Transcription
TWIN onMarineControl SystemControlManualModel:EC200/250/251Document Number: 1018434
NOTICETwin Disc, Incorporated makes no warranty or guaranty of anykind, expressed, implied or otherwise, with regard to theinformation contained within this manual. Twin Disc, Incorporatedhas developed this manual through research and testing of theinformation contained therein. Twin Disc, Incorporated assumesno responsibility for any errors that may appear in this manualand shall not be liable under any circumstances for incidental,consequential or punitive damages in connection with, or arisingout of, the use of this manual. The information contained withinthis manual is subject to change without notice.
Document Number1018434Revision FMarch, 2006Model EC200/250/251Marine Control SystemInstallation Manual
Note:Revision E is the same as Revision D except page 106 was replaced with aproperly scaled drawing. Added table on page 132.Revision F corrected some errors in a table on page 131. Reference ECN13959.
TWIN DISC, INCORPORATEDEXCLUSIVE LIMITED WARRANTYMarine Electronic Control SystemsA. Twin Disc, Incorporated warrants the aforementioned assembled products and parts (except component products or parts onwhich written warranties are issued by the respective manufacturers thereof and are furnished to the original customer, as towhich Twin Disc, Incorporated makes no warranty and assumes no liability) against defective materials or workmanship for a period offorty-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 ofservice, whichever occurs first . This is the only warranty made by Twin Disc, Incorporated and is in lieu of any and allother warranties, express or implied, including the warranties of merchantability and fitness for a particularpurpose 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,Incorporated’s 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, Incorporated’s limited liability), the exclusive remedy providedby 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 orreplacement 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 andremedy 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 TwinDisc, 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 tothe date placed in service.The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the productor part with installations properly engineered and in accordance with the practices, methods and instructions approved orprovided by Twin Disc, Incorporated.The warranty is void unless all required replacement parts or products are of Twin Disc origin or are Twin Disc authorizedreplacement parts, and otherwise identical with components of the original equipment. Replacement parts or products notof 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, includingwithout limitation, the original customer’s and subsequent purchaser’s employees and property, due to their acts or omissions orthe acts or omissions of their agents, and employees in the installation, transportation, maintenance, use and operation of saidequipment.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 inadvance in writing by Twin Disc, Incorporated.E.Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without beingobligated to incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers will notuse any such changes as evidence of insufficiency or inadequacy of prior designs or materials.F.If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on ano-charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on thecomplete unit.June 24, 2003TDWP3100
Table of ContentsTwin Disc, IncorporatedTable of ContentsGENERAL INFORMATION . 11GENERAL . 11SAFETY . 11WARRANTY. 11SERVICE INFORMATION . 11Section 1 - GENERAL . 13REQUIRED TOOLS .15REQUIRED SUPPLIES .15OTHER ITEMS WHICH MAY BE REQUIRED (DEPENDING ON .INSTALLATION).16MAXIMUM STANDARD LENGTH NOTICE:.20Section 2 - CONTROL AND TROLL ACTUATORINSTALLATION . 21IMPORTANT GENERAL NOTE .21Installation .23SECTION 3 - ENGINE SPEED SIGNAL .GENERATOR INSTALLATION (Twin EngineInstallations With Sync) . 27MAGNETIC PICKUP .27Magnetic Pickup Installation .28Sensor Doubler .29Tach Signal Generators .30IGNITION MODULE (SPARK IGNITION ENGINES ONLY) p/n1015172.30Ignition Module Installation Wiring .31EC200 Series Marine Control System Manual # 10184347
