Home

Installation Manual

1. e DISPLAY HARNESS WIRING TAN DISPLAY POWER La ER Y 9 CONNECTOR HARNESS WIRING TERMINATING RESISTOR J1939 CAN 2 PLACES CONNECTOR J1939 T CONNECTOR 2 PLACES RED GRN STRIPE J1939 CAN H gt b n J1939 CAN L LL GRN RED STRIPE J129 J130 J1939 CAN SHIELD gt 412 424V VDC POWER gt 1 WHITE i BATTERY GROUND 15 2 BLACK Tec BACKLIGHT CONTROL NOT FOR CUSTOMER USE 4 A EO Gr IBY BLACK V STATION ACTIVE 5 A i HARNESS WIRING NOT FOR CUSTOMER USE 5 6 MULTIPLE DISPLAY ADAPTER L V TO CONTROL HEAD PIN E FOR PORT PIN J FOR STBD 5 434 ABC NS EE ra Ld HARNESS WIRING COMMUNICATION A RED GRN STRIPE A 2 T TT GRN RED STRIPE 3 l 4 xec gt gt 82 GRN RED STRIPE B B 4 za X TT RED GRN STRIPE LL A ag gt c ck BLACK 5 B WHITE 1 SAA w 120 N x x x uj x w Sizi3 zz Z a S al Z a e 85 74231
2. 2 MODEL PAGE 1 4 15 08 11 33 04 AM N REVIEW EC300 1024108 DISPLAY 1018791 GASKET 1020740 ipeum 55 2 X9 9 MMON CUSTOMER SUPPLIED HARNESS 7358 TU X910 ENGINE THROTTLE S NOTE ALL MAN CONNECTIONS WITHIN DASH 14 AWG ee TB X9 7 DUTLINES ARE UNCENTR LLED AND FUR N REFERENCE ONLY CONSULT ENGINE T MANUAL OVERRIDE MANUFACTURER FOR VERIFICATION SWITCH HARNESS WIRING 14 35 10 1020706 SERIES us 1020690 ENGINE SPEED SENSOR INSERT SEALING PLUG JS 11 SIGNAL RED GRN STRIPE X9 3 FROM J8 D j IN UNUSED CONTACT POSITIONS J5 12 SENSOR RETURN GRN RED STRIPE SHEET 1 D ENGINE spem KE _ SENSOR CONNECTOR KIT o lt SEE TABLE FOR ENGINE 1020714 SPEED SENSOR TYPES B IF NOT SUPPLIED WITH TRANSMISSION 2 8 3 ENGINE ROOM ANALOG TRANS OIL e CONNECTOR KIT A TEMP SENSOR 1020713 7 NN J2 HARNESS SHOWN HARNESS WIRING S SPEED SENSOR ON SHEET 1 e 1020720 SERIES Yo Y SYN 3 PWM DRIVERS FIEL cm Ji HARNESS SHOWN N ae SBE NOTE 4 HARNESS WIRING SHEET 1 1020718 SERIES s lt REVS a J1939 CAN CONTROLLER EC300 4 10206764 ENGINE SPEED SENSORS F R REFER
3. HARNESS WIRING DUAL LEVER 7 PLACES BOX JUNCTION STATION DOUBLER 2 PLACES is e PORT CONTROL e 1 STARBOARD CONTROL A wuss bise E E 8 807 o 1 E 3 102 o 9 5 1012 1512 o o 254948 2 E o of Jo 62 62 J8 9 49 120 130 9 o ny 6 2 el 5 CONNECTOR TERMINATING RESISTOR 2 PLACES ao 0 HARNESS WIRING CONTROLLER COMMS S RECEPTACLE ES 1 7 T CONNECTOR 1939 HARNESS WIRING 2 PLACES COMMUNICATION Figure 33 Typical Five Station Dual Lever Control Head Wiring EC300 Marine Control System Installation Manual 1024168 73 Electrical Installation Note Twin Disc Incorporated Station D
4. Figure 36 Bracket to Transmission Harness Assembly The following criteria must be met when installing engine control harness wiring The Neutral Start Interlock wires must be 14 AWG stranded copper wire All other wires must be a minimum of 18 AWG stranded copper wire Q Before installing the Neutral Start Interlock Wiring plan if the Engine Throttle harnesses and or the Engine Speed Sensor Harness are to be installed Consider the harness routing for each component to consolidate wire routing Refer to General Electrical Installation Guidelines for harness routing criteria prior to proceeding with this section EC300 Marine Control System Installation Manual 1024168 81 82 Electrical Installation Twin Disc Incorporated Neutral Start Interlock Wiring Installation The EC300 Control is designed to ensure that a control head is in command and that the lever is in the neutral detent position before an engine can be started 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 The relay contact closes only when the system ignition is turned on a Control Head is selected and the lever for the selected Control Head is in the neutral position Neutral Start Interlock Wiring Requirements Normally the boat wiring routes the start command wire from the key s
5. 2 1020615 HARNESS WIRING 1020615 SERIES COMMS INTERFACE OPTIONAL TO J10 OF STBD CONTROLLER SHEET 2 WIRING 1020614 SERIES CUNTRUL CEA HARNESS WIRING MA RcoNNECTOR 1020615 SERIES 1 J1939 TERMINATING RESISTOR 4 PLACES LagNESS WIRING 1020615 SERIES EE a COMMUNICATION COMMUNICATION LER COMMS 1020614 020717 1020615 yi 4 DA INSTALL 1020717 J1939 TERMINATING RESISTOR HERE S INTERFACE HARNESS IS NUT IF OPTIONAL 1020615 CU Q9 CONNECTOR KIT 1020718 HARNESS WIRING 1020614 SERIES CONTROLLER COMMS DETAIL SEE NOTE CONTROLLER BOND TO VESSEL 27 BONDING 2 MOUNTING FOOT ON SYSTEM ONNECTOR 1020716 1939 T CONNECTOR PLACES CAUTION CONNECTOR KIT 1020690 INSERT SEALING PLUG THROTTLE SIGNAL CONTROL HEAD CONTROL HEAD iN UNUSED CONTACT POSITIONS THROTTLE COMMON J3 e 9 9 1
6. 8 2 5 1 12 24 VDC NOTE NOT FOR USE WITH CAT ENGINE APPLICATIONS J8 2 N MANUAL OVERRIDE SWITCH o n 18 3 N J8 4 2e TACHOMETER OUTPUT SIGNA J8 5 TACHOMETER RETURN SIGNAL J8 6 i The Bridge Signals Harness J8 provides wiring connections for the Ignition Switch Manual Override Switch and Tachometer Not all of these features may be used in any specific application The Bridge Signals Harness J8 is field fabricated The J8 connector kit is provided by Twin Disc Incorporated and consists of the EC300 J8 connector and all contacts and sealing plugs for the connector The equipment end of the harness is fabricated by the installer at the time of installation with components provided by the customer Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector Note EC300 Bridge Signals Harness J8 also may contain wiring for other features Route the harness to the most convenient location serving all the applicable connections This section contains the following sub sections Q Ignition Switch Wiring Manual Override Switch Wiring Tachometer Output Wiring Installation HARNESS WIRING BRIDGE SIGNALS CUSTOMER SUPPLIED CONNECTOR KIT BRIDGE SIGNALS Figure 44 Bridge Signals Harness J8 Connections EC300 Marine Conirol Sy
