Stern Drive Service Manual
Contents
1. 1 volt or more would confirm a problem with the servo motor or cable Step 5 You can also perform this test with the servo motor and resistor unplugged This would test the servo power cable independently if no problem is found with the cable alone then plugging in the servo motor will help identify the location of the problem PADDLEWHEEL TROUBLESHOOTING If your system works very well and controls smoothly in the rpm mode but surges and hunts in the speed based mote it is likely a paddlewheel related problem l Does the paddlewheel impeller spin freely Gf not change impeller Is the paddlewheel housing under the hull pointing straight forward The arrow on the housing must be pointing straight ahead Is the impeller installed in the assembly in the correct direction Is the paddle insert fully and properly set in the housing Are the two side shields bent Is the paddlewheel installed in the correct location Call for details on your boat model It cannot be installed directly behind a strake water intake etc which could disturb the flow of water a A a ay Standard Wiring Installation Master Module Paddle gt Wheel lt 100I OAIIS lt Avjdsig Paddle Adapter wheel Unit Source See Note 1 5Q Power Resistor 5 A Fuse 10 Notes from Standard Wiring Diagram 1 RPM Source Connection To RPM Signa TO RPM Signal Low Level Signal Inputs are given by LTR LT 1 and LS1 engines prior2. cable is rubbing against a decorative engine cover fuel rail motor box etc or does not align properly as cables come together at neutral adjust servomotor and cable to improve alignment Many plastic decorative engine shrouds can cause this problem Remove temporarily and run boat if you suspect this could be a problem Final Test With key OFF push manual throttle to full open position Watch PerfectPass throttle cable to ensure it can move freely without binding or interference Throttle Return Spring PerfectPass relies on the engine s throttle return spring for proper operation PerfectPass turns the servo counterclockwise to slow engine at which point the arm is pulled back by the return spring An engine without a spring or very weak spring may speed past the set point and never settle back WORLD LEADER IN SPEED CONTROL SERVO PHASE TEST 6 5NG SOFTWARE This test procedure is performed with control ON and is a good method for testing proper wiring amp operation of servo 1 Press Menu amp Up Keys at same time This will bring you to background Menu starting with CONTRAST Press Menu key until you get to DEVICE TEST 2 Press Up Key to enter Device Test and you will see SERVO ON SERVO OFF 3 Press Menu Key and PHASE TEST will appear Press Up Key to enter Phase Test 4 The screen will now identify each color wire in the cabling from Master Module to servo motor GREEN BLACK BROWN WHITE Each of t
3. lever on engine is at full idle stop In neutral there should be no inner cable showing here which means throttle lever is at full idle stop 14 Volvo 5 0 5 7 L Amended Instructions Image 1 The servo motor is mounted to the large rubber exhaust hose on drivers side as shown The PerfectPass cable should measure about 26 from bracket to end of cable The key to a good installation is a smooth 180 degree bend in cable back to throttle connection After installation perform a Linkage Test Image 2 Drawing shows existing connection of Volvo cable at engine throttle linkage Image 3 Shows proper installation of PerfectPass brass L Adapter on Volvo throttle arm Step 1 Remove cotter key from throttle arm shaft and remove throttle cable eye see image 2 Step 2 Unscrew throttle cable eye from Volvo throttle cable Step 3 Loosen the shaft locking nut and remove throttle arm shaft from throttle arm Step 4 Install PerfectPass brass L Adapter and shoulder bolt on throttle arm Ensure there is a nut on each side of throttle arm as shown in Image 3 Assembly should be snug but brass L Adapter must be able to swivel amp rotate Image 2 Image 1 Volvo Throttle Cable Lock Nut Pata te AN Matted mel Age JN Cotter Key Throttle Cable Eye Throttle Arm Shaft Image 3 Nut ri Lock Nut Pivot Bolt Xe Z L Bracket 7 Pivot Bolt Lock Nut Nut ie Pic v L Brac
4. to 2002 2 Paddle Wheel Cable Data e A 3 Servo Motor Cable Data PR PASS WORLD LEADER IN SPEED CONTROL 11 MerCruiser 2005 2007 I O Throttle Connection 5 0 5 7 amp 6 2 After you have servo motor connected to exhaust manifold you are ready to install the PerfectPass cable which connects to the MerCruiser cable and throttle arm Step 1 Remove MerCruiser throttle cable from throttle arm bolt then remove the throttle arm bolt assembly from the engine throttle arm Step 2 Install the U Bolt to the end of MerCruiser cable with nut and bolt as shown in photo Step 3 To allow clearance to simplify connection push throttle handle into gear Secure the brass L adapter and shoulder bolt to engine throttle arm Install washer between brass L and throttle arm The brass L adapter must be able to swivel freely Step 4 Before final tightening bring throttle back to neutral and the PerfectPass and MerCruiser cable should come together and touch Adjust the brass L slightly along the threaded section if necessary The engine and throttle movement should feel the same as it did before PerfectPass was installed Step 5 Tighten all nuts and bolts firmly Do not over tighten Step 6 Move the throttle handle to full open and closed position and make sure the cabling is properly aligned and at no point is anything rubbing or jamming There should be no extreme bends anywhere in the cable especially where th