Table of ContentsTwin Disc, IncorporatedSection 4 - LEVER, STATION, 1-TO-2 DOUBLER,AND COMMUNICATION HARNESS.INSTALLATION . 33Lever Installation.33Station Harness Installation .36Final Installation For Stations .38Communication and Sensor Harnesses .39SECTION 5 - J6 CONTROL CONNECTIONS . 41Neutral Start Wiring .42FOR INSTALLATIONS NOT REQUIRING AN ISOLATION RELAY .42FOR INSTALLATIONS REQUIRING A RELAY.44Stand Alone Troll Actuator Wiring (Installations with Troll Only) 45Ignition Switch Wiring .46Power Wiring .47Electronic Options Wiring .49THROTTLE: .49GEAR SHIFTER .59TROLLING VALVE CONTROL .60SECTION 6 - PRELIMINARY TESTS . 63Troll Actuator Tests(Installations with Mechanical TrollActuators) .66Speed Signal Generator Test (Twin Engine Installations w/Sync) .67Troubleshooting Magnetic Pickup Installations .68Troubleshooting Tachometer Generator Installations .69Troubleshooting Ignition Module Installations .70SECTION 7 - PUSH-PULL CABLE INSTALLATION . 71Throttle Push-Pull Cable Installation .72GEAR SELECT PUSH-PULL CABLE INSTALLATION .778EC200 Series Marine Control System Manual # 1018434
Twin Disc, IncorporatedTable of ContentsSECTION 8 - FINAL TESTS & ADJUSTMENTS 81Cable Tests .81Engine Running Test .82Fast Idle with Direction Disable Test .83Engine Synchronization (sync) Test .84Idle Set Speed Adjustments .87Throttle Clamp Selection .90Hold in Gear Time Adjustment.91Final Installation .93SECTION 9 - OPERATION . 95Basic System Features .95System Operation .96Engine Start .96Engine Warm-up .97Operation .97APPENDIX . 103MORSE 33 SERIES CABLE MOUNTING DIMENSIONS . 103CONTROL MOUNTING DIMENSIONS . 104TROLL ACTUATOR MOUNTING DIMENSIONS . 105CONTROL HEAD MOUNTING TEMPLATE . 106Push-Pull Cable Mounting . 107Push-Pull Cable Alignment/Check Procedure . 108Cable Alignment/Check Procedure . 109Shaft Brake Control Option Details .117Pressure Switch Based Throttle Clamp .119EC200 Series Marine Control System Manual # 10184349
Table of ContentsTwin Disc, IncorporatedEC250 INSTALLATION/OPERATION MANUALADDENDUM . 121GENERAL: . 121ACCESS PANEL . 124GEAR AND TROLL VALVE CONNECTIONS . 125EC250 TROLL SWITCH SETTING . 126Configuration Steps: . 126Troll Current Ranges for New EC200/250 PIC Software .1021410. 131EC251 EXPRESS INSTALLATION/OPERATIONADDENDUM . 133SYSTEM DESCRIPTION . 133INSTALLATION . 133General . 133Access panel . 136OPERATION. 137EC251 SWITCH SETTINGS . 141Configuring Cruise, Express and Troll . 141Configuration Steps: . 14110EC200 Series Marine Control System Manual # 1018434
GeneralTwin Disc, IncorporatedGENERAL INFORMATIONGENERALThis publication provides the information necessary for the installation, adjustment, and operation of the TwinDisc Model EC200 Marine Control System.SAFETYSafe operating practices must be employed by all people installing and operating this unit. Twin Disc is notresponsible for any personal injury resulting from unsafe and careless use of hand tools, power tools, liftingequipment or unsafe practices during installation and operation.Because of the possible danger to people or property from accidents which may result from the use ofmanufactured products, it is important that correct procedures be followed. Products must be used in accordancewith the information specified.Proper installation procedures must be used. Proper safety devices such as guards may be required asspecified in applicable codes. Safety devices are not provided by Twin Disc nor are they the responsibility ofTwin Disc.WARRANTYEquipment for which this manual was written has a limited warranty. Contact your dealer for details regardingthe limited warranty.SERVICE INFORMATIONEach series of manuals issued by Twin Disc are current at the time of printing. Changes are made to reflectadvances in technology and improvement in state of the art when required. All revisions and designimprovements are subject to change without notice.Individual product service bulletins are issued to provide the field with immediate notice of new service information.These service bulletins are distributed to all Twin Disc EC200 distributors throughout the United States andmany foreign countries. Contact your nearest Twin Disc distributor for the latest service information.NOTICEThere are several models of Twin Disc Marine Propulsion Control Systems.Use this manual (#1018434) for installation, setup, testing, and operation ofthe Model EC150, EC200, and EC250 control (actuator) boxes; Use also forEC200 lever (control head). Use manuals # ASM203414 and #ASM203415for installation, setup, testing, and operation of the EC150 lever (control head).Note: Unless otherwise specified, dimensions are shown ininches (mm).EC200 Series Marine Control System Installation Manual 101843411
General12Twin Disc, IncorporatedEC200 Series Marine Control System Installation Manual 1018434