7. o ol CONNECTORKIT e INSERT SEALING PLUG IN CONTACT POSITIONS 4 6 HARNESS WIRING POWER CUSTOMER SUPPLIED J13 3 POWER COMMON 14 AWG 15 n on o Oro J13 4 PRIMARY POWER INPUT 14 AWG N NEGATIVE CONTROL LEADS PORT SWITCH MUST BE CONNECTED TO BATTERY FUSE AND HOLDER ARE SUPPLIED SAME SINGLE POINT WITH CONNECTOR KIT INSTALL AS CLOSE TO BATTERY AS POSSIBLE FROM STARBOARD SWITCH 15 AUXILIARY POWER INPUT 14 AWG EC300 CONTROL z Oo Mo 13 2 AUXILIARY POWER INPUT 14 AWG IF USED BATTERY HOOKING UP PORT TTE d TO STARBOARD BATTERY IS OPTIONAL TO STARBOARD EC300 CONTROL IF USED Figure 52 Power Wiring Diagram for Switched Engine Powering Applications EC300 Marine Control System Installation Manual 1024168 143 Electrical Installation Twin Disc Incorporated O PORT EC300 CONTROLLER ON EN CONNECTOR KIT INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS HARNESS WIRING POWER CUSTOMER SUPPLIED PRIMARY POWER COMMON 14 AWG J13 3 15 PRIMARY POWER INPUT 14 AWG J Wa Ji3 4 Se h POR
8. 2 CONTROLLER BOND WIRE TO VESSEL BONDING SYSTEM TO J10 OF STBD CONTROLLER SHEET 2 WARNESS WIRING 1020615 SERIES COMMS INTERFACE lt OPTIONAL gt INSTALL 1020717 J1939 TERMINATING RESISTOR HERE IF OPTIONAL 1020615 COMMS INTERFACE HARNESS IS NOT INSTALLED CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 TO J5 1 NOTE NOT FOR USE WITH CAT ENGINE APPLICATIONS 1020613 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS mm OVERRIDE IGNITION SWITCH SWITCH MANUAL DVERRIDE c UPTIUN 1 TU BE USED WITH EC300 SUFTWARE VERSIUN 1 03 MANUAL OVERRIDE SWITCH OR EARLIER CONNECTOR ASSY 1021553 T PLUG OPTION 2 TO BE USED WITH EC300 SOFTWARE VERSION 1 04 OR LATER 1020717 J1939 TERMINATING RESISTOR 2 PLACES CONNECTOR 102 J1939 T CONNECTOR 2 PLACES HARNESS WIRING 1020614 SERIES CONTROLLER COMMS HARNESS WIRING 1020615 SERIES COMMUNICATION CONNECTOR KIT 1020618 1020676 PORT CONTROL INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS FUSE HOLDER SUPPLIED WITH CONNECTOR KIT 1020618 INSTALL NEAR BATTERY 14 AWG 14 AWG J13 3 J13 1 CUSTOMER SUPPLIED HARNESS POWER CUNNECTUR KIT 1020711 HARNESS WIRING 1020614 SERIES CONTROLLER COMMS CUSTOMER SUPPLIED HARNESS ACTUATOR POWER X HARNESS WIRING 1022865 SERIES ACTUATOR TWIN ENGINE WEIGH FIRS UNLESS
9. Pa mooo po pem R7 m Ww pest rs 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 is performed by Twin Disc Incorporated or its local distributor Refer to Appendix B for detailed electrical installation requirements for the engines listed 86 EC300 Marine Control System Installation Manual 1020607 Twin Disc Incorporated Electrical Installation Install the Engine Throttle Wiring portion of the Bracket to Transmission harnesses as follows Refer to General Electrical Installation Guidelines for harness routing criteria 1 Identify the wiring requirements from the installation drawing and from appendix B for the specific engine installation 2 Locate the necessary connecting points on the engine control module or engine control wiring circuits 3 Route the throttle harness portion of the Bracket to Transmission harness to the engine 4 Connect the throttle harness wires at the engine end 5 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 87 Electrical Installation Twin Disc Incorporated 88 Prewired Connection Inspection The transmission is supplied with the Bracket to Transmission harness prewired for all connections other than the t
10. 1020690 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS CONNECTOR KIT 1020714 CONNECTOR KIT 1020713 INSERT WIRE IN CONTACT POSITION J OF CIRCULAR CONNECTOR FROM CONTROL STATION 2 STBD DISPLAY SHEET 22 HARNESS WIRING 1020617 SERIES DUAL LEVER TO Je DF STBD CONTROL SHEET 22 PLUG IN UNUSED CONTACT POSITIONS rud WARNES WIRING 1021010 SERIES DISPLAY ADAPTER SOFTWARE VERSION 104 OR LATER HARNESS WIRING INSERT WHITE WIRE IN CONTACT POSITION 1020951 SERIES DISPLAY POWER HARNESS WIRING 1020615 SERIES RUARNESS WIRING COMMUNICATION 1020614 SERIES CONTROLLER COMMS INSERT BLACK WIRE IN CONTACT POSITION 3 4 5 UR 6 FOR EACH DISPLAY POWER HARNESS INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS 1020 J1939 TERMINATING RESISTOR 4 PLACES WIRING 1020615 SERIES TO J10 STBD 1 T CONTROLLER SHEET 2 INSTALL 1020717 J1939 TERMINATING RESISTOR HERE IF OPTIONAL 1020615 COMMS INTERFACE HARNESS IS NOT INSTALLED COMMUNICATION CUSTOMER SUPPLIED HARNESS THIS CONNECTION USED WITH CAT ENGINE APPLICATIONS ONLY ECM POWER SUPPLY THROTTLE SIGNAL POWER SUPPLY COMMON J9 31 35 2 Jo 3 REFER TD EC300 INSTALLATIDN MANUAL F R INFORMATION ON VARIOUS ENGINE CONNECTIONS ENGINE THROTTLE U CONNECTOR 1020716 START SWITCH 55 9 90 0 EL
