MasterCraft Service Manual - Perfect Pass
Contents
1. then Display should be changed 10 Troubleshooting Q amp A Cont d 6 10 11 Condition PerfectPass has no digital speed reading Solution I Oo Check Master Module to ensure paddle wheel cable is properly connected and pins are in proper position and not bent 2 Does paddle spin freely 3 If alllooks well perform a System Reset Condition Up key on Display does not respond Solution Make sure all 10 pins on Master Module are in line where display connects If connection is OK key pad switch is faulty return to PerfectPass for repair Condition Boat speed drops and throttle handle must be pushed far down to get acceleration Solution Servo Motor is not holding and rotating properly usually due to a bad connection at servo See Servo Motor Test page 6 Condition System is blowing the 5 amp fuse on 12v power cable Solution Generally caused by a short or grounding problem with the red 12v power cable on servo motor Closely inspect wiring particularly around gold resistor Remember resistor amp servo will run very hot which is normal Condition Speed control sometimes disengages on its own Solution Is manual handle pulling back Does sign appear on screen Condition Customer ordered a DigitalPro but on start up it say s WakeboardPro Solution Switch software by holding Menu and Down keys together as you turn key on to power system 11 LINKAGE2. TEST This test should confirm whether the PerfectPass throttle cable amp linkage connection 1s properly working With key OFF push the manual throttle to 1 2 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 If the cable is rubbing against a decorative engine cover fuel rail motor box etc 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 Boat Speeds Past Set Speed If the system beeps to confirm engagement but continues past set spee
3. time you turn the key on or start the boat PerfectPass becomes powered and the servo will perform an auto tighten function and will attempt to wind in the cable to confirm it is in normal position If in proper position it will appear simply as a click click click To check servo amp servo power wire with key off turn black knob on servo motor counter clockwise 34 of a turn Now turn key on and black knob should turn clockwise about 3 4 of a turn as part of auto tighten If it does repeat procedure except this time hold black knob gently to apply some resistance to auto tighten If it rotates with good strength then it would appear servo amp servo power cable are fine If it does not rotate or just vibrates then a wiring phase coming to the servo may be loose or broken Inspect all wiring around servo Pull both white plugs apart at servo amp inspect pins to ensure they are in place Gently tug on each wire to ensure they are securely in crimp Check at Master Module where cable is connected If you cannot locate problem contact PerfectPass Important Notes 1 The gold resistor will run extremely hot This is normal 2 If system is new make sure servo power cable is plugged into Master Module correctly and not upside down Tips on plug should point up towards label on Module Quick Reference Trouble Shooting Guide Problem Display does not power up No speed reading Not controlling well
4. Not controlling at all System beeps to confirm engagement but continues past set speed and does not control Button on keypad does not work System controls well in RPM mode but not smooth in speed mode Paddlewheel impellar damaged Displayed speed not correct 1 e system says 20 actual speed 22 System disengages on its own and boat slows Blowing 5 amp fuse Possible Cause Action Is display plugged into master module Check fuse Check 12 volt power source ground to PerfectPass Is paddle cable connected to master module Is paddle damaged Does it spin freely Perform servo motor test perform linkage test Perform servo motor test linkage test and return spring test Unplug display connector at master module and check pins Replace display Is speed mode setting 25 mph or less Is paddle wheel in good condition Install new impellar kit available from PerfectPass In Wakeboard mode press menu to enter Speed Adjust Quickly press down key and lower speed by 2 mph Is manual throttle handle pulling back on its own if not perform servo motor test Inspect red wiring around servo motor for a ground or short Troubleshooting Q amp A 1 Condition In both Speed amp RPM Mode the system beeps to engage but speed never settles in and hunts beyond amp below target speed Solution It appears that the PerfectPass throttle cable does not have free movement and is rubb
5. PerfectPass Correct Craft General Information Troubleshooting Guide lt a e gt 4 ul PERFECT PASS P Wont Dealer in Speed Contra MO Sf lke a p a e lt lt a EE February 2005 902 468 2150 Table of Contents Number List of Major Components System Schematic Wiring Detail How PerfectPass Works Thru Hull Paddlewheel Installing New Impellar Servo Motor Operation Servo Motor Testing Quick Reference Trouble Shooting Guide Trouble Shooting Q amp A Linkage Test System Reset Paddlewheel Trouble Shooting Switching Between WakeboardPro and DigitalPro KDW NN Wakeboard Settings Investigating Blown Fuse Tank Testing Fake A Lake Excalibur Installation Photo GT 40 Installation Photo PERFECT FASS FIP LE IWWORL DP LEADER IN SPELLED CONTROL Page 10 11 11 11 12 12 13 14 15 1 Master Control Module 2 Servo Motor Power Cable from Master Module to Servo Motor 3 Servo Motor amp Throttle Cable 4 In Dash Display Gauge 5 Thru Hull Paddle Wheel Speed Sensor ss 6 Power Cable amp RPM Cable Both connected to back of tachometer to provide 12 volts to power system as well as provide rpm signal See wiring schematic on next page Standard Wiring Installation Master Module Paddle Wheel lt 10JOJN OAJ9 lt Avjdsig Source See Note 50 Power Resistor 5 A Fuse Switched 12V Supply Notes from Standard Wiring Diagra