Section 1 GeneralTwin Disc, IncorporatedSection 1 - GENERALPLEASE READ THESE GENERAL COMMENTS ON INFORMATION TOFOLLOW:The following instructions are intended to cover typical installation of single ortwin engine systems with one or two control stations as standard, and up to sixcontrol stations with optional accessories and cables. For connecting andcabling, refer to the appropriate system drawing for your boat. The EC200control system has been provided with connectors to reduce installation timeand errors. Except for the power/interface cable, all other cables are availablefrom the factory in certain standard length increments, or custom made to lengthin two-foot increments. Since the power/interface cable is made up differentlyfor each boat, it is not practical to inventory these cables. Connector kits areavailable for use in making the power/interface cable assembly duringinstallations. The installer must provide suitable wire crimping tools and cable.The installer must follow the drawing provided for the system, and assemblethe connector on the boat. Cables should never be installed in a manner whichputs strain on the connector or which results in more than a foot or two of excesslength. A service loop, or drip leg, should be provided in each cable at thecontrol box but it should be tied down so that it will not freely move around whenthe boat is in motion and cause the wiring to fatigue and break apart. Theconnectors have a resilient seal insert that seals to the insulation of each wirein the connector. Do not attempt to fit two wires into any of the connectorpositions. Sealing plugs are provided for unused positions of the power/interface cable to insure the sealed nature of the connected cable assembly,do not discard these white plastic plugs, as they must be inserted into the unusedpositions.The following information is provided as a guide for your pre-installation partscheck to be sure that you have ordered and received all of the componentsnecessary for system installation. Typical system types and major componentsneeded are:Single engine with single station -- One (1) single lever control head,one (1) control box, one (1) station harness, one (1) power connectorkit, push-pull cables, installation hardware kits, and troll components iftroll option selected.Single engine with two stations -- Two (2) single lever control heads,EC200 Series Marine Control System Manual #101843413
Section 1 GeneralTwin Disc, Incorporatedone (1) control box, two (2) station harnesses, one (1) power connectorkit, push-pull cables, installation hardware kits, and troll components iftroll option selected.Twin engine with single station -- One (1) dual lever control head, two (2)control boxes, one (1) station harness, one (1) comm harness, two (2)power connector kits, push-pull cables, installation hardware kits, andtroll and/or sync components if those options were ordered.Twin engine with two stations -- Two (2) dual lever control heads, two (2)control boxes, two (2) station harnesses, one (1) comm harness, two (2)power connector kits, push-pull cables, installation hardware kits, andtroll and/or sync components if those options were ordered.This 1018434 manual is the installation manual for the Twin Disc Model EC200 Marine Control System. This section provides a list of required tools andsupplies for installing the system. The list is only representative of requirementsfor common installations and may not apply in all cases. The installer shouldperform the work in the order presented in this manual to simplify installation:Section 2 describes where and how to mount the controls and trollactuators (when used).Section 3 details the procedure for installing the speed signalgenerators used for sync operation (two or more engine installationsonly).Section 4 details the procedure for installing the lever wiringharnesses, lever assemblies, and 1-to-2 doublers (when used).Section 5 provides information for connecting the power, neutralsafety, control lever and speed sensor (when used) wiring to the controlsand troll actuators (when used), and electronic engines or transmissions(when present).Section 6provides procedures for pretesting the system.Section 7 contains information for installing and adjusting the engine,transmission and troll actuator push-pull cables (when used).14Section 8details system final adjustments and checks.Section 9covers general operation.EC200 Series Marine Control System Manual # 1018434