11. CONTROL STATION 1 CONTROL STATION 2 CONTROL STATION 3 CIRCULAR CONNECTOR wN HARNESS WIRING 5 PORT LEVER 8 8 3 PLACES e e Dy o o 599699 faisoo l fe00000l S o S Figure 30 Single Engine Single Lever Control Head Wiring EC300 Marine Control System Installation Manual 1024168 67 Electrical Installation Twin Disc Incorporated 68 Each single lever harness is designed to connect to the Control Head at one end and to the EC300 Control s 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 Install the Control Head harness 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 Refer to General Electrical Installation Guidelines for harness routing criteria 1 Connect the circular connector end of the Control Head harness to the Control Station 1 main most used Single Lever Control Head Note Align the large connector key with the large keyway and push the connector into place Then turn the connector
12. TWIN DISC Installation Manual Ma rine Control System Model EC300 Document Number 1024168 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 1024168 Revision 2 April 2008 Marine Control System Installation Manual TWIN DISC INCORPORATED EXCLUSIVE LIMITED WARRANTY PLEASURE CRAFT MARINE TRANSMISSION SURFACE DRIVE and ELECTRONIC CONTROL SYSTEMS A Twin Disc Incorporated warrants all assembled products and parts except component products or parts on which written warranties issued by the respective manufacturers thereof 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 thirty six 36 months from the date of original shipment by Twin Disc Incorporated to the original customer but not to exceed twenty
13. Note The Deutsch 14 AWG contact P N 0462 209 16141 can be identified by a green band 5 Remove the locking wedge from the Deutsch connector EC300 Marine Control System Installation Manual 1024168 93 Electrical Installation 94 10 11 12 Twin Disc Incorporated Insert the wire coming from the start switch at the helm into pin 9 of the J5 connector Note The J5 connector is provided in the Engine throttle connector kit Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information For the yellow with red stripe wire from the starter relay solenoid crimp the supplied Deutsch contact P N 0462 209 16141 using the Deutsch HDT crimp tool P N HDT 48 00 Insert the wire coming from the start relay solenoid into pin 10 of the J5 connector When all pins have been inserted in the connector body then insert the Deutsch locking wedge 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Electronic Control Module Throttle Wiring These signals interface with the engine Electronic Control Module s
14. 26 2 PLACES TERMINATING RESISTOR CONNECTOR 2 PLACES J1939 T CONNECTOR 2 PLACES DH DH S STRIPE RED GRN STRIPE GRN RED STRIPE 105 2 ADA GRN RED STRIPE COMMS 2 B B B 2 COMMON sp 4 1 gt c c5 4 4 1 c og L Lia 415 GRN RED STRIPE lt REDIGRN STRIPE Xu A Ag So of B B AN A lt WwW 120 N Figure 46 Dual Engine Communication Harness Assembly J10 Installation EC300 Marine Control System Installation Manual 1024168 123 Electrical Installation Twin Disc Incorporated Install the Communication Harness Assembly as follows See Figure 46 Note The specific application may have different lengths for each segment of communication harness Use the correct segments Refer to General Electrical Installation Guidelines before proceeding with this section 1 Install a J1939 T Connector receptacle on the 3 pin plug of each Controller Comms Harness Align the Controller Comms Harness connector with the J10 receptacle of each EC300 Controller and push it in until it snaps into place Connect the Communication Harness between the EC300 Controllers by installing the 3 pin plugs into the J1939 T Connector receptacles located on the Controller Comms Harness at each EC300 Controller Install a J1939 Terminati
15. Description of Flat Rate Labor hours allowed for function to the right gt External Sensor Removal and Reinstalation and Test and Reinstallation and Test Electronic Control Repair there are no serviceable internal components December 14 2007 TDWP10099B rev 2008 Twin Disc Incorporated Table of Contents Table of Contents Introduction MENT RR T E PS 13 13 General Information m 15 Replacement Parts Eo sa prs eV resa E EK E 16 LIS ST m I m 17 Source of Service 17 Bicis gon lw 18 Basic System 19 Additional Materlals 23 Component Installation 25 General Component Installation Guidelines 25 EC300 Control Installation eiie ottico eta tu 27 Control Head Installation 28 Single Dual Lever Control Head Assembly 29 Side Mount Control Head Assembly Binnacle Console Station 32 Control Head Lever Drag Adjustment 35 Twin Disc Display Installation 2 2 36 Speed
