-doubler harness to the Control Station 2 Dual Lever Control Head. Ensure that the Control Station 2 Dual Lever Control Head is firmly mounted. Route the Control Station 2 station-to-doubler harness to the Station Doubler. Plug the cable marked PORT into the receptacle marked STATION B on the side of the Station Doubler marked PORT.
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10. 11. 12. 13. 14. 15. 16.
Plug the cable marked STARBOARD into the receptacle marked STATION B on the side of the Station Doubler marked STBD. Connect the circular connector end of a Dual Lever Control Head harness to the receptacle on the Station Doubler marked CONTROL. Route the cable marked PORT to the EC300 Port Control. Plug the PORT cable into the J1 receptacle of the EC300 Port Control. Route the cable marked STARBOARD to the EC300 Starboard Control. Plug the STARBOARD cable into the J1 receptacle of the EC300 Starboard Control. If applicable, repeat steps 1 through 15 to connect Station 3 and 4 Dual Lever Control Heads through a second Station Doubler to the J2 receptacles of the EC300 Port and Starboard Controls. If applicable, repeat steps 1 through 15 to connect Station 5 and 6 Dual Lever Control Heads through a third Station Doubler to the J3 receptacle of the EC300 Port and Starboard Controls. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: The bonding conductor must be 14 AWG stranded copper wire. It must be colored green with a yellow stripe (preferred) or green in order to comply with ABYC standards.
17.
18.
19.
Route a bond wire from the vessel bonding system to the selected mounting pad on each Station Doubler. See Figure 30. Note: The ring lug must be properly sized for both the wire and the mounting fastener.
20. 21. 22.
Install a ring lug on the control end of the wire. Remove the mounting fastener at the bonding connection. Remove any paint at the mounting connection in order to ensure electrical contact.
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23. 24.
Insert the bonding wires ring lug on the Station Doubler. Reinstall and tighten fasteners up to 1.13 Nm (10 in-lb) maximum.
Split Single Lever Control Head Stations in Twin Engine Installations Without Station Doublers
Some dual-engine installations use split Single Lever Control Heads at control stations rather than Dual Lever Control Head control stations. For such installations, one port lever harness and one starboard lever harness are used. See Figure 31.
TD10032
Figure 31. View of Split Single Lever Cable Wiring
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Install the Control Head harnesses as follows: Note: The Control Head may be removed from the dash if this facilitates making the connection. If it is removed, then reinstall it after the connections have been made. Note: Provide enough length in the harness to allow removal of the Control Head in the future. Note: For each Control Head connector, align the large connector key with the large keyway and push the connector into place. Then, turn the connectors collar until engagement snap is felt. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Connect the circular connector end of the port lever harness to the port Control Head. Connect the circular connector end of the starboard harness to the starboard Control Head. Ensure that the port and starboard single lever Control Heads are firmly mounted. Route the port lever harness to the EC300 port Control. Connect the port lever harness at the EC300 port Control (J1). Route the starboard lever harness to the EC300 starboard Control. Connect the starboard lever harness at the EC300 starboard Control Connector (J1). If applicable, repeat Steps 1 through 6 for connecting the Control Station 2 split Single Lever Control Heads at each EC300 Control (J2). If applicable, repeat Steps 1 through 6 for connecting the Control Station 3 Single Lever Control Heads at each EC300 Control (J3). Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Control Head Wiring for Master Lever Function Switch Applications Without Station Doublers
When multiple EC300 Controls are used, it may be desirable to operate all EC300 Controls from one lever. This section addresses the option of using a lever function switch to enable single lever control for all EC300 Controls. See System Operation - Lever Function section for a detailed explanation of the Master Lever Function. For the example configuration shown in Figure 32, when Master Mode is entered (by selecting it with the Lever Function Switch and having all levers, at the active Control Station, in the FWD detent position), the Port lever at the active control station will control all engines and transmissions. If the system is configured as a master lever system, phantom mode is not available. 1. Connect the Control Heads per the instructions in Dual-Engine MultiStation Dual Lever Control Head Wiring Installation. Install the Lever Function Switch per the instructions in Lever Function Switch Installation. Wire the Lever Function Switch per the instructions in Lever Function Switch Wiring. Install the communications cables per Multiple Engine Communication Harness Installation.
2.
3.
4.
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TD10033
Figure 32. Control Head Wiring for Master Switch Applications
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Control Head Wiring for Phantom Lever Function Switch Applications Without Station Doublers
When multiple EC300 Controls are used, it may be desirable to operate multiple engines/transmissions from one lever. This section addresses the option of using a Lever Function Switch to enable Phantom Mode Control. See System Operation - Lever Function section for a detailed explanation of the Phantom Lever Function. For the example configuration shown in Figure 33, when Phantom Mode is entered (by selecting it with the Lever Function Switch and having all levers, at Control Station 1, in the NEUT detent position), the Port lever at Control Station 1 will control the Port and Center engines and transmissions.
TD10034
Figure 33. Control Head Wiring for Phantom Switch Applications
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If the system is configured as a phantom mode lever system, master lever mode is not available. 1. Connect the Control Heads per the instructions in the appropriate Control Head Wiring Installation sections. Install the Lever Function Switch per the instructions in Lever Function Switch Installation. Wire the Lever Function Switch per the instructions in Lever Function Switch Wiring. Install the communications cables per the Multiple Engine Communication Harness Installation.
2.
3.
4.
Multiple Lever Station Wiring Using Station Doublers

A maximum of six Control Heads can be used on an EC300 Control System installation. Each EC300 Control can directly accept up to three Control Head inputs. Using Station Doublers, a total of six Control Head inputs can be supported. Figure 34 shows five Control Heads and two Station Doublers. Using a third Station Doubler, a sixth Control Head can be combined with the inputs from the main or navigation bridge control station. The main or navigation bridge Control Head wiring should not be combined through the use of a Station Doubler unless necessary to obtain the maximum number of stations. 1. 2. Refer to the interconnection diagram supplied with your order. Perform the necessary wiring harness installations as outlined in the applicable component instructions. Install the communications harness per the Dual Engine Communication Harness Installation.
3.
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TD10035
Figure 34. Typical Five Station Dual Lever Control Head Wiring
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Service Connector (J4)

Factory Use Only
Engine Control Harness (J5) Installation

The Engine Control Harness (J5) is field fabricated to a connector supplied by Twin Disc Incorporated. See Figure 35. The J5 connector kit contains all contacts and sealing plugs that are required to fill the connector. Sealing plugs must be installed for any unused connector contact positions in order to maintain the integrity of the connector. This section contains the following sub-sections: q Neutral Start Interlock Wiring This wiring is present for all installations. q Electronic Engine Control Unit Throttle Wiring The electronic engine throttle control will not be used for mechanically governed engines. q Engine Speed Sensor Harness Installation The engine speed sensor may not be present in every application.
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TD10037
Figure 35. Engine Control Harness (J5)
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Neutral Start Interlock Wiring

The EC300 Control is designed to ensure that a control station is in command and that the Control Head is in the neutral detent position before an engine can be started. Thus, the output of the start or ignition switch is routed to the starter solenoid through the EC300 Control.
CAUTION
Bypassing of the neutral start interlock may cause damage or injury. Twin Disc Incorporated and its distributors are not responsible for the results of any improper wiring. Contact Twin Disc Incorporated or a local distributor for recommendations related to any engine-room start switch. Two pins are provided in the controls Engine throttle connector kit (J5) for neutral start interlock wiring. Connector J5 pin 9 and conector J5 pin 10 are for use with commonly available DC engine system voltages (12/24 VDC Nominal). See Figure 36. The neutral interlock contact rating is 5 amps DC maximum. The hook up wire must be 14 AWG stranded copper wire.
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TD10039
Figure 36. Neutral Start Interlock Schematic
89
A Neutral Start Interlock Relay must be used for isolation if the starter relay/ solenoid current exceeds 5 amps DC. Use an isolation relay if the starter solenoid/relay current is unknown or if no means to measure the current is available. Note: The EC300 Controls neutral start interlock contacts and any hardwired transmission neutral interlock must be wired in series with the vessels starting circuit. If a hardwired transmission neutral start switch is present, then modify the following installation procedures to accommodate the switch. Both interlock contacts must be in series from the positive battery connection. The exact nature of the customer wiring will depend upon whether or not a relay is required. It will also depend upon the nature of the customers existing wiring. The following steps assume that the Ignition Switch (start switch) Contact, the Starter Solenoid, and the Neutral Start Relay (if used) are already installed. 1. If a wire is present between the existing Ignition Switch Contact and the Starter Solenoid or Customer Relay, then remove it. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 2. Connect the first yellow with a red stripe wire to the load side of the Ignition Switch Contact. Connect the second yellow with a red stripe wire to the starter solenoid circuit as follows: q q q Connect to the Starter Solenoid coil if no relay or Transmission Neutral Switch is required. Connect to the relay coil if a relay is required. Connect to the hardwired Transmission Neutral Switch, if one is provided.
3.
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4.
Route both yellow with a red stripe wires to the EC300 Control. Note: The Deutsch 14 AWG contact (P/N 0462-209-16141) can be identified by a green band.
5.
For the first yellow with a red stripe wire from the start switch, crimp the supplied Deutsch contact (P/N 0462-209-16141) using the Deutsch HDT crimp tool (P/N 48-00). Remove the locking wedge (P/N W12S-P012) from the Deutsch connector. Note: Refer to the EC300 Dimensional Drawing in Engineering Drawings for pin numbering information. Note: The J5 connector is provided in the Engine throttle connector kit.
6.
7. 8.
Insert the first wire into position 9 of the J5 connector. For the second yellow with a red stripe wire from the starter solenoid circuit, crimp the supplied contact (Deutsch P/N 0462-209-16141) using the Deutsch crimp tool (P/N HDT 48-00). Insert the second wire into position 10 of the J5 connector. When all pins have been inserted in the connector body, then reinsert the locking wedge (Deutsch P/N W12S-P012). Ensure that sealing plugs are installed in all empty connector positions. Align the harness connector with the J5 receptacle of the EC300 Control and push it in until it snaps into place. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
9. 10.
11. 12.
13.
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Electronic Engine Control Unit Throttle Wiring

If the specific engine is not listed, contact Twin Disc Incorporated or a local distributor for custom information and support. Note: All EC300 Control configuration, with respect to the engine, is performed by Twin Disc Incorporated or its local distributor. The EC300 Control System currently supports the following types of electronic engine controls: q q q q q q q q q q q Caterpillar Cummins Centry Cummins Quantum Voltage Type Detroit Diesel Voltage Deutz Type 1 Deutz Type 2 John Deere MAN Current MTU Scania Volvo Penta
Refer to the Appendix for detailed electrical installation requirements for the engines listed.
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The next section provides general information about engine control wiring. Then, general instructions are provided for the fabrication and wiring of the engine harness for the engine controls.
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General Electronic Throttle Control Wiring

The EC300 Controls engine control output can consist of three signals as follows: q q q The throttle control signal An optional signal indicating the transmission is in neutral An optional signal indicating the transmission is not in neutral
These signals interface with the engine Electronic Control Modules (ECMs). The engine control module can also be referred to as the Electronic Control Unit (ECU), Electronic Engine Control (EEC), or other similar names. The engine manufacturer provides specific engine control manuals that detail the requirements for the throttle signal and power supply connections. The EC300 Controls Engine Harness (J5) has six pins for throttle control. Table 6 lists the pin functions. Table 6. Engine Control Pin Functions
Signal Name Function This is the positive terminal of the power source from the engine electronic control module. This signal is to be used as the power source for the throttle signal output. The throttle power supply may be the same as the engine controller's. The throttle signal is directed by the position of the lever at the active control head. However, the throttle signal is generated from this power supply. This is the throttle position output signal. Depending upon the engine manufacturer, this signal can be a programmed voltage or current. It can also be a pulse train with programmable low and high levels with variable frequency or pulse widths. This is configured by the Twin Disc distributor or at the factory. This is the common return path and reference point for engine throttle circuit.
Pin
J5 ECM Power Pin Supply 1
J5 Throttle Pin Signal 2
J5 ECM Power Pin Supply 3 Common
J5 Transmission This is a solid-state switch output that goes active Pin State 1 when the transmission is in neutral. This wire is used 4 only for specific engines. This is configured by the Twin Disc distributor or at the factory. J5 Transmission This is a solid-state switch output that goes active Pin State 2 when the transmission is not in neutral. This wire is 5 used only for specific engines. This is configured by the Twin Disc distributor or at the factory. J5 Transmission This is the return signal for the transmission state Pin State Return signals. This wire is used only for specific engines. 6
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Harness Fabrication and Wiring Procedure

Note: The connector kit supplied for Engine Harness J5 has enough contacts and plugs necessary to fill the connector. Use only the contacts that are needed. Unused connector positions must have a sealing plug inserted in order to maintain the environmental integrity of the connector. 1. 2. Identify the wiring requirements for the specific engine from the appendix. Locate the necessary connecting points on the engine control module or engine control wiring circuits. Note: The Engine Harness connector at the J5 receptacle of the EC300 Control also includes neutral start interlock wiring and may include speed sensor wiring. Note: The neutral start interlock wires (J5 pin 9 and J5 pin 10) must be 14 AWG stranded copper wire. All other wires must be a minimum of 18 AWG stranded copper wire. 3. 4. 5. Make a suitable interface cable containing the necessary conductors. Connect the engine harness cable at the engine end. Route the engine harness to the associated EC300 Control.
6. 7.
Crimp the contacts for the Engine Harness J5 connector on the wires. Insert the wires into the connector. See Figure 37. Note: Ensure that the crimp is uniform and complete. Ensure that the wires are fully inserted in the connector.
Figure 37. Connector J5 Pin Layout from the Front
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8. 9.
Ensure that sealing plugs are inserted in all unused connector positions. When all pins have been inserted in the connector body, then insert the Deutsch locking wedge (P/N W12S-P012). Align the harness connector with the J5 receptacle of the EC300 Control and push it in until it snaps into place. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
10.
11.
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Engine Speed Sensor Harness Installation