Section 1 GeneralTwin Disc, IncorporatedREQUIRED TOOLSInstallation requires the following tools that are not supplied with the base controlsystem:electric or pneumatic drillassorted drill bitscenter punchsmall hammer3/8 in. drive socket with extensions #1 Phillips screwdriverscrewdriver with a 1/8 in. bladewire terminal crimperstachometer or frequency counterDC voltmeterwatch with a seconds handwire strippers3/32 in. hex key (allen) wrench1/2 in. open-end wrench1/8 in. hex key (allen) wrenchDeutsch crimp toolREQUIRED SUPPLIESInstallation requires the following supplies that are not furnished with the basecontrol system:assorted wire terminal lugs, cable ties, and cable crimps.Dow Corning #4 dielectric compound (Twin Disc p/n MA-890).hookup wire (stranded copper, #14 AWG min. unless otherwise noted).Colors:yellow w/red stripepurpleblackredgreen-neutral startignitionbattery negative (-)*battery positive ( )*bonding*These wires must be a twisted pair.EC200 Series Marine Control System Manual #101843415
Section 1 GeneralTwin Disc, Incorporatedpush-pull cables (Morse 33 Series RED JAKET Supreme or equivalent).One required per mechanically governed engineOne required per mechanically shifted transmissionLength of cables depends on distance between components and routingof cables.brackets and hardware for mounting and connecting cables to theengine(s) and transmission selector valve(s).NOTE:MORSE 33 SERIES CABLE MOUNTING DIMENSIONSARE GIVEN IN THE BACK OF THIS MANUAL TO AID INBRACKET FABRICATION.NOTE:QUICK DISCONNECT BALL JOINT AND CLAMP KITSFOR MORSE 33 SERIES PUSH-PULL CABLES AREAVAILABLE FROM Twin Disc (P/N 1015169). ONE (1)KIT WILL ACCOMMODATE ONE END OF TWOCABLES (EXAMPLE: A TWIN ENGINE INSTALLATIONWITHOUT TROLL WOULD REQUIRE TWO (2) KITSTO MOUNT AND CONNECT THE CABLES TO THECONTROLS). THE KITS DO NOT INCLUDEMOUNTING BRACKETS TO SECURE THE CABLEAND CLAMP TO THE ENGINE OR TRANSMISSION.brackets and hardware for mounting the control(s). (1/4 in. maximumdiameter to mount the controls.)OTHER ITEMS WHICH MAY BE REQUIRED (DEPENDING ONINSTALLATION)For installations requiring four to six control stations:1-to-2 station doubler, Twin Disc p/n 1019759.One (1) doubler is required for installations with four (4) control stationsTwo (2) doublers are required for installations with five (5) control stationsThree (3) doublers are required for installations with six (6) controlstationslever-to-doubler harness (specify length). Two required per controlstation.16EC200 Series Marine Control System Manual # 1018434
Twin Disc, IncorporatedSection 1 GeneralPart number for the twin engine lever-to-doubler harness is 1018042 seriesand part number for the single engine lever-to-doubler harness is 1018043/1018044 series. One required per control station. Maximum length for eitherharness is 100 ft (30.5 m).brackets and hardware for mounting the doubler(s). (1/4 in. maximumdiameter for hardware to mount the doublers.)To substitute split single lever control heads for a dual lever controlhead in twin engine installations:single lever control head, Twin Disc p/n 1018024. One required perstation.starboard single lever control head, Twin Disc p/n 1018025. Onerequired per station.For installations with the sync option:engine speed signal generators. One required per engine (can be oneof the following)Magnetic Pickups (Twin Disc p/n XM-2936M or equivalent)Dual Output Magnetic Pickup (Twin Disc p/n 1015259 or equivalent)*Tachometer Generators (Twin Disc p/n COI206242A)Ignition Modules (Twin Disc p/n 1015172)EC200 Series Marine Control System Manual #101843417
Section 1 GeneralTwin Disc, IncorporatedSensor Doubler (Twin Disc p/n 1016446)*This magnetic pickup having two isolated outputs is available from Twin Disc.One required for each engine. One output can be used for EC200 sync inputand the other output can be used for instrumentation, etc. The dual-output pickuphas a 3/4 x 16 UNF thread and can be installed in place of existing pickups ifboth are electrically compatible. An alternate dual output pickup with a 5/8” x18 UNF package is also available.NOTE:BOTH ENGINES MUST USE SIGNAL GENERATORSOF THE SAME TYPE, MODEL AND PART NUMBER.speed signal generator cables, Twin Disc p/n 1018040 series (specifylength). Maximum length is 60 ft. (18.9 m). One required per engine.NOTE:THE SPEED SIGNAL GENERATOR CABLES ARE NOTREQUIRED FOR INSTALLATIONS USING IGNITIONMODULES.IMPORTANT GENERAL NOTESome systems will have troll actuators mounted in the maincontrol enclosure. If the actuator positions of the maincontrol are being used for throttle and gear selector, andthe troll option has been ordered, a separate stand alonetroll actuator assembly has been provided.For installations with the troll option:Control to stand-alone troll actuator harness —— An X238086 serieswiring harness is required to connect each stand-alone troll actuator toits control. Maximum length for the X238086 series harness is 16 ft(4.9 m).cables (Morse 33 Series RED JAKET Supreme or equivalent).One required per mechanically operated trolling valve. Lengthofcables depends on distance between components and routing of cables.brackets and hardware for mounting and connecting cables to the trollingvalve(s).18EC200 Series Marine Control System Manual # 1018434