16. J5 Pin2 Throttle Signal The throttle position output signal Depending upon the engine manufacturer this signal can be a programmed voltage or current The throttle signal is directed by the position of the lever at the active control head 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 J5 Pin8 Power Supply The common return path and reference point for engine throttle circuit Common in Appendix B for additional information J5 Pin5 Transmission State 2 solid state switch output that goes active when the transmission is not in neutral This wire is used only for specific engines See page B 12 in Appendix B for additional information J5 Pin6 Transmission State The return signal for the transmission state signal This wire is used Return only for specific engines See page B 12 in Appendix B for additional J5 Pin4 Transmission State 1 solid state switch output that goes active when the transmission is in neutral This wire is used only for specific engines See page B 12 information EC300 Marine Control System Installation Manual 1020607 85 Electrical Installation Twin Disc Incorporated The EC300 Control System currently supports the following types of electronic engine controls Table 9 Engines Supported pem a peer pemwer Wes
17. 0416 MG518 SERIES 10 0459 MG6557SC SERIES 70 0461 MG6557RV SERIES 710 0465 MG 6619A SERIES 10 0473 MG 520 HPSERIES 10 0441 MG 6650 00 SC SERIES 12 0446 MG 6848 00 SC SERIES 12 0478 MG 6690SC SERIES 12 0484 MGX 61500SC SERIES 12 0485 MGX 6650 SERIES 12 0487 MGX 6690SC SERIES 12 0488 MGX 6848SC SERIES 12 1721 MGX 6620SCSERIES 12 1737 MGX 6599A SERIES 12 ber 14 2007 N e e FLAT RATE HOUR ALLOWANCE MARINE PLEASURE CRAFT SURFACE DRIVE Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated Removal and Reinstallation and Reinstallation Recondition complete unit and test for leaks Replace front oil seal Replace front oil seal oil seal ae ce oo ne Replace input gear sprocket NI EMEN Ws ss Eee e messem 0 0 roa epa ptt pee mpeg ws mg sagas s pere EEA me cae FLAT RATE HOUR ALLOWANCE MARINE PLEASURE CRAFT ELECTRONIC CONTROL SYSTEMS Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated Travel and related expenses are not included as a part of Twin Disc Electronic Control Warranty
18. 14 AWG BOND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL REFER TO THE INSTALLATION MANUAL FDR MDRE INF RMATIDN THE COMMUNICATION BUS HAS OTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER S HARNESSES TO BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG UNLESS OTHERWISE SPECIFIED INCORPORATED RACINE 1 53403 USA WIRING DIAGRAM HARNESS WIRING 1020951 SERIES DISPLAY POWER WIRING 1020718 SERIES J1939 CAN ru NE 120 lt p __ _49 4 1 DH A BOC ABC C B DH CBA HARNESS WIRING 1020615 SERIES COMMUNICATION DH STBD ACTIVE CONTROL HEAD CONTROL STATION 2 STBD ACTIVE CONTROL HEAD CONTROL STATION 1 FROM 12 24 VDC POWER BATTERY GROUND BACKLIGHT CONTROL NOT FOR CUSTOMER USE STATION ACTIVE NOT FOR CUSTOMER USE J1939 CAN SHIELD B J1939 CAN L J1939 CAN H DH HARNESS WIRING 1020951 SERIES DISPLAY POWER 12 24 VDC POWER BATTERY GROUND BACKLIGHT CONTROL NOT FOR CUSTOMER USE STATION ACTIVE NOT FOR CUSTOMER USE J1939 CAN SHIELD
19. CRAS fe 8 m wu 3 Wa fs 5 FER WM o lo 24 22 o o ol lo 24 2 22 o o lo mE ES 1 4 5 5 1 4 2 5 200 1 J9 a m 20 n Je Jio mO 4265 9 3 OJ Q JO gas O i b J5 Je 24 2 5 24 24 5 88 5 o o o o o 5 2 5 5 o 22 4 419 4265 CONNECTOR TERMINATING RESISTOR HARNESS WIRING 2 PLACES CONTROLLER COMMS 3 PLACES CONNECTOR 0 21939 T CONNECTOR 3 PLACES HARNESS WIRING COMMUNICATION 2 PLACES mm Figure 47 Multiple more than two Engine Communication Harness Assembly J10 Installation EC300 Marine Control System Installation Manual 1024168 125 Electrical Installation 126 Twin Disc Incorporated Install the Communication Harness Assembly as follows See Figure 47 Note The specific application may have different lengths for each segment of communication harness Use the correct segments Refer to General Electrical Installation Guidelines before proceeding with this section 1 Install a J1939 T Connector receptacle on the 3 pin plug of each Controller Comms Harness Align the Controller Comms Harness connector with the J10 receptacle of each EC300 Cont
20. EC300 Marine Control System Installation Manual 1024168 17 Introduction Twin Disc Incorporated Required Tools Installation and Set up may require the following tools L1 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 00 08 0 0 0 0 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 OF Torque wrench capable of measuring 4 52 Nm 40 Ib in for installing speed sensor in the flywheel housing and for mounting components L1 File rasp or sandpaper to smooth cut surfaces 500 VDC Megohmmeter for testing power wiring as per ABS requirements L1 Laptop with latest MFST software updates L1 EC300 Communication Kit Twin Disc p n 1021108 L1 EC300 Display Harness and Display Twin Disc p n 1018791 18 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Introduction Basic System Components This section serves as a guide for your pre installation parts check Be sure that you have ordered and received all of the basic components necessary for this system installation Table 1 Required Components for Typical Applications c 5 S