The Engine Speed Sensor Harness is supplied by Twin Disc Inc. It plugs into J5 of the EC300 Control along with the field fabricated Neutral Start Interlock wiring and Electronic Engine Control Unit Throttle wiring (if applicable) via the 12-pin Deutsch connector (P/N DT06-12SD-P012). The 12-pin Deutsch connector is part of the Twin Disc supplied J5 connector kit. The Neutral Start Interlock wiring and Electronic Engine Control Unit Throttle wiring (if applicable) should be fabricated and routed to the EC300 Control prior to installing the Engine Speed Sensor Harness. Steps are provided below for installing the Engine Speed Sensor Harness. See Figure 38.
CAUTION
The engine speed sensor signal must connect only to the EC300 Control. If another speed sensor signal is required, use engine speed sensor doublers or dual output engine speed sensors. Note that a tachometer output is available from the EC300 Control.
TD10041
Figure 38. Engine Speed Sensor Harness Wiring
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1.
Plug the 2-pin connector of the Engine Speed Sensor Harness into the Engine Speed Sensor receptacle. Note: It may be desirable to complete any other terminations for this harness before securing the harness.
2. 3.
Route the Engine Speed Sensor Harness to the EC300 Control. Plug the red with a green stripe wire into position 11 of the J5 Connector (locking wedge must be removed from plug prior to inserting wires to properly seat the contact sockets). Plug the green with a red stripe wire into position 12 of the J5 Connector. Note: Refer to the EC300 Dimensional Drawing in Engineering Drawings for pin numbering information.
4.
5. 6.
Reinstall the locking wedge. Install the 12-pin connector into the J5 receptacle of the EC300 Control.
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Engine Room Analog Harness (J6) Installation

Engine Room Analog Harness Connector (J6) provides analog inputs from a transmission oil temperature sensor and a transmission output speed sensor. Not all of these available inputs may be used in any specific application. This instruction does not cover the physical installation of these sensors. Refer to the applicable manufacturers literature if it is necessary to install these components. The following sections provide instructions on the installation of the Engine Room Analog Harness (J6). See Figure 39.
TD10043
Figure 39. Engine Room Analog Harness (J6) Wiring Diagram Refer to the following sub-sections as applicable to the current installation: q q Transmission Oil Temperature Sensor Wiring Installation Transmission Output Speed Sensor Wiring Installation
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Transmission Oil Temperature Sensor Wiring Installation

Note: The Transmission Oil Temperature Sensor cable is part of the Engine Room Analog harness. Cable ties may be removed for routing purposes. Install the wiring connections for a Transmission Oil Temperature Sensor as follows: 1. 2. 3. If required, connect the Engine Room Analog Harness at the J6 receptacle of the EC300 Control. If required, route the Engine Room Analog Harness to the associated transmission. Install the Transmission Oil Temperature Sensor cables receptacle onto the transmission oil temperature sensors plug. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 4. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Transmission Output Speed Sensor Wiring Installation

Install the wiring connections for a Transmission Output Speed Sensor as follows: Note: The Transmission Output Speed Sensor cable is part of the Engine Room Analog harness. Cable ties may be removed for routing purposes. 1. If required, connect the Engine Room Analog Harness at the J6 receptacle of the EC300 Control. If required, route the Engine Room Analog Harness to the associated transmission. Install the Transmission Output Speed Sensor cables plug into the Transmission Output Speed Sensors receptacle. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
2.
3.
4.
Tooth Count
Note: The EC300 Control must be configured with the correct tooth count. Obtain the correct tooth count information from the manufacturers literature or count the teeth.
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PWM Drivers Harness (J7) Installation

The PWM Drivers Harness (J7) provides solenoid driver outputs for transmission gear selection. Not all of these available outputs may be used in any specific application. The following sections provide instructions on the installation of the PWM Drivers Harness.
TD10042
Figure 40. PWM Drivers Harness Wiring Diagram Refer to the following sub-sections as applicable to the current installation: q q Two Solenoid Transmission Clutch Control Wiring Installation Three Solenoid Transmission Clutch Control Wiring Installation
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Two Solenoid Transmission Clutch Control Wiring Installation

Install the wiring connections for a two-solenoid transmission as follows: Note: Refer to the transmission manufacturers technical manual as required to identify the solenoids. If the solenoids are not clearly identified, make the connections on a temporary basis until testing can confirm the selection. 1. 2. 3. If required, connect the PWM Drivers harness at the J7 receptacle of the EC300 Control. If required, route the PWM Drivers harness to the associated transmission control. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: Refer to Figure 40 for detailed information about the conductors. Refer to the transmission manufacturers technical manual for any recommendations for terminating the wires. Refer to Wire Connections for other requirements. 4. 5. 6. 7. Terminate the red with green stripe FWD J7 pin 1 wire to either lead for the Forward Clutch Solenoid. Terminate the green with red stripe FWD RETURN J7 pin 4 wire to the other lead for the Forward Clutch Solenoid. Terminate the yellow with purple stripe REV J7 pin 2 wire to either lead for the Reverse Clutch Solenoid. Terminate the purple with yellow stripe REV RETURN J7 pin 5 wire to the other lead for the Reverse Clutch Solenoid.
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Three Solenoid Transmission Clutch Control Wiring Installation

Install the wiring connections for a three-solenoid transmission as follows: Note: Refer to the transmission manufacturers technical manual as required to identify the solenoids. If the solenoids are not clearly identified, make the connections on a temporary basis until testing can confirm the selection. 1. 2. 3. If required, connect the transmission control harness at the J7 receptacle of the EC300 Control. If required, route the transmission control harness to the associated transmission control. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: Refer to Figure 40 for detailed information about the conductors. Refer to the transmission manufacturers technical manual for any recommendations for terminating the wires. Refer to Wire Connections for other requirements. 4. 5. 6. 7. 8. 9. Terminate the red with green stripe FWD J7 pin 1 wire to either lead for the Forward Clutch Solenoid. Terminate the green with red stripe FWD RETURN J7 pin 4 wire to the other lead for the Forward Clutch Solenoid. Terminate the yellow with purple stripe REV J7 pin 2 wire to either lead for the Reverse Clutch Solenoid. Terminate the purple with yellow stripe REV RETURN J7 pin 5 wire to the other lead for the Reverse Clutch Solenoid. Terminate the light blue with brown stripe NEUT J7 pin 3 wire to either lead for the Neutral Clutch Solenoid. Terminate the brown with light blue stripe NEUT RETURN J7 pin 6 wire to the other lead for the Neutral Clutch Solenoid.
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Miscellaneous Bridge Signals Harness (J8) Installation

This section addresses the wiring installation for the Miscellaneous Bridge Signals Harness that connects to Connector J8 on the EC300 Control. See Figure 41. This section contains the following sub-sections: q Ignition Switch Wiring The Ignition Switch Wiring installation procedure is applicable to all installations. q Lever Function Switch Wiring The Lever Function Switch Wiring installation procedure is only applicable to those installations that use a Master Enable Switch or a Phantom Enable Switch. q Tachometer Output Wiring Installation The Tachometer Output Wiring Installation procedure is applicable when an optional output, that may be wired to a dash-mounted tachometer, is used. q Alarm Output Wiring Installation The Alarm Output Wiring Installation procedure is applicable when an optional output, that may be wired to an alarm or annunciator system, is used.
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TD10036
Figure 41. Miscellaneous Bridge Signals Harness (J8) Connections
Note: The connector kit supplied for the Miscellaneous Bridge Signals Harness (J8) has enough contacts and sealing plugs necessary to fill the connector. Use only the contacts that are needed. Unused connector positions must have a sealing plug inserted in order to maintain the environmental integrity of the connector.
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Ignition Switch Wiring

Ignition switch wiring is accomplished through the multipurpose Miscellaneous Bridge Signals Harness (J8) that connects to the J8 receptacle at the EC300 Control. The ignition signal turns on power to the EC300 Control. The control will not function unless this terminal is connected to a DC signal source from the load side of the ignition switch. A connector kit is supplied by Twin Disc Incorporated. Cable is customer supplied. Note: The following instructions refer to a combination ignition switch. That is, the switch has an ON position and a START position. For this instruction, the wiring from this switch is from the ON position that does not open the contacts when the engine is started. If a common master power switch is used to enable separate START pushbuttons, then use this master ON switch as this signal source. Install the Ignition Switch input wiring as follows:
CAUTION
The DC voltage from the ignition switch must be at the same voltage and from the same source as the voltage used by the EC300 Control. It must not be interrupted when the engine is started. 1. Connect EC300 Miscellaneous Bridge Signals Harness (J8) at the control. Note: EC300 Miscellaneous Bridge Signals Harness (J8) also may contain wiring for other components. Route the harness to the most convenient location serving all the applicable connections. 2. 3. Route the harness to the ignition switch area. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 1 wire to the load side of the ignition switch. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 4. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Lever Function Switch Wiring

The lever function switch is used to enable either the single lever master mode control of multiple engines or the phantom mode control of multiple EC300 Controls from a single lever. If used, the lever function switch should be installed per Lever Function Switch Installation. Install the Lever Function Switch input wiring as follows: 1. If required, connect EC300 Miscellaneous Bridge Signals Harness (J8) at the EC300 Control. Note: EC300 Miscellaneous Bridge Signals Harness (J8) also may contain wiring for other components. Route the harness to the most convenient location serving all the applicable connections. 2. 3. 4. 5. If required, route the harness to the lever function switch area. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 3 wire to the load side of the Lever Function Switch. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 4 wire to the return side of the Lever Function Switch. Ensure that the Lever Function Switch is securely installed. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 6. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Tachometer Output Wiring Installation

The tachometer output circuit is used to drive a tachometer indicator. In a retrofit, an existing speed sensor may have driven the tachometer directly from the engine or transmission output speed sensor. With the EC300 Control installation, the engine speed sensor signal can be repeated from the EC300 so that the sensor can feed the EC300 control directly. Install the tachometer output wiring as follows: 1. If required, connect EC300 Miscellaneous Bridge Signals Harness (J8) at the control. Note: EC300 Miscellaneous Bridge Signals Harness (J8) also may contain wiring for other components. Route the harness to the most convenient location serving all the applicable connections. 2. 3. 4. 5. If required, route the harness to the tachometer area. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 5 wire to the signal input connection on the tachometer. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 6 wire to the return connection on the tachometer. If required, route power and ground wiring to the tachometer from the appropriate source. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 6. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
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Alarm Output Wiring Installation

The EC300 Control provides an alarm relay output rated at an operating current of 2 amp maximum. This output is used for remote audible or visual indication of problems associated with the EC300 Control System. The EC300 output is a normally open contact that closes when an alarm condition occurs. Note: If this output is used as an input to a digital annunciator or low-current relay, then an intermediate relay is not necessary. If the output drives a high current audible alarm or buzzer, then an intermediate relay is recommended. The following instructions assume the presence of an intermediate alarm relay and that the intermediate alarm relay contacts have already been wired. Install the alarm relay output wiring as follows: 1. If required, connect EC300 Miscellaneous Bridge Signals Harness (J8) at the control. Note: EC300 Miscellaneous Bridge Signals Harness (J8) also may contain wiring for other components. Route the harness to the most convenient location serving all the applicable connections. 2. 3. If required, route the harness to the alarm relay area. See Figure 42. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 7 wire to Positive System Voltage Source. Connect the EC300 Miscellaneous Bridge Signals Harness J8 pin 8 wire to the positive side of the relay coil. Connect the return side of the coil to Negative System Voltage Source. Note: It may be desirable to complete any other terminations for this harness before securing the harness. 6. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
4.
5.
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TD10218
Figure 42. Alarm Relay Output
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Twin Disc Display Harness (J9) Installation

The Twin Disc Display Harness Assembly consists of a communication harness, two adapter harnesses, two J1939 T-Connectors, and two J1929 terminating resistors. See Figure 43. The J1939 CAN Harness adapts the Communications Harness to the displays 3-pin receptacle via a J1939 T-Connector. The Multiple Display Adapter Harness adapts the Communications Harness to the controls J9 receptacle via a J1939 T-Connector. The Communication Harness has identical T-Connectors at each end. Each end is supplied with a pre-installed terminating resistor. Do not remove the J1939 terminating resistors. The Display Power Harness connects between the 8 - pin receptacle of the Multiple Display Adapter Harness and the 6 - pin receptacle of the display. The black wire at the display end of the harness connects to the circular connector of the Control Head. Note: The Twin Disc Display is an option. If it is provided, it may be installed at the customers desire. If physical installation is impractical, the display may be stored and only used temporarily during configuration and troubleshooting. The following assumes that the display has been installed.
TD10047A
Figure 43. Display Harness J9 Installation