5. Stern Drive Service Manual v 6 5NG October 2006 PerfectPass Control Systems Inc 14 Trider Crescent Dartmouth NS B2W 2R3 Phone 902 468 2150 Fax 902 468 8837 WORLD LEADER IN SPEED CONTROL Stern Drive Service Manual 6 5NG Table of Contents Key Components Navigating the Screen Changing modes Common Problems Appendix Servo Motor Test Linkage Test Servo Phase Test RPM Mode Testing On Water or Fake A Lake System Reset Investigating Blown Fuse Paddlewheel Troubleshooting System Wiring Diagram MerCruiser Install Tips Volvo Install Tips WORLD LEADER IN SPEED CONTROL SSC HAIN NN pd 12 13 14 15 KEY COMPONENTS The PerfectPass kit for this boat includes the following key components 1 Master Module Control Box 2 In Dash Display Gauge 3 12V Power Cable amp RPM Cable 4 Servo Power Cable Master Module to Servo Motor 5 Servo Motor amp throttle cable Connected to engine 6 Thru hull Paddle Wheel Speed Transducer See full system wiring diagram on Page 10 How PerfectPass Works Through the in dash display the driver sets the desired boat speed or engine RPM depending upon which mode of operation the driver has selected The master module computer calculates the speed of the boat from the paddlewheel signal and the engine RPM from the engine tachometer signal The servo motor control cable is connected to the throttle arm of the engine which allows the servo m
6. ble is not plugged into Master Module upside down Tips on connector should be facing up towards label on module WORLD LEADER IN SPEED CONTROL LINKAGE TEST This test should confirm whether the PerfectPass throttle cable amp linkage connection is properly working With key OFF push the manual throttle to 3 4 open position Now take black knob on servo and slowly turn the knob in a counterclockwise direction and then in a clockwise direction As you rotate the knob back amp forth you should see the throttle lever on engine opening amp closing very smoothly with each step of the motor As you turn the knob counterclockwise which lets out cable the throttle will close back towards neutral When you rotate it clockwise the throttle will open As you rotate the knob back and forth slowly and quickly the throttle should open amp close very smoothly and the brass L Adapter at linkage should be rotating as well to follow cable At no point should the throttle cable catch hook or come into interference with any part that could disrupt the cable movement At no point should you see slack or loose Dacron cord on the servo shaft unless the throttle lever on engine is back to full neutral stop Make sure there are no bends in the inner PerfectPass stainless cable where it connects to throttle lever last two inches at brass L adapter The PerfectPass cable and the boat throttle cable must seamlessly join together If the
7. e PerfectPass and MerCruiser cable join As a final test perform a Linkage Test as described in this manual followed by a Servo Motor auto tighten test once everything is powered Imag shows proper alignment in neutral U Bolt is straight no bending of cable etc 12 Mercruiser Stern Drives 5 0 5 7 6 2 L Fuel Injected Engines Amended instructions from manual for servo motor and throttle cable installation 1 Install servo motor on large rubber exhaust manifold as shown in this photo The throttle cable will come forward and turn back 180 degrees to where the PerfectPass cable joins the Mercruiser throttle cable See attached sheet Install on manifold hose as shown N This photo shows a properly installed cable with boat in nautral The brass L adapter should appear as in this photo with washer against brass chair The L adapter should freely swivel As you bring boat manual throttle handle to neutral the Mercruiser and PerfectPass cable should come together and just touch If adjustment is needed move the brass L adapter down the threads further The manual throttle should feel the same as before PerfectPass was installed Once complete perform a Linkage Test 13 05 Volvo Cable Installation These photos show a proper installation of cable amp servo motor location Throttle is in neutral position in photo In neutral there should be no gap where cables join Throttle