21. WEIGHT WRE FIRST USE ASSY mone EC300 LBs 0005 ALL ANGULAR TOLERANCES t1 GEDMETRIC TOLERANCING PER ASME 14 5 1994 NOTICE THIS PRINT CONTAINS FROPIETARY INFORMATION AND T NER DETRINENTAL TO THE INTEREST OF TWIN DISC INCDRPDRATE THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE E US GOVERNMENT OR OTHERS BY CONTRACT MATERIAL HEAT TREAT INCH NONE RACINE WI 53403 USA DN W Russell le BS 1024103 S NDT TD BE SIMILAR THIRD ANGLE PROJECTION SYSTEM CONTROL EC300 MAND R Conroy APPD REG DWG SHT REV SIZE D 1 OF 2 CONTROL STATION 1 C TRANSMISSION Ny
22. START MOTOR BATT MANUAL DVERRIDE HARNESS WIRING SWITCH 1020706 SERIES ENGINE SPEED SENSOR 5 1 SIGNAL RED GRN STRIPE J5 12 SENSOR RETURN GRN RED STRIPE SPEED SENSOR SEE TABLE FOR ENGINE SPEED SENSOR TYPES IF NOT SUPPLIED WITH TRANSMISSION J5 10 020706 gt lt HARNESS WIRING 1020609 SERIES ENGINE ROOM ANALOG TRANS DIL TEMP SENSOR TRANS DUTPUT 1020720 SERIES SPEED SENSOR PWM DRIVERS o VA XY SSF CONTROLLER EC300 1020676A ENGINE SPEED SENSORS FOR REFERENCE ONLY PORT CONTROL PART NUMBER THREAD GUTPUT CONNECTOR 20553 1020929 0 DEUTSCH mene ws 10 nua neursenzve 1021125 34 16 DEUTSCH WP 578 18 num neurscw ve MUST BE CONNECTED TO SAME SINGLE POINT TO STBD CONTROL FROM STBD BATT Noo PURT BATTERY 13 2 FROM STBD BATT OPTIONAL CONNECTOR KIT 1020618 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS NEGATIVE CONTROL LEADS FUSE HOLDER SUPPLIED WITH CONNECTOR KIT 1020618 INSTALL NEAR BATTERY 14 AWG 14 AWG LEGEND JUNCTION UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK
23. 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 29 Engine Connections at the Scania Engine EC300 Engine EC300 Signal Endine Connector Engine Signal Description Harness J5 Decsription 9 W DEC 2 J5 Pin 1 ECM Power Supply J8 Pin 2 TPSE J5 Pin 2 Throttle Signal C36 12 TPSS J5 Pin 3 CM Power Supply C36 11 TPSR Ye Common Switched Power C36 9 Remote Throttle Validation Note The 24V signal to C36 9 must be provide to prevent set Throttle Limp Home mode B 10 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B 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 engaged either the forward or reverse clutch the transmission in neutral output is off in this state
24. m 1020712 ALL POWER CONNECTIONS BATTERY AND INSERT WHITE WIRE IN CONTACT POSITION 1 2 7 OR 8 NEEDED IF COMMS INTERFACE NEUTRAL S ART SHOULD BE MADE USING INSERT BLACK WIRE IN CONTACT POSITION 3 4 5 HARNESS IS NOT INSTALLED DETAIL A FOR EACH DISPLAY POWER HARNESS SEE NOTE 2 14 AWG BOND WIRE TERMINATED AT ONE OF INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS SHE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL A REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION HARNESS WIRING 1021090 SERIES CAUTION ALL CONTROLS INCLUDING TROLL AND 0 3 COMMS INTERFACE BOND WIRE PROFILE MODULES MUST BE DISCONNECTED AND RTINA PERMANENTLY REMOVED FROM THE TRANSMISSION 00 PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESS WIRING E TO VESSEL HARNESSES BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A 1020615 SERIES BONDING SYSTEM ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG COMMUNICATION UNLESS OTHERWISE SPECIFIED TWIN DISG INCORPORATED UNLESS OTHERWISE SPECIFIED 7054 FIRST USE MATERIAL HEAT TREAT en NONE RACINE VI 53403 USA sere Tee L D oL 5800 nr esi PETIT pT ERT i SYSTEM 1 ALL ANGULAR TOLERANCES ti USED IN MANER DETRDENTA TO TNE INTEREST OF THIRD anae 10 GEDMETRIC TDLERANCING TININ 0155 nice RATE SYSTEM CONTROL EC300 SAT REV PER ASME 14 5 1994 THE US CONTRACT evel D 00F 1 il
25. neurscwve s e 18 nua neursc vwP LEGEND JUNCTION UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNECTOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END J6 6 J6 7 J6 8 TRANS DUTPUT SPEED SENSUR UIL FILTER SWITCH TRANSMISSION DIL PRESSURE SWITCH NOTES ALL POWER CONNECTIONS BATTERY AND NEUTRAL START SHOULD BE MADE USING 14 AWG WIRE A 14 AWG BOND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION THE COMMUNICATION BUS HAS OTHER POSSIBLE 4 5 aie e ERES dy SISTER CONTROL EC300 A CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION CAUTION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESSES TO BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG UNLESS OTHERWISE SPECIFIED
26. 2 Route the PWM Driver harness to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness 3 Ensure that sealing plugs are installed in all empty connector positions 4 Align the harness connector with the J7 receptacle of the EC300 Control and push it in until it snaps into place 5 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 107 Electrical Installation Twin Disc Incorporated Shaft Brake Wiring Installation Install the wiring for a shaft brake solenoid as follows See Figure 43 Note The connector kit supplied for the PWM Driver Harness 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 Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the red wire to the signal lead for the Shaft Brake Solenoid 2 Connect the black wire to the return lead for the Shaft Brake Solenoid 3 Route the red and black wires to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness 4 Remove the locking wedge from the Deutsch connector 5 Insert the red wi