Connect the Twin Disc Display Harness Assembly and the Display Power Harness as follows (See figure 43): 1. 2. 3. 4. 5. 6. 7. 8. Install a 3-pin plug of the J1939 Can harness into the 3-pin receptacle of the Twin Disc Display. Install a J1939 T-Connector onto the remaining 3-pin plug of the J1939 Can harness. Install a 3-pin plug of the Communications harness into the J1939 TConnector. Install the 6-pin plug of the Display Power harness into the 6-pin receptacle of the Twin Disc Display. Route the short black wire to the Control Head. If required, disconnect the Control Head. If required, disconnect the Control Head harness from the Control Head. Install the short black wire of the Display Power harness into the Control head receptacle (position E for a port lever application, position J for a starboard lever application). Route the Display Power harness and the Communications harness to J9 of the EC300 Control. Install a J1939 T-Connector onto the 3-pin plug of the Multiple Display Adapter harness. Install the 3-pin plug of the Communications harness into the J1939 TConnector Remove the 8-pin receptacle from the Multiple Display Adapter harness located at J9 of the EC300 Control. Remove the locking wedge from the Multiple Display Adapter harnesss plug (the locking wedge must be removed to properly seat the contacts into the plug). Install the white wire of the Display Power harness into position 2, 7, or 8 of the 8-pin plug of the Multiple Display Adapter harness.
9. 10. 11. 12. 13.
14.
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15.
Install the black wire of the Display Power harness into position 4, 5, or 6 of the 8-pin plug of the Multiple Display Adapter harness. Install a J1939 terminating resistor into the J1939 T-Connector receptacle located at each end of the routing path for the Twin Disc Display Harness Assembly. Note: Terminating resistors must be installed at each end of the Twin Disc Display Harness Assembly for the communications to work properly.
16.
17. 18.
Repeat steps 1 through 16 for each additional Twin Disc Display. Install the locking wedge into the Multiple Display Adapter harnesss 8pin plug. Install the 8-pin receptacle onto the Multiple Display Adapter harnesss 8-pin plug. Secure all harnesses to a supporting structure with clamps or cable ties at 406mm (16 in) intervals.
19.
20.
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Communication Harness (J10) Installation

This section contains the following sub-sections: q q Dual Engine Communication Harness Installation Multiple Engine Communication Harness Installation
Dual Engine Communication Harness Installation

A Communication Harness Assembly is required to connect the two EC300 Controls on a dual engine installation. This prefabricated harness assembly comes with connectors at both ends. Connect the communication harness to the EC300 Control at each end. The main communications harness must be terminated at each end. The terminators are installed in the T-Connectors as part of the prefabricated harness assembly.
TD10045
Figure 44. Dual Engine Communication Harness Assembly J10 Installation
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Connect the Communication Harness Assembly as follows (See figure 44): Note: The specific application may have different lengths for each segment of communication harness. Use the correct segments. 1. 2 3. Install a J1939 T-Connector receptacle on the 3-pin plug of each Controller Comms Harness. Install a Controller Comms Harness into the J10 receptacle of each EC300 Control. Connect the Controller Comms Harness between the EC300 Controls by installing the 3-pin plugs into the J1939 T-Connector receptacles located on the Controller Comms Harness at each EC300 Control. Install a J1939 Terminating Resistor into the J1939 T-Connector receptacle located at each end of the routing path for the Communication Harness Assembly. Note: Terminating resistors must be installed at each end of the Communication Harness Assembly for the communications to work properly. 5. As required, secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
4.
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Multiple (more than two) Engine Communication Harness Installation

For installations that contain three or more engines, multiple communications harnesses and multiple J1939 T-Connectors are required. See Figure 45. The T-connector allows daisy chaining to the J10 connector at each EC300 Control. Each communications harness is connected to the EC300 Control through a short controller communications harness. Finally, each main communications harness must be terminated at each end. The terminators are shipped with the harnesses.
TD10046
Figure 45. Multiple (more than two) Engine Communication Harness Assembly J10 Installation
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Connect the Communication Harness Assembly as follows (see Figure 45): Note: The specific application may have different lengths for each segment of communication harness. Use the correct segments. 1. 2. 3. Install a J1939 T-Connector receptacle on the 3-pin plug of each Controller Comms Harness. Install a Controller Comms Harness into the J10 receptacle of each EC300 Control. Daisy chain the Communication Harness between the EC300 Controls by installing the 3-pin plugs into the J1939 T-Connector receptacles located on the Controller Comms Harness at each EC300 Control. Install a J1939 Terminating Resistor into the J1939 T-Connector receptacle located at each end of the routing path for the Communication Harness Assembly. Note: Terminating resistors must be installed at each end of the Communication Harness Assembly for the communications to work properly. 5. As required, secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements.
4.
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Servo Actuator Harness (J11) Installation

The Servo Actuator Harness connects between the EC300 Controls J11 receptacle and the Servo Actuator connector. See Figure 46. The harness is prefabricated with connectors at both ends.
TD10038
Figure 46. Wiring the Servo Actuator
Install the Servo Actuator Harness as follows: 1. Connect the Servo Actuator harness at the J11 receptacle on the EC300 Control. Route the Servo Actuator harness to the Servo Actuator.
2.
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Note: To connect the connector, align the connector key with the keyway and push the connector into place. Then, turn the connectors collar until engagement snap is felt. 3. 4. 5. Connect the harness to the Servo Actuator. Repeat Steps 1 through 3 for any remaining Servo Actuators that may be used on other EC300 Controls. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: The bonding conductor must be 14 AWG stranded copper wire. It must be colored green with a yellow stripe (preferred) or green in order to comply with ABYC standards. 6. Route a bond wire from the vessel bonding system to the selected mounting pad on each Servo Actuator. See Figure 46. Note: The ring lug must be properly sized for both the wire and the mounting fastener. 7. 8. 9. 10. 11. Install a ring lug on the Servo Actuator end of the wire. Remove the mounting fastener at the bonding connection. Remove any paint at the mounting connection in order to ensure electrical contact. Insert the bonding wires ring lug on the Servo Actuator. Reinstall and tighten fasteners up to 1.13 Nm (10 in-lb) maximum.
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Engine Room Switch Harness (J12) Installation

The Engine Room Switch Harness (J12) provides digital inputs from a transmission oil filter switch, and a transmission oil pressure switch. Not all of these available inputs may be used in any specific application. This instruction does not cover the physical installation of these sensors. Refer to the applicable manufacturers literature if it is necessary to install these components. The following sections provide instructions on the installation of the Engine Room Switch Harness (J12) at the available switches.
TD10044
Figure 47. Transmission Switch Harness Wiring Diagram
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Transmission Oil Filter Differential Pressure Switch Wiring Installation

Install the wiring connections for a Transmission Oil Filter Differential Pressure Switch as follows: Note: The Transmission Oil Filter Differential Pressure Switch Cable is part of the Engine Room Switch harness. Cable ties may be removed for routing purposes. 1. 2. 3. If required, connect the Engine Room Switch Harness at the J12 receptacle of the EC300 Control. If required, route the Engine Room Switch Harness to the Transmission Oil Filter Differential Pressure Switch area. Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm (16 in) intervals. See Routing Requirements. Note: Refer to Figure 47 for detailed information about the conductors. Refer to the transmission manufacturers technical manual for any recommendations for terminating the wires. Refer to Wire Connections for other requirements. 4. 5. Terminate the red with green stripe OIL FILTER J12 pin 1 wire to either lead for the Transmission Oil Filter Differential Pressure Switch. Terminate the green with red stripe OIL FILTER J12 pin 2 wire to the other lead for the Transmission Oil Filter Differential Pressure Switch.
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Transmission Oil Pressure Switch Wiring Installation

Install the wiring connections for a Transmission Oil Pressure Switch as follows: Note: The Transmission Oil Pressure Switch cable is part of the Engine Room Switch harness. Cable ties may be removed for routing purposes. 1. 2. 3. If required, connect the Engine Room Switch Harness at the J12 receptacle of the EC300 Control. If required, route the Engine Room Switch Harness to the Transmission Oil Pressure Switch area. Secure all harnesses to a supporting structure with clamps or cable ties at 40 cm (16 in) intervals. Note: Refer to Figure 47 for detailed information about the conductors. Refer to the transmission manufacturers technical manual for any recommendations for terminating the wires. Refer to Wire Connections for other requirements. 4. 5. Terminate the light blue with brown stripe OIL PRESSURE SWITCH J12 pin 3 wire to either lead for the Transmission Oil Pressure Switch. Terminate the brown with light blue stripe OIL PRESSURE SWITCH J12 pin 4 wire to the other lead for the Transmission Oil Pressure Switch.
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EC300 Control Power and Grounding Harness (J13) Installation

The EC300 Control operates on voltages between 10 and 28 VDC. DC to DC converters must be used for other system voltages. Power wiring must be a twisted pair of 14 AWG stranded copper wire. See Table 4.
CAUTION
Obtain power either from primary distribution for the engine or directly from the batteries. Primary distribution is the first location to which the heavy-duty battery wires connect.
CAUTION
Controller power or grounding connections can not be made at any conductor through which motor starting current flows. The following sub-sections provide the detailed instructions for this section: q q EC300 Control Power Wiring EC300 Control Bonding Installation
EC300 Control Power Wiring

Note: Refer to Power Wiring Requirements for a listing of requirements. Note: Using switched power to the EC300 Control is not recommended. However, if standards or agencies require that all electronic circuits have on-off control, then use the same switched power that also feeds the engine controller.
CAUTION
Use the same source of power for the EC300 Control as used for the electronically controlled engine, if applicable. Ensure that the circuit current rating is adequate for combined load of the EC300 Control and the engine controller.
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CAUTION
Obtain power either from primary distribution for the engine or directly from the batteries. Primary distribution is the first location to which the heavy-duty battery wires connect. Do not connect downstream of any secondary circuit breaker or fuse.
CAUTION
Do not use a connection directly on the engine or starter. Locate the connection as close to the battery as practical.
TD10049
Figure 48. Power Wiring Diagram for Unswitched Engine Powering Applications
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TD10050
Figure 49. Power Wiring Diagram for Switched Engine Powering Applications
Note: Figure 48 and Figure 49 both show auxiliary batteries as is required by certain codes and standards. If redundant (port and starboard) batteries are present, then use the port battery for the port controllers main battery connection on J13 pin 1. Use the starboard battery for the auxiliary connections on J13 pin 2. Reverse the connector assignments for the starboard EC300 Control.
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Note: Figure 48 and Figure 49 both show two single batteries. This is typical for 12 VDC systems using 12 VDC batteries. The 24 VDC system typically connects two 12 VDC batteries in series to obtain 24 VDC. However, 6 VDC batteries can also be connected in series to achieve either 12 VDC or 24 VDC. Additionally, batteries can be connected in parallel in order to increase the available battery current. If uncertain about which battery terminals are to be used, check the voltage with a multimeter. Install the control power wiring as follows: 1. If required, install two fuses or circuit breakers at the battery positive or engine controller power distribution connections. See Power Wiring Requirements. If required, route power wiring to the fuses or circuit breakers. Temporarily remove the fuses or open the circuit breakers. Note: Power wiring must be a twisted pair of 14 AWG stranded copper wire. See Power Wiring Requirements.
2. 3.
Ensure that the EC300 Control power wiring is electrically identical to that used for any associated engine controller. 4. Connect the first red wire going to EC300 Control Connector J13 Pin 1 to the load side of Main Battery fuse or circuit breaker. Note: If no auxiliary battery is present, do not install a wire to J13 Pin 2. Pin 2 should be plugged. 5. Connect the second red wire going to EC300 Control Connector J13 Pin 2 to the load side of the Auxiliary Battery fuse or circuit breaker.
CAUTION
The EC300 Controls negative power connection must be made at the same point that the two batteries share a common negative connection. That is, the two batteries must share a common negative connection and the EC300 Controls negative power connection must be made at the same point.
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6.
Connect the yellow (preferred) or black wire going to EC300 Control Connector J13 Pin 3 to the DC Grounding Bus or the DC Negative Bus as is applicable. Note: Refer to Routing Requirements.
7.
Route the EC300 Control Power and Grounding Harness (J13) to the associated EC300 Control. Note: The Deutsch contacts (14 AWG) (P/N 0462-209-16141) have a green band.
8. 9. 10. 11.
Using the Deutsch crimping tool (P/N HDT 48-00), crimp the wires to the Deutsch contacts (14 AWG) (P/N 0462-209-16141). Assemble the J13 Deutsch Mating Connector (P/N DT06-6S-P012). See Figure 48. Ensure that sealing plugs are installed in all empty connector positions. Ensure that the assembled harness is properly supported and protected. Note: For vessels complying with American Bureau of Shipping (ABS) Rules for Building and Classing Steel Vessels 2002 or Rules for Building and Classing Steel Vessels Under 90 Meters (295 Feet) 2001, insulation resistance of power and lighting cables is to be measured. Appliances connected to the circuits may be disconnected for this test. Each power and each lighting circuit is to have an insulation resistance between conductors and between each conductor and earth of not less than 0.4 Megohms for loads less than 25 amps.
12. 13.
Ensure that the power harness conductors for J13 pin 1 through J13 pin 6 are disconnected at both ends. Using a 500 VDC Megohmmeter or equivalent, measure the resistance between each of the following sets of conductors: q q q J13 pin 1 and Earth or Bonding System J13 pin 2 and Earth or Bonding System J13 pin 3 and Earth or Bonding System
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14.
Verify that all measurements are greater than or equal to 0.4 Megohms. Note: Leave EC300 Control Power and Grounding Harness (J13) disconnected from the EC300 Control until all wiring has been completed.
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EC300 Control Bonding Installation