6. d perform a Servo Motor Test and Linkage Test If these tests indicate all is well it could be a Throttle Return Spring problem Throttle Return Spring PerfectPass can open the throttle by turning clockwise but relies on the engine return spring to close the throttle when the servo turns counterclockwise The return spring is always applying pressure against the throttle back towards the neutral position If the servo turns counterclockwise to slow the boat but the throttle lever on engine does not move or moves very slowly the return spring could be weak broken etc If you feel the spring is weak or damaged an external return spring can be added 12 Resetting a Wakeboard Pro Version 6 3 6 4 6 5 You can do a System Reset by pressing and holding the ON OFF amp MENU Keys together as you turn key on to power system Continue holding as the Perfect Pass display goes through its normal start up procedure until System Reset Yes appears Press the UP key to continue the reset It will then display Reset RPM Yes Answer yes by pressing the UP key Next on the display will be Read in MPH Yes Answer yes by pressing the UP key Next Wakeboard Only Yes will appear Answer yes by pressing the UP key For WakeboardPro press Down for DigitalPro Paddle Wheel Troubleshooting If your system works very well and controls smoothly in the rpm mode but surges and hunts in the speed based mode it is likely a padd
7. ing against engine cover or some other obstacle A Linkage Test should be performed Condition System beeps to confirm engagement but boat continues past set speed and never locks in Solution Computer is attempting to control but servo not responding Perform Servo Motor Test Servomotor could be seized Condition System hunting in speed mode only RPM Mode working perfectly Solution I Inspect paddle wheel for damage does it spin very freely 2 Is paddle wheel fully seated in housing is arrow pointing forward Condition PerfectPass digital speed reading shows 22 mph but GPS indicates boat speed 1s actually 24 mph Solution Press menu key once and Speedo Calibrate will appear Quickly press down key several times and drop calibration speed by 2 mph Can be done in the shop or on the water Remember the LCD screen simply shows the data from Master Module so there is no reason to suspect the Display is a problem Condition PerfectPass green light in display is on but no data on screen Solution Check to see if servo motor is powered if not then the system does not have adequate voltage or is poorly grounded and will not start Measure voltage on PerfectPass power cable which should be in excess of 12v Note When key is off the black knob on servo turns very easily When powered knob is stiff and is difficult to turn If servo is powered and performs auto tighten rotation but Display has no data
8. le wheel related problem 1 Does the paddle wheel impeller spin freely If not change impeller 2 Is the paddle wheel housing under the hull pointing straight forward The arrow on the housing must be pointing straight ahead 3 Is the impeller installed in the assembly in the correct direction 4 Is the paddle insert fully and properly set in the housing 5 Is the paddle wheel installed in the correct location Call for details on your boat model It can not be installed directly behind a strake water intake etc which could disturb the flow of water 6 Perform a System Reset Press amp hold the ON OFF amp MENU Keys together as you power up the system Continue holding until you see the System Reset Prompt 7 Ifit only surges when the boat is heavily loaded in a certain configuration it may be a location problem TEST Drive boat in RPM mode at a value of 2800 RPM When RPM is locked on watch PerfectPass digital speed reading It should only be varying by one or 2 tenth s If it is varying more than this then the paddle signal to PerfectPass is not consistent Switching from WakeboardPro lt gt DigitalPro The Master Module for both systems 1s identical and the software for both is stored inside If a system was set up incorrectly ie customer ordered a WakeboardPro but when he turns it on it says DigitalPro this can be easily changed Simply press amp hold the Menu amp Down Keys together as you turn the key
9. m 1 RPM Source Connection To RPM Signal SND POST ON TACH To Ground GRD POST ON TACH 2 Paddle Wheel Cable Data 3 Servo Motor Cable Data White Moor Phase 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 motor 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 1s 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 PerfectPa
10. mperature probe built in which can be displayed on the PerfectPass gauge The paddle wheel impellar must be able to turn freely in order for an accurate signal to be produced It must be properly installed in an area of the hull where the water flowing back over the paddle is clean and undisturbed It must be installed facing straight ahead If any part of the paddle wheel or shaft becomes damaged or slightly bent the speed signal will not appear on the screen or will be inconsistent The impellar can be quickly changed The paddle wheel is designed to be most accurate at speeds under 35 mph At high speeds depending on trim position and hull dynamics the speed displayed may not be accurate Wakeboarding is typically enjoyed at speeds in the 16 22 mph range At higher speeds and for skiing users will typically find the rpm mode smoother If the displayed speed on the PerfectPass gauge is incorrect ie the system indicates 20 but actual speed 1s 22 this can be easily calibrated by pressing the Menu Key to enter Speedo Adjust then press the down key to lower speed by 2 mph Changing Impellar The life of the paddle wheel axle and bearing is designed for years of trouble free operation In the event of damage to the rotating paddle or axle ideally the boat should be removed from the water for inspection Clean debris if necessary If the paddle requires replacement remove large housing nut and pull paddle assembly out of housi