27. J1939 CAN L J1939 CAN H HARNESS WIRING 1020718 SERIES J1939 CAN SHEET 1 STBD CONTROL Je SHEET 1 STBD CONTROL Ji TRANSMISSION DISPLAY 1018791 TRANSMISSION 0 NX DISPLAY 1018791 HARNESS WIRING 1020615 SERIES COMMUNICATION FROM SHEET 1 STBD COMMUNICATIONS J10 TO SHEET 1 TO SHEET 1 CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 TO 5 1 CONNECTOR KIT 1020713 Fs IGNITION SWITCH 12 24 VDC BATT O 0 J8 1 MANUAL OVERRIDE SWITCH mass CUSTOMER SUPPLIED HARNESS MISC BRIDGE SIGNALS J8 3 J8 4 CONNECTOR KIT HARNESS WIRING 1021010 SERIES DISPLAY ADAPTER QOO Na CUSTDMER SUPPLIED HARNESS ENGINE THROTTLE SIGNAL SENSDR RETURN X THROTTLE SIGNAL THROTTLE COMMON JS 2 REFER TO EC300 INSTALLATION MANUAL FOR J5 3 INFORMATION ON VARIOUS ENGINE CONNECTIONS START SWITCH L 14 AWG gg e BATT 14 AWG 5 10 J5 11 HARNESS WIRING 1020706 ENGINE SPEED SENSOR CONNECTOR KIT 1020714 CONNECTOR KIT 1020618 gt lt DH ENGINE SPEED SENSOR SEE TABLE FOR ENGINE SPEED SENSOR TYPES IF NOT SUPPLIED WITH TRANSMISSION HARNESS WIRING 1020609 SERIES ENGINE ROOM ANALOG HARNESS WIRING PWM DRIVERS MP J7 1 J7 4 B FDRWARD CLUTCH JE REVERSE CLUTCH J7 5 B 73 NEUTRAL CLUTCH J7 6 B SE
28. POSITION SIGNAL POSITION SIGNAL REF ACTUATOR 1022749 NEGATIVE CONTROL LEADS TO STBD CONTROL FROM STBD BATT MUST BE CONNECTED SAME SINGLE POINT PORT BATTERY FUSE HOLDER SUPPLIED WITH ACTUATOR HARNESS 1022865 INSTALL NEAR BATTERY TO STBD BATT S AMP DETAIL eiu CONTROLLER B BOND WIRE TO VESSEL SYSTEM MOUNTING FOOT MATERIAL CAUTION pope em ISIMILAR TD eum ANGLE Sma ee cm gt lt DWH 06 1 J6 8 B J6 6 gt TRANS DUTPUT decr C SPEED SENSUR J6 8 B DH DH DIL FILTER Jie e B SWITCH 2 213 B TRANSMISSION DIL PRESSURE Aeg SWITCH DH ENGINE SPEED SENSORS FOR REFERENCE ONLY 1020929 Mig 10 pnEuTscH 202124 10 DEUTSCH wP___ 1021125 3 4 6 DuaL 5 102126 sve ie LEGEND JUNCTION UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNECTOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END TRANS OIL TEMP SENSOR NOTES ALL POWER CONNECTIONS BATTERY AND NEUTRAL START SHOULD BE MADE USING 14 AWG WIRE
29. System 2 Twin Engine 2 Stations Sheet 1 Port Control 162 System 2 Twin Engine 2 Stations Sheet 2 Starboard Control 163 System 3 Twin Engine 1 Station with Mechanical Actuators Sheet 1 Port Control uininzdciicees 164 System 3 Twin Engine 1 Station with Mechanical Actuators Sheet 2 Starboard Control 165 System Control EC300 with MAN Engine Sheet 1 1024103 166 System Control EC300 with MAN Engine Sheet 2 1024103 167 Wiring Diagram Sheet 1 Port Control 168 Wiring Diagram Sheet 2 Starboard Control 169 EC300 Marine Control System Installation Manual 1024168 11 Table of Contents Twin Disc Incorporated Appendix dELE eT A 1 Environmental 22 A 1 Appendix i e B 1 Engine Connection Requirements B 1 Transmission State Signals 1 B 11 12 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Introduction Preface Introduction The Twin Disc Incorporated product line of electronic Marine Control Systems provides remote operation of engine throttle and transmission engagement The mo
30. Twin Disc Incorporated Racine WI 53405 EC300 Marine Control System Installation Manual 1020607 15 Introduction Twin Disc Incorporated 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 Incorporated or the nearest authorized Twin Disc Incorporated Distributor Ordering Parts 16 All replacement parts or products must be of Twin Disc Incorporated 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 Twin Disc Incorporated 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 Incorporated Renewal parts and service parts kits may be obtained from an authorized Twin Disc Incorporated distributor or service dealer EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated 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 equipm
31. four 24 months or one thousand 1 000 hours 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 or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc Incorporated This warranty applies only to private non commercial non revenue earnin marine pleasure craft applications The original customer does not rely upon any tests or inspections by Twin Disc Incorporated or on Twin Disc Incorporated s application engineering Twin Disc Incorporated is not responsible for any specific application installation or performance standard Any analysis program by Twin Disc Incorporated based upon customer supplied information is done solely as an accommodation to the customer and is not to be interpreted or construed as an approval for specific application or installation or a guarantee of performance B 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 For all models except MG340 and MG360 this include the labor to perform that work and to rem