The EC300 Control enclosure connects directly to the surface on which it is mounted. For both conductive and nonconductive vessels, the bonding connection is also made in order to ensure that the metallic enclosure is bonded. Bonding provides a means of making a controlled path for the removal of electrical noise that could be introduced to the EC300 Control through the wiring by inductive interference from motors or generators or by electromagnetic interference from radar or radios. Applicable codes may prevent bonding connections to the battery negative. Some codes do require that the bonding connection and battery negative are connected at one point only. Other codes require that there be no connection between the bonding system and the battery negative. Install the bonding system as per the applicable code.
CAUTION
The bonding wire used for the EC300 Control must be connected to the same bonding system as used for the engine. Ground the EC300 Control bonding wire to the negative battery terminal only if the engine is grounded to the negative battery terminal. Note: The bonding conductor must be 14 AWG stranded copper wire. It must be colored green with a yellow stripe (preferred) or green in order to comply with ABYC standards. Install the EC300 Control bonding connection as follows: 1. Route a bond wire, connected to the vessel bonding system, to one of the unpainted mounting feet of each EC300 Control. See Figure 50.
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TD10027
Figure 50. EC300 Control Bond Connection Diagram Note: The ring lug must be properly sized for both the wire and the mounting fastener. 2. 3. 4. 5. 6. Install a ring lug on the control end of the wire. Remove the mounting fastener at the bonding connection. Remove any paint at the mounting connection in order to ensure electrical contact. Insert the bonding wires ring lug on the EC300 Control. Reinstall and tighten fasteners up to 1.13 Nm (10 in-lb) maximum.
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Configuration
Configuration
Introduction
The EC300 Control System must be properly configured for installation in the vessel to match the control parameters to the customer selected hardware, desired operational configurations, and optional equipment. Note: If the Control is replaced, the replacement Control must be re-configured. The following variables can be configured: o o o o Lever arrangement Engine type and throttle parameters Transmission type, ratio, and related parameters Optional inputs for monitoring by the control.
The configuration is accomplished by an installation technician with the use of the EC300 Marine Field Support Tool (MFST). The MFST is a Windows based software program and is generally used on a portable laptop computer. After the computer is connected to the EC300 Control System, the MFST will instruct the installation technician to perform the steps in the proper sequence. The following figures are actual screen shots from an installation of a two Controller System (twin engine).
Figure 51. First screen when MFST is opened.

Configuration
Configure the Control System

This section refers to configuring the system in the field, so clicking on the Field Configuration tab will start the process. Note that there is an extensive help section, and additional explanations can be seen by clicking on the ? in the upper right of the screen, and dragging it over a subject. Click on the Field Setup tab to start the configuration process.
Figure 52. Field Configuration Menu
Note: It is very important to follow the steps in the proper sequence as directed by the prompts.
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Configuration
You will be prompted to enter the name of the boat followed by clicking on the Next tab. The configuration information will be stored in a directory corresponding to the boat name.
Figure 53. Fill in the name of the boat The next screen will prompt you to click on Open or Next. Click on the Next tab to continue. The screen will prompt you to power down all controllers in case they were powered on. Select the drop down box in the upper right, and select the number of controllers in this installation.
Figure 54. Select Next for controller # 1. Power down all controls.
Configuration
Figure 55. Select number of controllers. Power up controller # 1. After selecting the number of controllers, power up controller # 1 as directed. You will be instructed to wait while the MFST takes control and reads data from the master controller.
Figure 56. MFST takes control and transfers data
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Configuration
You will be prompted to select the desired lever function from the list. Most applications will select the standard configuration. After selection, click on the Next tab, and data will be transferred.
Figure 57. Select lever configuration and data transfer. After updating the configuration data, a backup file will be created and saved.
Figure 58. Backup of data.
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Configuration
You will be prompted to power down controller # 1, and then directed to power up controller # 1. Be sure to wait until prompted.
Figure 59. Power down controller # 1, and the power up controller # 1. You will be prompted to power up controller # 2, and data will be transferred to the controller.
Figure 60. Power up controller # 2 and data transfers.
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Configuration
After updating the configuration data, a backup file will be created and saved.
Figure 61. Backup of data. You will be prompted to power down controller # 2, and then controller # 1.
Figure 62. Power down controller # 2 followed by controller # 1.
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Configuration
You will be prompted to power up controller # 1, followed by powering up all other controllers.
Figure 63. Power up controller # 1. Power up all other controllers. You will be prompted to wait while the MFST again takes control.
Figure 64. Wait until the MFST takes control.
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Configuration
Configure Head Types

Once the following screen has appeared, click the box on the right side of the screen to Update All Controllers. This ensures all Controls are simultaneously updated. Next, select the Control Head for each station from the drop down list. There may be different Control Head Types at different stations. Note that when the Head Type is selected, the graphic to the right of the Head Type identifier shows the levers and the Modes that are present with that Head Type. Also note in the lower section of the Control Stations graphic that all Modes present on the boat are shown. Note: At this time, it is no longer necessary to follow a particular sequence, however the sequence shown is suggested.
Figure 65. Select Control Station Head Types and update
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Configuration
Configure Engine
Click on the Engine Tab on the upper right area of the screen, and select the appropriate engine from the drop down bar located in the upper left of the display as shown in the next two screens. The engine information is included in the database in the MFST, and the applicable parameters will be set by the MFST. Certain throttle parameters can be changed by the technician during configuration, and can be selected by clicking on the data boxes that are shown in black on the engine screen. These can also be reached with the use of the tab key on the computer. Data that cannot be changed for the engine type that is selected will be grayed out and cannot be selected by the technician.
Figure 66. Engine Screen
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Configuration
Figure 67. Engine screen with drop down box shown.
Configure Transmission
Click on the Transmission Tab on the upper right area of the screen, and select the applicable transmission from the drop down bar located in the upper left area of the display as shown in the next two screens.
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Configuration
The transmission information is included in the database in the MFST, and the applicable parameters will be set by the MFST. Certain transmission related parameters can be changed by the technician during configuration, and can be selected by clicking on the data boxes that are shown in black on the transmission screen. These can also be reached with the use of the tab key on the computer. Data that cannot be changed for the transmission type that is selected will be grayed out and cannot be selected by the technician. The Engine and Propeller Speed Sensors (if equipped) must be enabled. The technician must configure the appropriate gear ratio by clicking in the black data box and entering the gear ratio of the transmissions installed in the boat. The number of teeth that are used to signal the input and propeller speed sensors (if equipped) must be entered under Tooth Count. The Direction Reversal Inhibit Parameters (time in seconds) can be modified by the technician if desired.
Figure 68. Transmission Screen.
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Configuration
Figure 69. Transmission screen with drop down box shown. When a new transmission is selected, a screen will open, and allow selection of the transmission ratio, and the number of teeth on the speed wheel, if those values are not already known by the control.
Figure 70. Transmission Gear Ratio and Speed Wheel Tooth Count
Configuration
Controls that have troll will allow the Lever Maps screen to be selected. The valve coil command signal (current) can be defined as a function of throttle lever travel. Although the screen indicates for use when output speed is not available, this should be set on applications even if an output speed sensor is present. This map will be used in case of a speed sensor fault.
Figure 71. Lever Maps Troll Idle Speed Calibration
146
Configuration
Configure Options
Click on the Operational Tab on the upper right area of the screen. Certain Optional parameters can be selected and set by the technician during configuration, and can be selected by clicking on the data boxes that are shown on the Operational screen. These can also be reached with the use of the tab key on the computer. Data that cannot be changed for the installation will be grayed out and cannot be selected by the technician. Station Transfer options must be selected on this screen.
Figure 72. Operational Screen for Option Enables This completes the Configuration of the EC300 Marine Electronic Control System. Click on the Exit tab to exit the configuration program and disconnect the MFST.
147
Configuration
Miscellaneous Configuration Notes

Acceleration Ramp Time (sec)
In cruise mode, record the time (in seconds) to accelerate from the vessel speed with the Control Head Lever(s) in the Idle Detent position to maximum vessel speed with the Control Head Lever in the full throttle position.
Deceleration Ramp Time (sec)

In cruise mode, operate the vessel at full throttle until moving at full speed. Record the time for the vessel to coast to a stop when the Control Head Lever(s) are moved to the Idle Detent position.
Throttle Clamp (msec)

These values should be set to the time it takes for the clutch engagement profiles to command 100% coil current. These values can be viewed on the transmission parameter screen by pressing the Shift Profiler select button.
Lever Calibration
All Levers on all Control Heads at all stations must be calibrated. This can be done via the Twin Disc Display as described in Test 3 (STATN TEST) in the Troubleshooting Section. Alternately, this can be done via the MFST Diagnostics.
148
System Operation
System Operation
Introduction
This section includes basic operating information for the EC300 Control System. The following sub-sections make up this section: o o o o o o o o o o o o Introduction Basic System Features Lever Function in Cruise Mode Lever Function in Express Mode Lever Function in Troll Mode Lever Function in Master Lever Function Lever Function in Phantom Lever Function Mode Select Switch Display Features Station Transfer Manual Mechanical Control Engine synchronization
149
System Operation
Basic System Features

The basic EC300 Control System consists of an EC300 Control, a Control Head, an optional Servo Actuator, an optional Display, and several wire harnesses. One EC300 Control System is required for each engine. The Control System coordinates both engine and marine transmission functions. One or two Levers, a Station Select Button, and a Mode Select Switch on the Control Head enable the operator to control the operation of the system and the installed options. See the following figures for the identification information.
STBD LEVER PORT LEVER
NEUTRAL INDICATOR LED (2 PLACES)

N SI RI N TE ITIO N. HIF POS OR O S S AR AL AT ES GE UTRINDIC L PR NE EN OL EX TR WH C
R
BD
STATION SELECT BUTTON
N SY
UI CR
SE
MODE SELECT SWITCH STATION SELECT INDICATOR LED (2 PLACES)
T N S TIO TA ECT S L SE RT O
ISC
P0 WE
RC
OM
0 30 EC ER D AN M
TW
IN
TD10103
Figure 73. Operator Controls on the Control Head
150
System Operation
Figure 74. Side View of Control Head Note: A single lever Control Head will have only one lever. Each Lever controls gear selection and throttle for one engine/gear set. If the boat is equipped with Phantom or Master Lever configured controls, each Lever may control two or more engine/transmission sets. A separate switch (not shown) is used to select multiple Engine/Transmission control from one Lever. The Station Select Button on the Control Head takes command at a specific location. The red Station Select Indicator LED light(s) next to the Station Select Button verify that the Control Head is active when continuously illuminated. When the Station Select Indicator LED is flashing or off, the Control Head is not active. The Mode Select Switch on the Control Head selects up to three engine cruise speeds, up to three trolling speeds, and/or optional Engine Synchronization, or Express Modes. The yellow Neutral Indicator LED light(s) provide for transmission status indication. Each Neutral Indicator LED will light constantly if the Transmission is in Neutral. It will flash if the Controller is in the Direction Disable Mode during engine warm-up. See Engine Warm-up while using direction Disable Mode.
151
System Operation
Lever Function in Cruise Mode

Selecting Forward (Ahead)
Move the Lever toward the bow of the boat to the Ahead Detent Position in order to select the ahead vessel direction. At this position, the transmission shifts into the forward or ahead gear. The remaining Lever travel after the Ahead Detent Position controls the engine throttle.
Selecting Reverse (Astern)

Move the Lever toward the stern of the boat to the Astern Detent Position in order to select the reverse vessel direction. At this position, the transmission shifts into the reverse or astern gear. The remaining Lever travel after the Astern Detent Position controls the engine throttle.
Direction Reversal
Reversals of direction can be made at any time. An automatic timed sequence forces the throttle to idle while the vessel slows before engaging the clutch for the opposite direction. This is followed by the return of the engine throttle to the position called for by the Lever.
152
System Operation
Lever Function in Express Mode

This mode allows the operator to achieve very low propeller speed by means of a controlled slipping clutch when the Lever is placed in the Ahead Detent or Astern Detent Position. Slight propeller speed variation at the Detent Position is normal in Express Mode. The propeller speed and engine speed will increase as the Lever is advanced, until the lever reaches a point where the clutch is fully engaged and then engine speed continues to increase as Lever position increases. The propeller speed at the Ahead Detent Position is calibrated by the operator placing the Port Lever in the Ahead Detent Position, and the Starboard Lever in the Neutral Detent Position, and then holding the Station Select Button depressed for more than two seconds. While keeping the Station Select Button depressed, the operator advances the Lever until the desired propeller speed is achieved. At this time, the operator releases the Station Select Button and then momentarily depresses the Station Select Button twice, and moves the Lever to the Neutral Detent Position. Note that if the optional display is present, it will prompt the user during this process. Repeat the above procedure for the Starboard Lever.
153
System Operation
Lever Function in Troll Mode