Section 1 GeneralTwin Disc, IncorporatedNOTE: QUICK DISCONNECT BALL JOINT AND CLAMP KITSFOR MORSE 33 SERIES PUSH-PULL CABLES AREAVAILABLE FROM TWIN DISC (P/N 1015170). ONEKIT WILL ACCOMMODATE ONE END OF ONE CABLE(EXAMPLE: TROLL IN A TWIN ENGINEINSTALLATION WOULD REQUIRE TWO (2) KITS TOMOUNT AND CONNECT THE CABLES TO THETROLL ACTUATORS). THE KITS DO NOT INCLUDEMOUNTING BRACKETS TO SECURE THE CABLEAND CLAMP TO THE TROLLING VALVE.brackets and hardware for mounting stand-alone troll actuator(s). (1/4in. maximum diameter for hardware to mount actuator(s).For installation in starter solenoid circuits greater than 5 amperes:Normally Open (NO) SPST relay with a coil voltage rating equal to thestarter solenoid voltage and contacts with a current rating greater thanthe starter solenoid current. One required per control.NOTE:INSULATED PUSH-PULL CABLE MOUNTINGHARDWARE MAY BE NECESSARY TO SATISFYBOND/ISOLATION REQUIREMENTS, ESPECIALLY IFTHE ENGINE BLOCK IS NOT GROUNDED ORBONDED. CONSULT FACTORY FOR FURTHERINFORMATION, OR TO ORDER INSULATED PUSHPULL CABLE MOUNTING HARDWARE. Twin Disc,USA, 262-638-4000.For installation on nonconductive vessels, Twin Disc has madeavailable the following components:ASM203251 Dual Nylon Installation Kit consisting of: (Used in place ofp/n 1015169). Two (2) Morse terminal pins and plastic terminaleyes (1 used per electronic control)1016430 Single Nylon Installation Kit consisting of: (Used in place ofp/n 1015170). One (1) Morse terminal pin and plastic terminal eye(1 used per troll actuator -1003836 series)EC200 Series Marine Control System Manual #101843419
Section 1 GeneralTwin Disc, IncorporatedMAXIMUM STANDARD LENGTH NOTICE:Wiring Harnesses for the EC200 Control System have specified maximumlengths that must be considered when mounting the controls, troll actuators anddoublers. The chart below lists the maximum standard installation lengths forthese harnesses:Twin Discp/n SeriesMax.Length,ft(m)10180431018044100 (30.5)(Single Engine Lever to Control Harness)(Starboard Single Engine Lever to ControlHarness)1018042(Twin Engine Lever to Controls Harness)1018042(Twin Engine Lever-to-Station Doubler Harness)1018043/44 (Single Engine Lever-to-Station DoublerHarness)1018040(Engine Speed Sensor Harness)1018041(Control to Control Communications Harness)X238086(Control to Troll Actuator Harness)100 (30.5)100 (30.5)100 (30.5)100 (30.5)60 (18.9)50 (15.3)16 (4.88)NOTE: ADDITIONAL WIRE CANNOT BE ADDED TO ANYHARNESS.NOTE:FOR HARNESS LENGTHS BEYOND THEMAXIMUMS LISTED CONSULT FACTORY. PLAN TOPROVIDE INFORMATION ON THE BOAT LENGTH,NUMBER OF STATIONS, AND OPTIONS TO BEADDED.20EC200 Series Marine Control System Manual # 1018434
Section 2Twin Disc, IncorporatedSection 2 - CONTROL AND TROLL ACTUATORINSTALLATIONIMPORTANT GENERAL NOTEControl boxes should be mounted near the engines in a locationreasonably free from direct splash and spray, and protected frommechanical abuse. When selecting the location for mounting the controlbox(es), consideration should be given to the push pull cable routing toavoid sharp bends or excessive lengths. The mounting surface shouldbe flat, or shimmed so that the control box is secured without distortionto the bottom plate. Control boxes should not be mounted on the enginesunless they are protected by a heat shield and mounted to a vibrationdamped plate. In systems that have the sync option, one (1) control boxwill be identified as sync, and one (1) will not. The sync box must beinstalled on the starboard side, and the other box on the port side.Ensure a suitable location is chosen for mounting the control(s) and trollactuator(s). Choose a location that:!is not on any drivetrain components!is away from heat sources!is clear of service areas!is away from high current conduct
cabling, refer to the appropriate system drawing for your boat. The EC200 control system has been provided with connectors to reduce installation time and errors. Except for the power/interface cable, all other cables are available from the factory in certain standard length increments, or custom made to length in two-foot increments.