32. 1018791 ENGINE THROTTLE GASKET 1020740 START SWITCH 45 1 Js e REFER TO EC300 INSTALLATION MANUAL FOR INFORMATION ON VARIOUS ENGINE CONNECTIONS 0 CONNECTOR KIT D BATTE 1020690 INSERT SEALING PLUG PANNA a IN UNUSED CONTACT POSITIONS HARNESS WIRING 14 AWG J5 10 1020706 SERIES ENGINE SPEED SENSUR CONNECTOR KIT 15 1 SIGNAL RED GRN STRIPE 1020714 J5 12 SENSOR RETURN GRN RED STRIPE 0 1 T SY lt a ENGINE 01279 cE SPEED SENSOR CONNECTOR KIT 2 lt SEE TABLE ENGINE 1020713 SPEED SENSUR TYPES IF NUT SUPPLIED WITH HARNESS WIRING INSERT WIRE IN TRANSMISSIDN 1020609 SERIES CONTACT POSITION E HARNESS WIRING ENGINE ROOM ANALOG TRANS DIL Y TEMP SENSOR Pea at 1020593 SERIES CONNECTOR KIT CONNEETUR PDRT LEVER 1020713 TRANS DUTPUT HARNESS WIRING Ee HARNESS WIRING DE 1020720 SERIES SPEED SENSOR 1020718 SERIES Za J1939 CAN lt SEE 3 CONNECTOR 1020717 TYPICAL COMMUNICATION CABLE PLACEMENT S 1939 TERMINATING CABLE END MAY BE PLACED AT ANY CONTROL RESISTOR STATION OR OTHER LOCATION THAT ALLOWS NEEDED IF 1021090 ACCESS TO THE CONNECTOR AT OR NEAR A HELM CONNECTOR COMMS INTERFACE CONTROLEER EC300 1020676A J1939 TERMINATING RES Ide HARNESS IS CUSTOMER SUPPLIED WIRE Y 3 ENGINE SPEED SENSORS F R REFERENCE ONLY e PLACES ECM PDWER SUPPLY CONNOTE NUT FOR USE WITH X edic Gk wensss s e is CA
33. 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 harnesses 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 harnesses See 4 8 2 7 7 1 and Note 4 of 4 8 3 Table 6 in the ABS document The rated temperature of the harness s insulating material is to be at least 10 C 18 F higher than the maximum ambient temperature likely to be in the space where the harness is installed Harness constructions shall use 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 6 Table 6 Power Wire Color Codes as per ABYC Standard E 9 Color Code fFundin Yellow w Red Stripe Neutral Start Relay Contacts J5 pins 9 amp 10 Pape nionSwich US pin 7 Yellow preferred or Black Battery Negative J13 pin 3 Battery Positive J13 pin 1 Auxilliary Battery Positive J13 pin2 Green w Yellow Stripe preferred DC Grounding Conductors or Banding Only or Green EC300 Marine Control System Installation Manual 1020607 61
34. 4 20 MA Common and Pin 8 Battery from T531 Note Wiring may be required inside MAN engine control to get switched battery terminal 15 to wiring side of connector X9 Pin 7 Note The connections shown in table 27 are OBSOLETE and should NOT be used They are shown only for reference MAN has indicated the engine warranty will become void if controller connections use MAN power or common references EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B 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 28 Engine Connections at the MTU Engine EC300 Engine EC300 Signal Enaine Connector Engine Signal Description Harness J5 Decsription g W EL55 MOEL pr Power Supply LOP 1 Terminal 91 24 pu e Signal LOP 1 Terminal 83 HMM in 4 20 MA J5 Pin 3 ECM Power Supply LOP 1 Terminal 84 GRND Common Note Connections are for MDEC ECS 5 version only Check wiring diagram for engine to verify connection terminal numbers for other controls EC300 Marine Control System Installation Manual 1024168 B 9 Appendix B Twin Disc Incorporated
35. 46 23 6 185 1 82 d 22 22 19 04 o9 750 NOMINAL V A SCREW FLAT HEAD 10 32 X 1 1 2 4 PLACES 215 87 2 625 SHAFT WITH 3 16 KEYWAY INTERFACE ASSEMBLY CONSOLE MOUNTING PLATE 4 Figure 6 Side Mount Interface Mounting 11 Install the Selector Assembly using the gasket and stainless steel hardware provided with the unit 12 Setdrag per Control Head Lever Drag Adjustment See Control Head Lever Drag Adjustment on page 33 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 Install the Interface Assembly Assemblies using the mounting plate and stainless hardware provided 14 Connect the Interface Harness between the Interface Assembly and the Selector Assembly and secure strain relieve as necessary 15 Attach the Lever to the 15 87 mm 0 625 in diameter shaft of the Interface Assembly following the instructions provided with the lever 34 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Control Head Lever Drag Adjustment 1 Adjust drag as needed Refer to Figure 7 and 8 for drag adjustment screw locations 2 Access the drag adjustment screw and insert an 1 8 in hex key wrench into the opening for each lever Remove the access screw on side mount control heads See Figure 7 and Figure 8 3 Tighten the dr
36. A DAADADAD Figure 45 Display Harness J9 Installation EC300 Marine Conirol System Installation Manual 1024168 119 Electrical Installation Twin Disc Incorporated Twin Disc Display Harness Wiring Install the Twin Disc Display Harness Assembly and the Display Power Harness as follows See Figure 45 Refer to General Electrical Installation Guidelines before proceeding with this section 1 Align the 3 pin plug of the J1939 Can harness with the 3 pin receptacle of the Twin Disc Display and push together until the lock snaps into place 2 Install a J1939 T Connector into the remaining 3 pin plug of the J1939 Can harness 3 Install a 3 pin plug of the Communications harness into the J1939 T Connector 4 Align the 6 pin plug of the Display Power harness with the 6 pin receptacle of the Twin Disc Display and push together until the lock snaps into place 5 Route the short black wire to the Control Head 6 Access the Control Head connector 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 7 Disconnect the Control Head harness from the Control Head 8 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 9 Route the Display Power harness and the Communications har