This mode allows the operation of the vessel at low speed by means of a controlled slipping clutch with the engine speed fixed, and the Lever controlling the propeller speed. The propeller speed at the Ahead Detent Position is calibrated by the operator placing the Port and Starboard Levers in the Ahead Detent Position and then holding the Station Select Button Depressed for at least two seconds. The yellow Neutral LED flashes at a rate proportional to propeller speed. While keeping the Station Select Button depressed, the operator then slowly advances the port Lever until the desired propeller speed is achieved on both the port and starboard sides. At this time, the operator releases the Station Select Button and then momentarily depresses the Station Select Button twice, and moves the Levers to the Neutral Detent Position. The propeller speed at the Ahead Detent Position is now updated and stored in memory for both the port and starboard controls. Note that if the optional display is present, it will prompt the user during this process.
154
System Operation
Lever Function in Master Lever Function

The Master Lever Function allows multiple engine vessels to be operated from the port most Lever at the active Control Station in the Ahead direction only. Although this function can be used on dual engine vessels, it is more commonly employed on vessels with three or more engines. The function can only be engaged when all Levers at the active Control Station are in the Ahead Detent Position, and The Master Lever Function Switch is on. The Master Lever Function is cancelled if any Lever at the active Control Station is moved out of Ahead or if the Master Lever Function Switch is turned off. When the Master Lever Function is active, all Controls in the system receive their Lever position commands and Mode Switch command from the port most Lever. All transmissions on the vessel will be in the Ahead gear, all Controls will be operating in the same Mode, and all engines will be operating at the same throttle setting. If the Master Lever function cannot be engaged, all controls will continue to use their own Lever and System Mode commands.
CAUTION When the Master Lever Function is cancelled, for any reason, each Control will revert to receiving throttle commands and system mode commands from its own Lever. If the position of the port Lever is significantly different from the position of the controls own Lever, this can potentially cause abrupt changes in vessel speed.
155
System Operation
Lever Function in Phantom Lever Function

The Phantom Lever Function allows multiple engines in a multiple engine vessel to be operated from one Lever while other engines are operated from other Levers. Although this function can be used on dual engine vessels, it is more commonly employed on vessels with three or more engines. This function can only be engaged when all Levers at the active Control Station are at the Neutral Detent Position and the Phantom Lever Function Switch is on. When the system is configured, one or more Controls are designated as phantom masters. Likewise, one or more Controls are designated as phantom slaves. A vessel employing the Phantom Lever Function must have at least one phantom master and one phantom slave. During configuration, when a control is designated as a phantom slave, it must also be assigned to a phantom master. When the Phantom Lever Function is engaged, all slaves receive throttle, gear, and system Mode commands from the phantom master to which they were assigned during configuration. The phantom slave control then operates at the same throttle, gear, and system mode settings as the master Control. The Phantom Lever Function is cancelled if any slaves Lever is moved from the Neutral Detent Position or if the Phantom Lever Function Switch is turned off. Note: The system will engage the Phantom Lever function by default if a Control Station is made active and any slave Control does not have a Lever attached to that station. In this case, the slave control will receive throttle, gear, and system Mode commands from its assigned master. If the Phantom Lever Function cannot be engaged, all slave Controls will command their engine to idle and their transmission to Neutral.
156
System Operation
Mode Select Switch

The operations that can be controlled by the Mode Select Switch depend on the type of Control Heads that are installed on the boat. Control Heads are available with a variety of function combinations. The following figures show the labels from several different Control Head configurations, some of which may be available in both single Lever and dual Lever Control Heads.
GEAR SHIFTER IS IN NEUTRAL POSITION WHEN INDICATOR ON. GEAR SHIFTER IS IN NEUTRAL POSITION WHEN INDICATOR ON.
SYNC CRUISE
EXPRESS TROLL
CRUISE 1
CRUISE 2
CRUISE 3
PORT
STATION SELECT
STBD
PORT
STATION SELECT
STBD
POWER COMMANDER
POWER COMMANDER
Figure 75. Control Head Labels

GEAR SHIFTER IS IN NEUTRAL POSITION WHEN INDICATOR ON. GEAR SHIFTER IS IN NEUTRAL POSITION WHEN INDICATOR ON.
CRUISE 1 SYNC
CRUISE 2 CRUISE 3
CRUISE 2 CRUISE 1
TROLL 1 TROLL 2
PORT
STATION SELECT
STBD
PORT
STATION SELECT
STBD
POWER COMMANDER
POWER COMMANDER
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System Operation
GEAR SHIFTER IS IN NEUTRAL POSITION WHEN INDICATOR ON.
CRUISE 2 CRUISE 1
SYNC
SYNC CRUISE EXPRESS
TROLL 1 TROLL 2
PORT
STATION SELECT
STBD
PORT
STATION SELECT
STBD
POWER COMMANDER
POWER COMMANDER

CRUISE 2 CRUISE 1 EXPRESS
CRUISE
EXPRESS
TROLL
PORT
STATION SELECT
STBD
PORT
STATION SELECT
STBD
POWER COMMANDER
POWER COMMANDER
The Mode Select Switch can be used to select any of the following, depending on the Control Head type that is installed at the active Control Station. o o o o o Select Cruise mode, and select up to three preset engine speeds while in the Cruise mode with the Levers in the Ahead Detent Position, Neutral Detent Position, or Astern Detent Position. Select Troll mode, and select up to two preset engine speeds while in the Troll mode. Select engine synchronization while in the Cruise mode. Select Express mode. Select engine synchronization while in the Express mode.
158
System Operation
Display Features
The optional Display can be used to provide a variety of information to the operator. There are two lines of data displayed at any time. When the Control is powered up, and a Control Station selected, the top line of the Display will show N, FWD, or REV, followed by CS1, CS2, or CS3 denoting the Control Station that is in command. The lower line of the Display will show CRUISE, CRUISE S, EXPRES, EXPRES S, or TROLL. This indicates the Mode in which the Control is operating, and whether it is operating in a Synchronized condition or not. The optional Display can be used to supply operating data at any time by pushing either the up arrow button or the down arrow button to scroll through the available information. The data that can be selected is PROP SPD on the top line, and XXXX RPM on the bottom line, ENGN SPD on the top line, and XXXX RPM on the bottom line and TRAN TMP on the top line, and XXX C on the bottom line.
159
System Operation
Station Transfer
Station Transfer is accomplished by pressing the Station Select Button on the Control Head.
Station Transfer Types

The EC300 Control System supports several optional types of Station Transfer. Twin Disc Incorporated or the local Technician makes the selection during Configuration. The four major types of Station transfer are discussed in the following sections. o o o o Instant Station Transfer Neutral Station Transfer Lever Match Station Transfer Lever Match with Acknowledge Station Transfer
160
System Operation
Instant Station Transfer

In this configuration, the station is selected as soon as the Station Select Button is pressed. This is regardless of the Lever position on either the active Control Head or the target Control Head. When the target Control Head is made active, all other Control Heads in the system are made inactive.
If a Station Select Button is depressed at a Control Head other than the active Control Head, the Controller will respond to the Lever positions and Mode Select Switch at the newly activated Control Head. Unexpected vessel operation can occur if Lever positions and Mode Select Switch settings are not in the desired positions prior to taking command at a new Control Station. 1. Place all Mode Select Switches and Levers in the desired position at the desired Control Station. Depress the Station Select Button on the Control Head to take command at the desired Control Station. Observe that the red Station Select Indicator LED light(s) next to the Station Select Button illuminate. Make other control selections as desired.
2.
3.
4.
Neutral Station Transfer

In this configuration, station transfers are only allowed when the Station Select Button on the target Control Head is pressed and the Lever(s) on the target Control Head are in the Neutral Detent Position. If the Station Select Button on the target Control Head is pressed, and the Lever(s) are not in the Neutral Detent Position, the Station Select Indicator LEDs (lights) on both the active Control Head and the target Control Head will flash. When the lever(s) on the target Control Head are moved to the Neutral Detent Position, the Station Select Indicator LEDs will stop flashing and the target Control Head will become the active Control Head. If the Target Control Head Lever(s) are not moved to the Neutral Detent Position within 10 seconds of the request, the station transfer request shall be cancelled and the Station Select Indicator LEDs will stop flashing. It is important to note that the target Control Station can be selected at any time by two consecutive presses of the Station Select Button to allow Control Station Transfer during emergency situations.
161
System Operation
Lever Match Station Transfer

This type of station transfer is designed to satisfy certain American Bureau of Shipping (ABS) specification requirements. In this configuration, station transfers are only allowed when the levers on the target and active Control Heads are in matching positions. If the Station Select Button on the target Control Head is pressed, and the Lever(s) on the target Control Head are mismatched from those on the active control head, the Station Select Indicator LEDs (lights) on both the active Control Head and the target Control Head will flash. The greater the mismatch, the slower the LED flash rate will be. As the Lever(s) on the target Control Head are moved closer to the position of the Lever(s) on the active Control Head, the LED flash rate increases. When the levers are matched, the target Control Head is automatically made active and the active Control Head made inactive. The Station Select Indicator LED on the now active Control Head will remain on. If at any time, while a mismatch condition exists, the Lever(s) on the active Control Head are moved, or if 10 seconds pass without the Lever(s) on the target Control Head being moved, the station transfer request shall be cancelled and the Station Select Indicator LEDs will stop flashing. It is important to note that the target Control Station can be selected at any time by two consecutive presses of the Station Select Button to allow Control Station Transfer during emergency situations.
162
System Operation
Lever Match with Acknowledge Station Transfer

This type of station transfer is designed to satisfy certain ABS specification requirements. In this configuration, station transfers are only allowed when the levers on the target and active control station are in matching positions and when the station transfer is acknowledged by the active Control Head. To initiate a station transfer, a Station Select Button on a Control Head at the target station must be pressed. The Station Select Indicator LEDs at both the active and target stations will begin to flash. This indicates to the active station that the target station has requested a transfer. Note: the Neutral Indicator LED for any Lever(s) at the active station which are at the neutral detent will also flash indicating that the associated transmission is in neutral. To continue, a Station Select Button on a Control Head at the active station must be pressed. This causes the Neutral Indicator LEDs on both stations to begin to flash, indicating to the target station that the active station has acknowledged the transfer request. If the Lever(s) at the active station and the target station are not matched, the Station Select Indicator LEDs and the Neutral Indicator LEDs on both the active and the target stations will be flashing. As the Lever(s) at the target station are moved closer to the position of the Lever(s) at the active station, the flash rate of the LEDs will increase. When the Lever(s) at the target station match the position of the Lever(s) at the active station, the Station Select Indicator LEDs at both stations will cease flashing and remain on while the Neutral Indicator LEDs at both stations will go to a rapid flash. This indicates to both stations that the Lever(s) are matched and the transfer may continue. The transfer is completed when the Station Select Button on a Control Head at the target control station is pressed. The button press is only recognized if the Lever(s) are matched. If, at anytime, no activity is seen at either station after a transfer has been initiated for a period of ten seconds, the transfer sequence will be canceled. Also, if the acknowledge has been made and the Lever(s) on the active control station are moved, the transfer will be cancel. It is important to note that the target Control Station can be selected at any time by two consecutive presses of the Station Select Button to allow Control Station Transfer during emergency situations.
163
System Operation
Manual Mechanical Control

This section addresses mechanical control at the push-pull cable connection at the engine, transmission, or troll valve in case of electrical or Control System failure. For electronic controls, see the applicable manufacturers literature for any suggestions. Some transmissions have a manual gear select capability in addition to electronic control. In the event that the Control System becomes inoperative, the push-pull cables are mechanically and electrically free to move. The throttle, troll, or gear select lever may be operated manually as required. If the servo actuator is resisting manual control, unplug the connector at the servo actuator. If the EC300 Marine Control system is at least partially functioning and a Twin Disc Display is present the Neutral Start Relay can be forced on in order to start the engine. Refer to the Troubleshooting Section for more detailed information. If the EC300 Marine Control System is not functioning, the engine can be started by placing a jumper between the neutral start interlock pins 9 and 10 in the cable connected to the EC300 Controls Connector J5. This jumper should be placed at the engine control if practical. Refer to the engine manufacturers drawings and wiring diagrams.
164
System Operation
Individual Engine Operations

Engine Start
1. At the selected Control Station, place the Lever(s) in the Neutral Detent Position. Place the ignition switch for the desired engine in the On position as required to activate the EC300 Control System. Press and release the Station Select Button on the Control Head. Note: The red Station Select Indicator LED for the desired engine must illuminate. Note: If only one Control is powered up in twin engine installations, starting of the second engine will require that the Station Select Button be depressed after the second engines ignition switch is turned on. 4. Verify that the red Station Select Indicator LED(s) next to the Station Select Button is illuminated. This indicates that the station is in command. Start the engine with the ignition switch. Warm the engine using the Mode Select Switch in a higher Cruise position, or Direction Disabling ,as required.
2.
3.
5. 6.
165
System Operation
Engine Warm-up while using Direction Disable Mode