8. ed in KPH Press the UP key to reset as a Wakeboard Pro or the DOWN key to reset as a Digital Pro WORLD LEADER IN SPEED CONTROL INVESTIGATING BLOWN FUSE Fuse 1 25 5 AMP Typically a fuse will only blow if there is a short in the red wire found within the gray servo power cable which carries 12 volts from the Master Module to the servo motor Closely inspect the servo motor power cable connector both at the Master Module end and at the servo motor and gold resistor end located at the engine If the red wire is split frayed etc it could be the cause of the grounding out of this 12 volt supply causing the fuse to blow Pinching or crushing of this cable could also cause a ground out of the 12 volt supply and blow the fuse If after careful inspection of this cable the problem has not been found then the following procedure can be followed to help identify the source of the blown fuse Step 1 With the key off unplug all plugs from the Master Module except the Display Step 2 Turn key on and go to the Battery Voltage reading on the PerfectPass Display Press Menu amp Up Keys together then press the Menu key Make a note of the battery voltage displayed Step 3 Now plug in the paddle wheel plug The displayed voltage should not change Step 4 Now plug in servo power cable with the servo motor connections intact The voltage reading with a good cable should drop about 0 3 volts A significant voltage drop
9. est Page 4 SERVO MOTOR TEST Auto Tighten Test Each time PerfectPass is powered the position of servo is checked by an auto tighten rotation With key OFF you should be able to easily turn the black knob on servomotor shaft If you cannot turn the knob then the servomotor is seized The black knob moves the shaft on servo motor To check servomotor turn knob in clockwise direction until snug then turn it back counterclockwise one full turn Now turn key ON which will power PerfectPass When you hear the beep from the PerfectPass Display the servo will perform its auto tighten function and wind in the servo in a clockwise direction by of a turn Gently hold the knob during this rotation test to add a little resistance If the servo winds in the cable smoothly then this would generally confirm the wiring to servomotor is good If the motor does not wind in the cable or it just vibrates then an electrical connection or crimp is bad Unplug the two white connectors at servomotor and inspect the wires going into the connectors Gently pull on each wire to see if one is loose or not securely in crimp Also check the wires at plug in the gray servo power cable where it exits the Master Module If the problem cannot be located you can perform a Phase Test See Page 6 New Installation If the system was just installed and the servo will not perform the auto tighten check to make sure the gray servo ca
10. hese wire colors should show a voltage level of about 3 If a wire shows 0 then that color wire does not have continuity and should be checked where it exits the Master Module and at the servo motor 5 Press Menu Key to exit 6 ROTATE SERVO will appear next If you press the Up Key the servo motor will rotate back amp forth until you press the Up Key to RESET SERVO If servo rotates smoothly back amp forth then servo operation would appear to be normal If you have handle well forward during servo rotation you can watch how smoothly the throttle arm is opening and closing gt tjZ2ass WORLD LEADER IN SPEED CONTROL RPM MODE TESTING ON WATER OR FAKE A LAKE Graphics Display Systems This test confirms that mechanically the throttle cable amp linkage is OK Go to RPM Mode by highlighting the Menu Arrow Icon in the upper right hand corner of screen When highlighted press Up Key and this will move you to the other event modes from which to select WAKEBOARD RPM SLALOM Use Menu Key to highlight RPM then press up key to select You will now be in RPM Mode Set RPM Value at 2400 and start engine in neutral Speed Base gt Speed Base gt Speed Tachometer Speed will read O when ona hose Throttle engine up to 3000 RPM or more If you do not throttle up far enough system will surge up amp down Does it lock in and hold at 2400 RPM If you were to watch black knob on servo the servo motor wil
11. ket Throttle Arm Arm
12. l turn counter clockwise to slow engine after engagement As it counter rotates the throttle lever on engine will slowly move back amp slow engine speed until it reaches 2400 In RPM Mode it should hold very tightly at 2400 if it does not settle down to 2400 or controls erratically Perform a Linkage Test While it is controlling at 2400 advance throttle lever an inch or two and engine should throttle up but PerfectPass will slow engine speed back to 2400 Control Problem If customer indicated it did not hold a steady speed in Wakeboard Speed Mode but it controls well during this test then you must inspect the paddle wheel Contact us for more details SYSTEM RESET VERSION 6 5 NG GRAPHIC DISPLAY You can do a System Reset by pressing and holding the ON OFF amp MENU keys together as you power up the system turning ignition ON or to ACC Continue holding keys as the skier moves across the screen and system information is displayed The following screen should now appear NOTE if this screen does not appear turn off the ignition and try again making sure to hold ON OFF and MENU keys Press the UP key to continue the reset Press the UP key to reset RPM Baselines and speedometer calibrations to factory settings Press the UP if you have a standard engine Press the DOWN key if you have a 6 0L or 8 1L NOTE Message will vary on OEM versions Press the UP key to display the speed in MPH or the DOWN key to display spe