11. ng Note the direction of rotation of impellar so flat surfaces are toward bow as per arrow on assembly Press the axle out of position and install new one You may wish to install new O rings at this time as well Re insert paddle wheel assembly ensuring the unit is in the notch Re install locking cap If your digital speed readout is suddenly reading extremely low or not at all check paddle assembly Servo Motor Red fp 0 O CC White TAN __ Pe re KR White Black LIN l Crest Red Engineering Green Blue Brown Black The 4 Phase servo motor can make hundreds of adjustments per second to maintain the correct speed It is vitally important that the throttle cable has free movement and the brass L Adapter Volvo only connecting the PerfectPass throttle cable to throttle arm can swivel and rotate smoothly If a servo motor is not installed in the correct location the throttle cable may have too much of a bend or may jam against the engine cover which will cause improper operation Anytime you suspect the system is not controlling properly A Servomotor Test should be performed as follows If servo motor test is successful perform a linkage test on page 10 Servo Motor Test Auto Tighten Test Every time you return the boat to neutral when PerfectPass is on the servo will wind in the cable until snug in a clockwise direct This is the normal starting point for the servo Each
12. on to power system Keep holding for a few seconds until you see Servo Test Yes Press no or down key to move into sub menu When you see Wakeboard only Yes press up for WakeboardPro or down for DigitalPro 13 Adjusting KDW NN KDW If you wish to change this control parameter press OFF then press the UP amp DOWN Keys together You can then change the KDW using the up or down keys Higher values more aggressive control response Factory setting is 60 Example Heavily loaded boats may need a higher value to maintain a steady crisp pull Try 100 150 After adjustment press MENU to process NN This follows KDW and represents the filter factor of the paddle wheel Typical values 120 160 Higher values mean the system will sample more revolutions prior to making a speed adjustment If you feel the system should be smoother try raising the NN 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 ca
13. s mounts in a vertical position as per photo Bolt should swivel freely lubricate fromjtime to time Throttle is in neutral position in this photo and shows proper installation On newer models with 3 holes in arm use the center one If there are only 2 holes install in the same hole that was used by factory Make sure when in neutral there is no gap here or engine may surge in neutral Flip L bracket around if necessary Warning Tie back all wires and make sure throttle moves freely in full gear before operating 17
14. screen You will feel a soft spot in throttle as you accelerate continue pushing throttle up and past 2800 When 2800 is reached you will hear a beep to confirm engagement and system should start controlling The digital tach should settle in and hold steady at about 2800 3 As system is controlling at 2800 you can press throttle handle forward which will cause engine to speed up briefly it will then settle back at lock in again at 2800 4 If you then bring throttle to neutral servo motor will wind in cable clockwise to its normal starting position 5 With key on spin paddle wheel and a digital speed signal will register on screen 6 Throttle on boat should feel the same as a boat without PerfectPass it should smoothly go into and out of gear The key to a good installation 1s to ensure the PerfectPass throttle cable has a smooth alignment to where it attaches to boat throttle cable There should be no excessive bends where cable could bind Perform a Linkage Test if necessary 15 2002 PCM EXCALIBER Engine PCM has provided a metal mounting plate designed to hold the PerfectPass Servo Motor amp Resistor Simply attach these parts as indicated on the photos Ihe PerfectPass throttle is shorter than our standard cable It measures 13 inches get a ee Hipi Bort min 2 ETTU reagi ri 16 GT 40 INSTALLATION Install as per standard instructions except Piyot bolt
15. ss 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 motor is powered If you then spin the paddle wheel you should see a speed signal register on the PerfectPass Display confirming proper operation The WakeboardPro has two operating modes 1 Speed Based Wakeboard designed primarily for wakeboarding in the 15 25 mph range User sets a speed on the main screen WKBD 20 0 0 0 P Ta set speed digital speedometer 2 RPM Mode where the user sets an rpm value Designed for higher speed use such as open water skiing or cruising Set rpm ia 2800 00 0 0 x x tach digital speedometer Thru Hull Paddle Wheel Red 12 V Power Bare Ground Green Speed White Water Temp Brown Water Temp The Thru Hull Paddle Wheel Model ST300 is manufactured by AirMar Technologies Its primary purpose 1s to provide a digital speed signal to the PerfectPass Gauge It also has a water te
16. use 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 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 1f no problem is found with the cable alone then plugging in the servo motor will help identify the location of the problem 14 PerfectPass Tank Testing 1 Move screen function to RPM Mode Press Menu twice and Wkbd Spd A SLM will appear Press up key twice to move to RPM Mode which will appear as Set RPM Tachometer Actual Speed 2 With throttle locked in neutral aggressively accelerate engine up and well beyond 2800 You will see the digital tachometer in center of
Download Pdf Manuals
Related Search