Note: The direction disable feature can be used any time that engine speed above idle is required while keeping the transmission in neutral. The engine speed can be varied from minimum to maximum.
When the Lever is returned to the Neutral Detent Position from the Direction Disable Mode, the Controller will reset and normal operation will resume. That is, the transmission will shift when the Lever is moved in the Ahead or in the Astern direction without depressing and holding the Station Select Button. 1. Depress and hold the Station Select Button while moving the Lever(s) in either the Ahead or Astern direction. Set the desired engine speed by positioning the Lever(s). When the engine is warm, return the Lever(s) to the Neutral Detent Position.
2. 3.
Engine Shutdown
1. At the selected Control Station, place the Lever in the Neutral Detent Position. Place the ignition switch for the engine in the Off position in order to deenergize the EC300 Control System.
2.
166
System Operation
Engine Synchronization
Note: The port most engine is the master. All other engines are slaves. Synchronization operation in the EC300 Control System has the following features and characteristics: q q Logically controlled to operate only if all active engines are in Cruise Sync or Express Sync mode and Forward (Ahead) direction. Automatically turns on if all Levers are moved in the Forward (Ahead) direction and all Mode Select Switches are in the Cruise Sync or Express Sync position. Automatically shuts off if any Lever is moved out of the Forward (Ahead) direction. Authority is limited to approximately 7 1/2 degrees of the slaves Lever(s) position. A slave Control can add or subtract up to 7 1/2 degrees of lever travel from the engine throttle command received from the master control. Throttles can be used to maneuver the boat without turning synchronization off. A slaves engine speed will start to increase or decrease (depending on the direction of travel) if the slaves Lever has left the 7 1/2 degree synchronization window. With the master engine stable, the slave engine(s) will normally be brought to match the master engines speed within 5 rpm in 5 to 10 seconds. The timing depends on the differences between engine speeds prior to engaging synchronization. Synchronization is deselected by moving the Mode Select Switch out of the Cruise Sync or the Express Sync position.
q q
167
System Operation
Synchronizing Engines
Note: Synchronization occurs when all active slave Levers are within 7 1/2 degrees (approximately two finger widths) of the master Lever. 1. Move all Levers together while setting the master engine to the desired operating speed. Move the Mode Select Switch to the Cruise Sync or Express Sync position on all Control Heads. Note: The slave engine(s) will increase or decrease speed to match the master engine speed each time the master Lever is moved provided each slaves Lever is within 7 1/2 degrees of the master Lever. 3. To slightly change speeds, move the master Lever ensuring that the 7 1/2 degree synchronization window is maintained. To significantly change speeds, move all Levers together ensuring that the 7 1/2 degree synchronization window is maintained.
2.
4.
Ending Engine Synchronization

1. To end synchronization, do one of the following actions: q q q 2. At the selected Control Station, deselect Sync mode. Select the Neutral Detent Position or Reverse Detent Position with either Lever. Move either Lever beyond the 7 1/2 degree limitation in position.
Observe that the starboard engine speed no longer follows the port engine speed. Control engine speeds independently using the appropriate Levers.
3.
168
Troubleshooting
Troubleshooting
Introduction
This section includes diagnostic test mode instructions. Note: The Twin Disc display is required to run these tests. Note: These tests are also available via the Marine Field Support Tool (MFST).
Diagnostics Test Mode

Diagnostics mode is available for control system tests, and for ease in certain troubleshooting procedures. These tests verify operation of the control, integrity and function of the external circuits, and provide a means to energize clutches individually. They are also helpful in troubleshooting the transmission. Sixteen separate tests can be individually selected and performed via the display unit. This mode is entered by simultaneously depressing the up and down arrow switches on the display unit while powering the control by cycling the key switch off and back on.
169
Troubleshooting
Note: The TroubleshootingTesting discussions and charts that follow may include selections that do not apply to your installation.
Test 1. Display Test 1 DSPLAY TEST

Upon entering the Troubleshooting Mode, the display test will be entered automatically. 1 DSPLAY TEST will appear. After two seconds, all display segments/pixels will be displayed. After five seconds, the display will begin alternating between 1 DSPLAY TEST (for one second), all segments/pixels (for one second), and the firmware checksum, CHECKSUM XXXX. Test 1 may be exited by depressing either the up or down arrow button. If the down arrow button is pushed, the next display will be 2 POWER TEST. If the up arrow button is pushed, the next display will be 16 FAULT LOG. Subsequently pushing the up or down arrow button will scroll through the list of possible tests, numbered 1 through 16 (in either direction). When the desired test identifier is displayed, the test can be entered by simultaneously depressing the up and down arrow button.
170
EC300 Marine Control System Installation Manual # 1020607
Troubleshooting
Test 2. Power Supply Test 2 POWER TEST

The following sub-menu items will be displayed: SUPPLY VOLTAGE, REFERENC VOLTAGE, INTERNAL POWER, EXIT TEST. These are scrolled through by depressing the up or down arrow button. To enter one of the tests, simultaneously depress both the up and down arrow button. Once entered, the sub menu test may be exited by pushing the up arrow button. SUPPLY VOLTAGE will display the voltage level that is supplied to the primary and auxiliary power input pins on the controller. Note that connecting voltage to the auxiliary pins is optional. The display will show P:XX.XXV A:YY.YYV, where XX.XX is the voltage on the primary power input, and YY.YY is the voltage on the auxiliary power unit. Below 8 volts will indicate a blank display, and above 50 volts, the display will flash 50.00 V. Note: Both primary and auxilliary supply must be less than 32.0 VDC. Both primary and auxiliary supply must be greater than 10.1 VDC. REFERENC VOLTAGE will display the measured reference voltage for the analog to digital converter. If the voltage is not 2.50 V +/- 50 mv, the control cannot reliably measure any analog signal. The display will show REF X.XX V where X.XX is the reference voltage. INTERNAL POWER is a scan test of the other internal power supply nodes, and reports any nodes that measure outside of preset limits. Upon successful completion of this scan, the display will show TEST PASSED. If any voltages are out of range, the display will indicate the voltage name and the word FAILED. The internal voltage names are: REF, VSUST, OVR POW, XITE. The control must be replaced if one of these voltages are failed, and the proper voltage is being supplied to the Control. EXIT TEST will return the control to the main menu at the same point that it was when the test was entered.
171
Troubleshooting
Test 3. Station Test 3 STATN TEST

This test allows inspection of the three control station ports on the control. Upon entering this test, STATION1, STATION2, STATION3, or EXIT TEST can be selected. When a station is selected, the following sub-menu can be scrolled through: LeverCal, LEVER, MODE, POS VOLT, STAT SEL, POS CUR, REV SWCH, FWD SWCH, NEU LITE, EXIT SUB. Each individual test can be entered by simultaneously depressing the up and down arrow buttons. Upon entering LeverCal, a sequential sub-menu appears as follows: FULL FWD, DET FWD, FULL REV, DET REV. Each position also displays XXXX mV, indicating the voltage level at the lever position. Each position must be selected for calibration or skipped for the next selection to appear. The lever can be calibrated by placing the Lever in the position indicated, and simultaneously depressing the up and down arrow buttons. In each position, as both buttons are depressed, the message CalPoint SAVED will be momentarily displayed. If only the up arrow button is pressed, the message CalPoint SKIPPED will be momentarily displayed before the next selection is displayed. DEFAULT USED means the lever voltage was outside of the expected range. Lever calibration requires saving the value at each of the four positions in the order listed. After all four positions have been calibrated, the display returns to the sub-menu. Upon entering LEVER, LEVER X.XXV is displayed. Momentarily pressing the down arrow button will display LEVER YY.Y%, where X.XX or YY.Y is the Lever position in volts or percent. These displays will alternately be displayed each time the down arrow button is pressed. Upon entering MODE, the display will show the voltage that represents the position that the Mode Select Switch is in. Momentarily pressing the down arrow button will display the position that the Mode Select Switch is in. The positions listed will depend on the Control Head Type that is installed. One Control Head is used here as an example. Repetitively pressing the down arrow button will cause the display to alternate between two screens, such as MODE CRUISE and MODE X.XXV. Other alternating displays with the Mode Select Switch in other positions may include MODE CSYNC and MODE X.XXV, MODE ESYNC and MODE X.XXV, MODE EXPRESS and MODE X.XXV, MODE TROLL and MODE X.XXV, where X.XX is the voltage level. Upon entering POS VOLT, +X.XXV will be displayed where X.XX is the voltage level. Upon entering STAT SEL, STAT SEL X.XXV will be displayed. Repetitively pressing the down arrow button will cause the display to alternate between STAT SEL X.XXV and STAT SEL St1-PORT(OR STBD), where X.XX is the
172 EC300 Marine Control System Installation Manual # 1020607
Troubleshooting
voltage level, and PORT or STBD will depend on which controller is being tested. Upon entering POS CUR, +XXmA will be displayed where XX is the CURRENT level. Upon entering REV SWCH, CLOSED or OPEN will be displayed, indicating whether the lever is in the reverse position or not. Upon entering FWD SWCH, CLOSED or OPEN will be displayed, indicating whether the lever is in the forward position or not. Upon entering NEU LITE, OFF or ON can be toggled with the use of the down arrow button. The Neutral position light will be turned on and off. To exit the sub-menu, momentarily depress the up and down arrow button simultaneously while EXIT SUB is displayed. The test can be repeated for the other stations.
173
Troubleshooting
Test 4. Discrete Switch Test 4 SWITCH TEST

This test shows the status of the selected switches that are enabled on your installation. Upon entering this test, SHFT BRK STATUS, OIL PRES STATUS, OIL FILT STATUS, LVR ENB STATUS, DiagBoot STATUS, or EXIT TEST can be scrolled through with the use of the up or down arrow buttons. The displayed status is either OPEN or CLOSED.
SHFT BRK STATUS OIL PRES STATUS OIL FILT STATUS
= = =
Shaft Brake Switch Status Oil Pressure Switch Status Oil Filter Differential Pressure Switch Status Lever Function Switch Status Diagnostic Boot Switch Status (Not for Customer Use)
LVR ENB STATUS DiagBoot STATUS
= =
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Troubleshooting
Test 5. Boundary Scan Test 5 SCAN TEST
CAUTION
The engine must not be running when entering this test. If the engine is running, severe transmission and engine damage can result. Two options will be displayed on the sub-menu: RUN TEST and EXIT TEST. Upon selecting RUN TEST, the control will automatically check all speed sensor and coil circuits for continuity and miscellaneous sensors to verify that the signal is in the proper range. The display will show TESTING, followed by TEST PASSED if all functions are normal. Depressing the up arrow button will terminate the test and display EXIT TEST. If a fault is detected in a speed sensor circuit, the top half of the display will indicate which sensor is being tested, and the bottom half of the display will indicate the fault condition found. Pressing the up arrow button will allow the test to resume from that positiion, and continue until all sensors have been tested. EXIT TEST will then be displayed. The speeds tested are PROP SPD and ENGN SPD. The coils tested are FWD, REV, NEUTRAL, TROLL, and SHFT BRK.
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Troubleshooting
Test 6. Speed Read Test 6 SPEED RD TEST

The transmission input speed (ENG SPD), transmission output speed (PROP SPD), and EXIT TEST can be displayed during this test. The choices are displayed on the first line of the display, and the appropriate data is shown on the second line. The speed data will be displayed as XXXX RPM. The display will blink if the speed is above 9999 RPM. The display will show 0 RPM when the frequency is below 40 hz. The data value will be displayed until the up or down arrow button is pressed, and when EXIT TEST is selected, the control is returned to the main menu.
Test 7. Sensor Test 7 SENSOR RD TEST

This test allows the operator to view the data generated by the oil temperature sensor (OIL TEMP), and the internal temperature sensor (INT TEMP). When selected, the value is listed on the lower line as SXXX C. The S stands for the sign of the number, and XXX is the current temperature in degrees Celsius. The data value will be displayed until the up or down arrow button is pressed, and when EXIT TEST is selected, the control is returned to the main menu.
176
Troubleshooting
Test 8. Coil Test 8 COIL TEST

Upon entering this test, FWD, REV, SHFT BRK, TROLL, NEUTRAL, and EXIT TEST can be selected (depending on the software configuration). After selection of an individual coil, a sub menu will be displayed, showing the following options: FULL ON, MODULATE, PRESET, and EXIT SUB MENU. If FULL ON is selected, the selected coil will be powered with full on current. The display will show the coil selected and display FULL ON. Depressing the up arrow button will turn the coil off and go back to the sub menu. If MODULATE is selected, the selected coil can be toggled on in increments of 5% of full current with the use of the up arrow button. It can be reduced in increments of 5% of full current with the use of the down arrow button. The display will identify the coil selected, the percentage of full current, and the current value. (Example: FWD 55% .13A) The test can be terminated by reaching 100% and pressing the up arrow button again, or by simultaneously depressing both the up and down arrow buttons at any time. These actions will both result in EXIT SUB MENU being displayed. If PRESET is selected, current to the selected coil will be ramped linearly from zero to full current in 7.5 seconds, and then from full current to zero current over the next 7.5 seconds. This cycle will be continuously repeated until the up arrow button is pushed. This will turn the current to zero, and return the control to the sub menu listing the choices. While the cycling is continuing, the display will identify the coil, the percentage of full current, and the current level.
Test 9. Communication Tests 9 COMM TESTS

This test may be used to confirm the functionality of an externally installed RS232 communication link. This test requires special test harnesses, and is only used by qualified electronic technicians. Listed selections are RS232, Address, RS485, and EXIT TEST. If RS232 is entered, and proper connections are made, the message BAD LINK CONNECT Rx TO Tx or WORKING will be displayed. If Address is entered, the address of the communication port will be displayed as Address PORT Y-XX, STBD Y-XX, or INVALID, where Y is 0,1,2, or 3, and XX is 00, 01, 10, 11, 20, 21, 30, or 31. If RS485 is entered, the message RS485 WORKING or RS485 BAD LINK will be displayed.
177
Troubleshooting
Test 10. Speed Out Test 10 SPEED OUT TEST