13. or is powered If you then spin the paddle wheel you should see a speed signal register on the PerfectPass Display confirming proper operation NAVIGATING THE DASH DISPLAY Wakeboard Mode Speed Based 2 Name Mode Speed Base Speed Mode Indicator There are two key operating modes The main Wakeboard Mode is speed based from the thru hull paddle wheel In this mode you select a mph setting such as 20 mph The other mode is RPM where you select an RPM set point Tachometer To move between modes simply highlight the Menu Arrow Icon in the upper right hand part of the screen using the Menu Key Once this Icon is highlighted quickly press the Up Key and the following screen will appear Mone SELECT _ALOM Use Menu Key to PM highlight desired mode AKEBOARD i SETTINGS ee SELECT To select the RPM mode you would press the UP Key when RPM is highlighted Speed Base Mode Indicator Tachometer 2 COMMON PROBLEMS Control Issues Any complaint that the PerfectPass is surging or not holding speed properly should lead you to a Servo Motor and Linkage Test If the boat is in the shop run the boat in RPM Mode See procedure on page 7 to confirm if the system is mechanically working properly L Customer Complaint System Surging not holding speed Action Perform a Servo Motor Auto Tighten Test and Phase Test Perform a Linkage Test Pages 4 5 amp 6 These
14. otor to control the engine s power This control cable operates the throttle in cooperation with the manual throttle cable so that both the driver and the servo motor are able to change the engine output As the driver advances the throttle handle to bring the boat up to speed the servo motor prepares to take control at the point where the boat speed or engine RPM has reached the desired level the system beeps to indicate it is beginning to control and the driver stops moving the throttle handle The servo motor adjusts the engine throttle as required to continuously maintain the set speed or RPM The driver is able to change the set speed or RPM while the system is engaged by simply pressing the up or down keys for each 4 mph change in speed or 25 RPM change desired At any time the driver may pull back on the manual throttle to slow the boat down the PerfectPass system immediately stops controlling the engine and the driver once again has full control Start Up Procedure The Master Module is the heart of the system and requires a solid and continuous 12 volts before the relay will allow the Intel Processor to start Upon proper start up the Dash Display will become active and the servo motor will power up and perform an auto tighten rotation check A great deal can be confirmed from visually watching this routine start up If the key is moved to the on position the PerfectPass Display should become active amp beep and servo mot
15. will confirm whether the servo motor amp mechanical connection are OK Ideally run the engine on a Fake A Lake in RPM mode See RPM Mode Testing Page 7 Inspect paddlewheel for damage Customer Complaint System engages and controls but boat speed all of sudden slows right down to 5 or 6 miles per hour Action A loose wire or crimp in the main servo motor power cable could cause this See Servo Motor Test amp Phase Test Pages 4 amp 6 Customer Complaint No Speed Reading Very Low Speed Reading Action Inspect paddle wheel speed sensor under boat to ensure it is not damaged If you spin paddle you should see at least 7 mph on screen If the speed reading is very low perform a quick System Reset that will re establish the calibration points See Page 8 Customer Complaint LCD Screen on Display going black or characters upside down Action Electrical interference from an outside source such as operating the trim system can cause this This can be solved by moving the PerfectPass Display cable behind dash as far away from the other boat wiring including trim electrical as possible Customer Complaint Hard to read LCD Display Action Press Menu amp Up Key together to access Contrast Adjustment Customer Complaint System beeps to confirm engagement but system never takes control Action This means the Master Module is taking control but the servo motor is not responding See Servo Motor T
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