This test allows the operator to generate a frequency via the control to test the vessels tachometer readout. Upon entering the test, TACH HZ and EXIT TEST will be displayed. If TACH HZ is selected, the display will show TACH HZ on the top line, and 0500 on the bottom line with the right most digit flashing to indicate it is selected for change. The flashing digit can be changed by using the up arrow. The other digits can be selected by using the down arrow. A frequency will be generated and sent to the tachometer output until the test is exited by simultaneously depressing the up and down arrow buttons.
Test 11. Warranty Date and Software/Hardware Version 11 VERSN WARRANTY

Four sub-menu items are available during this test: SOFTWARE VERSION, HARDWARE VERSION, WARRANTY DATE, and EXIT TEST. If SOFTWARE VERSION or HARDWARE VERSION are selected, the part number and the version will be displayed. Depressing the up arrow button will result in the sub menu again being displayed. If WARRANTY DATE is selected, the date shall be taken from memory and displayed as DDMMMYY. If the warranty has not been initialized, it will display NOT STARTED.
Test 12. Adjust Display 12 ADJST DISPLAY

Four sub menu items are available during this test: ADJUST BACKLITE, ADJUST CONTRAST, FACTORY DEFAULT, and EXIT TEST. If ADJUST BACKLITE is selected, three options are ADJUST BRITENES, SET MIN VALUE, and EXIT SUB MENU. If ADJUST BRITENES is selected, the display will indicate ADJUST NOW, and the brightness level can be adjusted by the up and down arrow buttons. The SET MIN VALUE will apply the lowest allowable setting to the brightness. EXIT SUB MENU will again display the first sub menu options. Selecting ADJUST CONTRAST will display ADJUST NOW, and allow the contrast to be adjusted by the up or down arrow buttons. Simultaneously depressing the up and down arrow buttons will display the first sub menu options. Selecting FACTORY DEFAULT will return the brightness and contrast to the factory default condition. The message, WORKING, will be displayed for two seconds to indicate that the action is complete. After FACTORY DEFAULT is again displayed, the test can be exited by simultaneously depressing the up and down arrow button, and then selecting EXIT TEST.
178
Troubleshooting
Test 13. Servo Test 13 SERVO TEST

This test will allow the operator to test the Servo Power driver and the servo position. Upon entering the test, the display will show TEST SERVO or EXIT TEST. If TEST SERVO is selected, the control will turn on the Servo Power driver, and OVER CURRENT or SERVO XXX% will be displayed. If SERVO XXX% is displayed, the right most digit will flash to indicate it is selected for change. The flashing digit can be changed by using the up arrow. The other digits can be selected by using the down arrow. The Servo will be positioned to the percentage of full rotation that is shown on the display. Press both the up and down arrow buttons simultaneously to set the servo output to zero, turn the Servo Power driver off, and exit. If OVER CURRENT is displayed, the Servo Power driver experienced an over current condition and was turned off. Press both the up and down arrow buttons simultaneously to turn the Servo Power driver off, reset the fault detection circuitry and exit to the Servo Test menu.
Test 14. Control Outputs 14 SWTCH OUTPUTS

This test allows the operator to select certain outputs that are a part of the control system, and turn them on or off as desired. ALM DRV, NEUT RLY, or EXIT TEST can be selected. If a switch or relay is present and selected, the display can be toggled between the open and closed condition, such as ALMDRV OPEN, and ALMDRV CLOSED, by pressing the down arrow button. Press the up arrow button to exit.
179
Troubleshooting
Test 15. Engine Throttle 15 ENGIN THROTTLE

This test allows the operator to manipulate the throttle output. Upon entering, TEST THROTTLE, or EXIT TEST can be selected. If TEST THROTTLE is selected, THROTTLE will be displayed on the top line, and XX% will be displayed on the bottom line with the right most digit flashing, indicating that it is ready for changing. Pressing the up arrow will increment the flashing digit. Pressing the down arrow will move the selected digit one to the left. The throttle will be set to the value shown. Pressing both buttons simultaneously will reset the value to zero and exit the test. If, upon entering the TEST THROTTLE, a problem exists, the message ThrotPwr FAULT will be displayed.
180
Troubleshooting
Test 16. Fault Log 16 FAULT LOG

This test gives limited access to the Fault Log Memory with the date and time of occurrences of logged fault messages. The following are the sub menu choices with a description of the contents. Note: The acronym NVM refers to the Non Volatile Memory in the control. ALL FAULTS SPEED SENSORS = = Record of all faults written to NVM Record of Speed Sensor faults written to NVM Record of Temperature Sensor Signal faults written to NVM Record of Station faults written to NVM Record of Lever faults written to NVM Record of Discrete Switch faults written to NVM Record of Coil Driver faults written to NVM Record of Power Supply faults written to NVM Record of Internal Controller faults written to NVM Record of Communication faults written to NVM Exit to Main Menu
TEMP SENSORS = STATION LEVER SWITCHES COILS POWER SUPPLIES INTERNAL FAULTS COMM FAULTS EXIT TEST = = = = = = = =
181
Troubleshooting
When any selection is made other than EXIT TEST, the sub menu of SHORT LOG LIST, LONG LOG LIST, and EXIT SUB MENU will be displayed. Selecting the SHORT LOG LIST will allow scrolling (by using the up and down arrow buttons) through any faults that have been logged into memory since the memory was last cleared. The logged code, date, and time for any faults logged for the category selected will be displayed, followed by the message END OF LOG. If no messages have been logged, the message NO LOG FAULTS will be displayed. The short log list can be cleared by depressing and holding the up arrow button for six seconds when at the beginning of the fault list. If this is done, the message CLEARING SHORT LG will be displayed while the clearing is occurring. Once cleared, the message NO LOG FAULTS will appear. Selecting the LONG LOG LIST will allow scrolling through any faults that had been logged into memory (by using the up and down arrow buttons). The logged code, date, and time for any faults logged for the category selected will be displayed, followed by the message END OF LOG. This list of faults can not be cleared. If the allocated memory capacity is exceeded, the first in faults will be overwritten. If no faults have occurred, NO LOG FAULTS will be displayed. Simultaneously depressing both up and down arrow buttons will exit the list, and EXIT SUB MENU must be selected to return to the main menu. Selecting EXIT TEST will return the control to the main menu.
Exit Test Mode

Exit the Test Mode by cycling the key switch off and back on.
182
Troubleshooting
CONTROL SYSTEM TROUBLESHOOTING

These rules apply to each of the test sequences on the following pages: v Simultaneously press both up and down arrow buttons while powering with the key switch to enter the test sequence v Simultaneously press both up and down arrow buttons to select any displayed test from the menu selection v Press down button to scroll through menu selection in order shown v Press up button to exit to the previous sub menu v Cycle power to exit testing v v v v
DISPLAY ACTION SEC
This shape shows exactly what is seen in the display This shape shows an action that must be accomplished This shape shows a programmed time delay This shape shows a decision that is reached
1 DSPLAY TEST 1 DSPLAY TEST 2 SEC DELAY ALL DOTS ON 5 SEC DELAY ALL DOTS ON CHECKSUM XXXX
PRESS UP OR DOWN ARROW OR BOTH TO EXIT TO MAIN MENU
Note: Be certain that the supply voltage is to spec before replacing a Control because of an Internal Power Failure. SUPPLY VOLTAGE REFERENC VOLTAGE INTERNAL POWER EXIT TEST P:XX.XX V A:XX.XXV REF X.XXV TEST PASSED
OR
2 POWER TEST
PRESS UP BUTTON TO EXIT SUB MENU
XXXXX FAILED
REPLACE CONTROL
Figure 79. Troubleshooting Flowchart
183
Troubleshooting

LEVER X.XX V LEVER XXX.X %
3 STATN TEST
LeverCal LEVER MODE
STATION1 STATION2 STATION3 EXIT TEST POS VOLT
MODE CRUISE MODE CSYNC MODE ESYNC MODE EXPRESS MODE TROLL X.XXV STAT SEL St1-PORT
OR
MODE X.XX V MODE X.XX V MODE X.XX V MODE X.XX V MODE X.XX V
FULL FWD XXXX mV DET FWD XXXXmV FULL REV XXXX mV DET REV XXXXmV PRESS UP and DOWN ARROWS TO CALIBRATE. PRESS UP ARROW TO SKIP STEP
STAT SEL
POS CUR REV SWCH FWD SWCH NEU LITE EXIT SUB
STAT SEL St1-STBD XXmA OPEN/ CLOSED OPEN/ CLOSED ON/OFF
STAT SEL X.XXV
TOGGLE WITH DOWN ARROW BUTTON
SHFT BRK OPEN/CLOSED OIL PRES OPEN/CLOSED OIL FILT OPEN/CLOSED LVR ENB OPEN/CLOSED DiagBoot OPEN/CLOSED EXIT TEST
4 SWITCH TEST
184
Troubleshooting

ENGN SPD FAILED PROP SPD FAILED FWD FAILED REV FAILED NEUTRAL FAILED TROLL FAILED SHFT BRK FAILED
5 SCAN TEST
ENGINE OFF
TESTING TEST PASSED
OR
RUN TEST EXIT TEST
PRESS UP BUTTON
PRESS UP BUTTON TO CONTINUE THRU TEST ENG SPD XXXX RPM PROP SPD XXXX RPM EXIT TEST OIL TEMP XXX O C 7 SENSOR RD TEST INT TEMP XXX O C EXIT TEST
6 SPEED RD TEST
FWD 8 COIL TEST REV SHFT BRK TROLL NEUTRAL EXIT TEST
FULL ON MODULATE PRESET EXIT SUB MENU
COIL ID FULL ON COIL ID XX% .XXA COIL ID XX% .XXA
PRESS UP OR DOWN ARROW TO CHANGE 5%. UP ARROW AFTER 100% OR PRESS BOTH TO EXIT
185
Troubleshooting

PORT CONTROL SHOWN RS232 WORKING RS232
OR
RS232 BAD LINK RS485 WORKING RS485 9 COMM TESTS Address EXIT TEST
OR
CONNECT RX TO TX
RS485 BAD LINK Address PORT X-XX

OR
INVALID
10 SPEED OUT TEST
TACH HZ EXIT TEST
TACH HZ 0000
PRESS DOWN ARROW TO SELECT DIGIT. PRESS UP ARROW TO INCREMENT DIGIT. PRESS BOTH TO EXIT TEST
SOFTWARE VERSION 11 VERSN WARRANTY HARDWARE VERSION WARRANTY DATE EXIT TEST
XXXXXXX X.XX XXXXXXX X DDMMMYY

OR
PRESS UP BUTTON TO EXIT
NOT STARTED

186 EC300 Marine Control System Installation Manual # 1020607
Troubleshooting

ADJUST BACKLITE 12 ADJST DISPLAY ADJUST BRITENES SET MIN VALUE EXIT SUB MENU ADJUST NOW WORKING 2 SEC
PRESS UP TO INCREASE PRESS DOWN TO DECREASE PRESS BOTH TO EXIT PRESS UP TO INCREASE PRESS DOWN TO DECREASE PRESS BOTH TO EXIT
ADJUST CONTRAST FACTORY DEFAULT EXIT TEST
ADJUST NOW WORKING 2 SEC
PRESS BOTH UP AND DOWN ARROW TO TURN DRIVER OFF, RESET FAULT CIRCUIT, AND EXIT TEST
BAD
13 SERVO TEST
TEST SERVO EXIT TEST
OVER CURRENT SERVO XXX% PRESS DOWN ARROW TO SELECT DIGIT. PRESS UP ARROW TO INCREMENT DIGIT. PRESS BOTH TO EXIT TEST
IF GOOD
ALM DRV 14 SWTCH OUTPUTS NEUT RLY EXIT TEST Selected output OPEN or CLOSED
PRESS DOWN ARROW TO TOGGLE.

EC300 Marine Control System Installation Manual # 1020607 187
Troubleshooting

ThrotPwr FAULT THROTTLE XXX%
15 ENGIN THROTTLE
TEST THROTTLE EXIT TEST
BAD IF GOOD
DEPRESS BOTH SWITCHES TO EXIT TEST
16 FAULT LOG ALL FAULTS SPEED SENSORS TEMP SENSORS STATION LEVER SWITCHES COILS POWER SUPPLIES INTERNAL FAULTS COMM FAULTS EXIT TEST EXIT SUB MENU LONG LOG LIST SHORT LOG LIST
DEPRESS BOTH SWITCHES TO EXIT TEST SCROLL THRU FAULTS WITH UP OR DOWN ARROW
OR
CLEAR SHORT FAULTS BY HOLDING UPARROW FOR SIX SECONDS AT BEGINNING OF LIST
NO LOG FAULTS
CLEARING SHORT LG
SCROLL THRU FAULTS WITH UP OR DOWN ARROW
AFTER 2 SECONDS FAULT AND DATE/ TIME WILL ALTERNATE
DEPRESS BOTH SWITCHES TO EXIT TEST END OF LOG
188
Preventative Maintenance
Periodic Visual Inspection

Check all electrical wiring, components (switches, magnetic pickups, etc.) and connections for security, chafing and/or other damage. Tighten loose connections and replace any damaged parts. Reroute or otherwise secure wiring to prevent chafing damage.
Control Cables and Wiring

Inspect and care for control cables and harnesses as follows: 1. Check that cables and/or harnesses are away from hot surfaces, moving parts and oil locations. Check that circular connectors are hand tight. Inspect connectors for damage or defects. For example: bent pins, pushed-back sockets, broken keys, etc. Check the cable and/or harness tie downs. Keep cable securely fastened. Check the condition of the cables and/or harnesses at any rub points. Check cables and/or harnesses for cracks, effects of vibration, abrasion, brittleness or abuse.
2. 3.
4.
5. 6.
189
Control Head
Chrome plated Control Heads should be polished periodically using a chrome polish.
Control
Inspect mounting points for security and damage. Re-torque any loose mounting bolts. Confirm security of bond wire ring lug. Check that Control is not mounted where it may be subject to significant heat or vibration.
Station Doubler
Inspect mounting points for security and damage. Re-torque any loose mounting bolts. Confirm security of bond wire ring lug. Check that Station Doubler is not mounted where it may be subject to significant heat or vibration.
Servo Actuator
Inspect and correct any damage or concerns in the following: q q q q q Mounting points Bond wire Heat/ vibration related distress Push/pull Cables Actuator arm and cable ends
190
Engineering Drawings
List of Engineering Drawings

The following pages include the generic engineering drawings that are applicable to the EC300 Control System. These generic drawings are listed below. Application specific drawings may also be applicable if they are supplied separately. Note: Any part numbers listed in the following engineering drawings are for reference only. Please refer to your bill of materials for part numbers specific to your application. q q q q q q q q q 1018791 EX8892 Morse 33 Series Cable Mounting Dimensions 1020676 EC300 Control Mounting Dimensions Sheet 1 EC300 Control Mounting Dimensions Sheet 2 Servo Actuator Mounting Dimensions Twin Disc Display Mounting Dimensions Generic Interconnection and Wiring Diagrams Sheet 1 Generic Interconnection and Wiring Diagrams Sheet 2 Generic Interconnection and Wiring Diagrams Sheet 3 Generic Interconnection and Wiring Diagrams Sheet 4
1020676
EX8892
EX8892
EX8892
191
q q q
Control Head Mounting Template Interface Assembly Mounting Template Selector Assembly Mounting Template
192
Morse 33 Series Cable Mounting Dimensions
69.9 (2.75)
184.1 (7.25)
FABRICATE BRACKET LEVER TO PROVIDE DIMENSIONS SHOWN 25.4 (1.00)
CABLE CLAMP SHIM

TD10005
193
EC300 Control Mounting Dimensions Sheet 1 (1020676)
194
EC300 Control Mounting Dimensions Sheet 2 (1020676)
195
Servo Actuator Mounting Dimensions
196
Twin Disc Display Mounting Dimensions (1018791)
197
198
200
202
204
206
Control Head Mounting Template
207
208
Interface Assembly Mounting Template
209
210
Selector Assembly Mounting Template
211
212
Appendix
Appendix
Caterpillar Engine Connection Requirements
This throttle signal configuration is known as a PWM/Duty Cycle. The EC300 throttle signal is set to approximately 9% at idle and 92% at full throttle. Generally, the EC300 is connected to the engine control at the connections designated for the Primary Throttle Position Sensor or TPS. Depending on the model and harnessing provided, the EC300 Engine Harness (J5) will either be connected to the Primary Throttle Position Sensor connector, or directly to the Customer Connector. See Table 7 and Table 8. Refer to the engine manufacturers literature to resolve any discrepancies. Table 7. Engine Connections at Caterpillars TPS Connector
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common TP S Connector A C B
(Note 2) (Note 1)
Engine Signal Description Switched Positive (ECM Power) Primary Throttle Position Signal Negative Battery (ECM Power)
1) The Battery Positive connection to J5-1 should be switched and from ECM wiring. 2) The Battery Negative connection to J5-3 should be from ECM wiring - not battery bus.
Table 8. Engine Connections at Caterpillars Customer Connector

EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Customer Connector P i n 30 P i n 10 Pi n 2 Engine Signal Description Battery + (switched) Primary Throttle Battery -
A-1
Appendix
Cummins Engine Connection Requirements

Vary with Type (Series) of Engine
Cummins Centry Engine Connection Requirements

The EC300 supports the Cummins Centry Type 8 engine controller. This controller is used on QSK, QSM-11, 485, 480C, and KTA type engines. The KTA engine is configured for a current loop interface. All other types are voltage interfaces. The EC300 supplies approximately 1.1 volts at idle and 3.95 volts at full throttle when configured as a Cummins voltage output and 5.5 ma at idle and 19.8 ma at full throttle when configured as a Cummins current loop output. All Cummins installations require pin one of J5 on the EC300 controller to be connected to a 12 to 24 volt supply controlled by the ignition switch. A three pin GM Packard Weather Pack connector (12010717) mates with the Cummins OEM throttle connector.
Table 9. Engine Connections at Cummins 50 pin Connector

EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Cummins OEM Connector Ignition Switched +12 or +24 Volts Pi n B Pi n A Throttoe Position (Throttle) V Throttle Return (GND) Engine Signal Description
A-2
C300 Marine Control System Installation Manual #1020607
Appendix
Cummins Quantum Voltage Type Engine Connection Requirements

This throttle signal configuration is a DC voltage. The EC300 throttle signal is set to approximately 0.1.1 VDC at idle and 3.95 VDC at full throttle. This configuration is typically used with Cummins QSM-11, 485C and QSK models with Quantum series engine controls. Generally, the EC300 is connected to the engine control at the connections designated for the throttle or throttle pot. Depending on the model and harnessing, the EC300 wiring will connect to the Throttle or the OEM connector. See Table10 and Table 11. Refer to the engine manufacturers literature to resolve any discrepancies.
Table 10. Engine Connections at the Cummins Throttle Harness Stub

EC 300 Engine H arness J5 J5-1 EC 300 Signal D escription EC M Power Supply Throttle C onnector Igni ti on Swi tched +12 or +24 Volts D D Pi n B D D Pi n A Throttle Posi ti on (Throttle) V Throttle Return (GND ) Engine Signal D escription
J5-2 J5-3
Throttle Si gnal EC M Power Supply C ommon
Note: Not all QSK Throttle Pot C onnectors are "D D ".
Table 11. Engine Connections at the Cummins Quantum QSM-11 Engine with Voltage Control
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common OEM Connector QSM-11 D D Pi n C D D Pi n B D D Pi n A Engine Signal Description V Throttle (VTP) Throttle Position (Throttle) V Throttle Return (GND)
A-3
Appendix
Detroit Diesel Voltage Engine Connection Requirements

for Voltage Control Table 12. Engine Connections at the Detroit Diesel Engine
EC300 Engine Harness J5 J5-1 J5-2 EC300 Signal Description ECM Power Supply Throttle Signal Engine Connector Engine Signal Description
Ignition Switched +12 to +24 Volts MIM Plug DRC16-24S P i n 14 MIM Plug DRC16-24S P i n 15 Series 60 Wiper Series 60 RTN
J5-3
ECM Power Supply Common
Deutz Type 1 Engine Connection Requirements

for Voltage Control Table 13. Engine Connections at the Deutz Type 1 Engine
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Engine Connector Engine Signal Description D S C 1005 60V
Ignition Switched +12 to +24 Volts B8 A7 X 4 P i n 81 Signal X 4 P i n 82 Ground

(Note 1)
(Note 1)
1) Remove wiring from signal input range transformer
A-4
Appendix
Deutz Type 2 Engine Connection Requirements

for 4-20mA Loop Control Table 14. Engine Connections at the Deutz Type 2 Engine
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Engine Connector Engine Signal Description W/RSC 671 From 5550/5570 Governor Via Diode From 671 Speed Control From 671 Module Speed Control
Terminal F of Gov Terminal 4 of Speed Control Terminal 5 of Speed Control
Note: Verify that Terminal F of the speed control is switched power (Battery +) that will be turned off when the boat is not in use.
John Deere Engine Connection Requirements

This throttle signal configuration is a DC voltage. The EC300 throttle signal is set to approximately 0.50 VDC at idle to 4.50 VDC at full throttle. This configuration is similar to the voltage types explained above; however, see the engine manual for complete details on interconnections for throttle input to the engine harness/engine control. Table 15. Engine Connections at the John Deere Engine
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Engine Connector W/SE4/ECU Ignition Switched +12 to +24 Volts S1 Pi n B S1 Pi n A Throttle Pot Wiper Sensor Return Engine Signal Description
Note: Connections should be made as close to the Engine Control Unit (ECU) as possible
A-5
Appendix
MAN Current Engine Connection Requirements

for 4-20mA Loop Control This throttle signal configuration is a current loop and is set to approximately 3.8 mA at idle and 20.3 mA at full throttle. This configuration is similar to the Cummins current loop explained above; however, see the engine manual for complete details on interconnections for throttle input to the engine harness/ engine control. Table 16. Engine Connections at the MAN Engine with Current Control
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Engine Connector
(Note 1)
Engine Signal Description Batt + From T515 4-20 MA + 4-20 MA Batt - From T531
X9 Pi n 7 X9 Pi n 9 X 9 P i n 10 and Pin 8
1) Wiring may be required inside MAN engine control to get switched battery + (terminal 15) to wiring side of connector X9 Pin 7.
A-6
Appendix
MTU Engine Connection Requirements

for 4-20mA Loop Control This throttle signal configuration is a current loop and is set to approximately 3.8 mA at idle and 20.3 mA at full throttle. This configuration is similar to the Cummins current loop explained above; however, see the engine manual for complete details on interconnections for throttle input to the engine harness/ engine control. Table 17. Engine Connections at the MTU Engine
EC300 Engine Harness J5 J5-1 J5-2 J5-3 EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Engine Connector Engine Signal Description W/EL55 (MOEL) + 24V D C I in 4-20 MA GRND
LOP1 Terminal 91 LOP1 Terminal 83 LOP1 Terminal 84
Note: Connecions are for MDEC (ECS 5) version only. Check wiring diagram for engine to verify connection terminal numbers for other controls.
A-7
Appendix
Volvo Penta Engine Connection Requirements

This throttle signal configuration is a DC voltage. The EC300 throttle is set to approximately 0.44 VDC at full throttle reverse, 1.65 VDC at reverse idle, 1.90 VDC at neutral idle, 2.15 VDC at forward idle, and 3.80 VDC at full throttle forward. See the engine manual for complete details on interconnections for throttle input to the engine harness/engine control. Table 18. Engine Connections at the Volvo Penta Engine
EC300 Engine Harness J5 J5-1 J5-2 EC300 Signal Description ECM Power Supply Throttle Signal Engine Connector Engine Signal Description TAMD Series
Ignition Switched +12 to +24 Volts Throttle Pot Connector Pi n 3 Throttle Pot Connector Pi n 2 ED C Green/Orange wire (GN/OR) ED C Green/Yellow wire (GN/Y)
J5-3
ECM Power Supply Common
Note: Wires should be connected as close to engine control (Electronic Diesel Control) as possible.
A-8
Appendix
Scania Engine Connection Requirements

This throttle signal configuration is a DC voltage and is set to approximately 0.35 VDC at idle and 3.10 VDC at full throttle. This configuration is similar to the voltage types explained above; however, see the engine manual for complete details on interconnections for throttle input to the engine harness/engine control. Table 19. Engine Connections at the Scania Engine
EC300 Engine Harness J5 J5-1 J5-2 J5-3 +24V EC300 Signal Description ECM Power Supply Throttle Signal ECM Power Supply Common Switched Power Engine Connector Engine Signal Description W/DEC 2 TPSE TPSS TPSR Ye Remote Throttle Validation
Ignition Switched +12 to +24 Volts C36-12 C36-11 C36-9
Note: The +24V signal to C36-9 must by provided to prevent 'set' Throttle Limp Home mode.
A-9
Appendix
Transmission State Signals

The EC300 provides complimentary transmission state signal outputs. These are optically isolated outputs capable of sinking or sourcing 50 mA of current, depending on the wiring configuration. The transmission in neutral output allows current to flow when the EC300 is commanding the transmission to neutral; the transmission in gear output is off in this state. Likewise, the transmission in gear output allows current to flow when the EC300 has engages either the forward or reverse clutch; the transmission in neutral output is off in this state. The options below depict the various wiring options for these outputs.
A-10
#1020607 09/03
TWIN DISC, INCORPORATED
RACINE, WISCONSIN 53403, U.S.A.
262-638-4000/262-638-4482 (FAX)
WWW.TWINDISC.COM

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INCORPORATED INCORPORATED

Installation Installation and Operators Oper ators Manual

Document Number: 1020607

Document Number 1020607

Marine Control System Installation and Operators Manual

Twin Disc, Incorporated

Component Installation ................................................ 27

Electrical Installation .................................................... 61

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Configuration .............................................................. 133

System Operation ........................................................ 149

Preventative Maintenance .......................................... 189

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Engineering Drawings ................................................ 191

Appendix ...................................................................... A-1

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

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EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Source of Service Information

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Twin Disc, Incorporated

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Basic System Components

Single engine with one station

Single engine with two stations

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Table 2. Typical Components for Basic Systems (continued)

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Table 3. Typical Speed Sensor Types

Tachometer Generator with Drive Tang

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Other Items Which May Be Required

Installations Requiring Four to Six Control Stations

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Brackets and hardware for mounting the Station Doubler(s)

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Installations With a Servo Actuator Option

EC300 Marine Control System Installation Manual #1020607

Twin Disc, Incorporated

Installation In Starter Solenoid Circuits Greater Than 5 Amps

Push-Pull Cable Installation on Nonconductive Vessels

Master or Phantom Switch Installations

EC300 Marine Control System Installation Manual #1020607