37. Actuator is connected to Mark the travel distance of the Servo Actuator lever and the engine transmission troll lever 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 1 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 troll lever to its proper positions without coming bottoming out against the engine transmission troll lever end stops When the final alignment is complete tighten all clamps and associated hardware 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 26 ADJUST BALL JOINT POSITION DOWN RESULT Figure 26 Adjustment of Cable Attachment EC300 Marine Control System Installation Manual 1024168 57 Component Installation Twin Disc Incorporated 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
38. CONNECTOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END J13 3 J13 1 TO STBD CONTROL OPTIONAL AUXILIARY 13 2 15 AMP 14 AWG CUSTDMER SUPPLIED HARNESS POWER 1020711 NDTES ALL POWER CONNECTIONS BATTERY AND NEUTRAL START SHDULD BE MADE USING 14 AWG WIRE A 14 AWG BOND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL A REFER TD THE INSTALLATION MANUAL FOR MORE INFORMATION THE COMMUNICATION BUS HAS OTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION CAUTION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESSES TO BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG UNLESS OTHERWISE SPECIFIED 1020712 eran A SEE NOTE 2 CONTROLLER HARNESS WIRING 1020614 SERIES CONTROLLER COMMS BOND WIRE TO VESSEL BONDING SYSTEM J1939 T CONNECTOR UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIONS 0030 TWIN EX vem FIRST USE INCORPORATED Pa Eee ANY AL TD THE INTEREST OF TWIN DISC INCORPORATE ees p SYSTEM 2 2 SYSTEM CONTROL EC300
39. Control and push it in until it snaps into place Align the J8 harness connector with the J8 receptacle of the EC300 Control and push it in until it snaps into place Align the J12 harness connector with the J12 receptacle of the EC300 Control and push it in until it snaps into place Ensure that sealing plugs are installed in all empty connector positions of each connector Route the Control to Bracket Harness to the transmission Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Bracket to Transmission Wiring Installation Marine transmissions with this option will come from the factory with the Bracket to Transmission harness prefabricated and installed The installer will need to fabricate and install the J5 Neutral Start Interlock and Engine Throttle wiring The Neutral Start Interlock connector is supplied by Twin Disc Incorporated The installer will need to provide the wires and terminate them to the connector and to the neutral start interlock connections on the engine The Bracket to Transmission harness provides the wires approximately 3 m 10 ft long which the installer will need to terminate to the Engine Throttle Input See Figure 36 z
40. ECM s throttle input 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 Engine Control Harness J5 has six pins for throttle control Table 10 lists the pin functions The engine control output can consist of three signals as follows Q The throttle control signal Q An optional signal indicating the transmission is in neutral Q An optional signal indicating the transmission is not in neutral Table 10 Engine Control Pin Functions ECM Power Supply Power supply for the Throttle Signal It is most often a power supply coming from J8 pin 2 In some cases it may be power coming from the ECM This signal is to be used as the power source for the throttle signal output J5 Pin2 Throttle Signal The throttle position output signal Depending upon the engine manufacturer this signal can be a programmed voltage or current The throttle signal is directed by the position of the lever at the active control head 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 J5 Pin3 ECM Power Supply The common return path and reference point for engine throttle circuit P e t RR
41. Electrical Installation Guidelines before proceeding with this section 1 10 11 12 13 Align the Servo Actuator harness connector with the J11 receptacle of the EC300 Controller and push it in until it snaps into place Route the Servo Actuator harness to the Servo Actuator Remove the locking wedge from the Servo Actuator connector Make a suitable interface harness containing the necessary conductors Note The wires must be a minimum of 14 AWG stranded copper wire Install the primary battery positive wire into pin 4 of the servo actuator connector If used install the auxiliary battery positive wire into pin 5 of the servo actuator connector Install the ground wire into pin 6 of the servo actuator connector When all pins have been inserted in the connector body reinsert the locking wedge into the front of the connector body Ensure that sealing plugs are installed in all empty connector positions Align the harness connector with the connector on the Servo Actuator and push it in until it snaps into place Route the primary positive and the ground wires to the Port battery and connect to the battery If used route the auxiliary positive wire to the Starboard battery and connect to the battery Repeat Steps 1 through 12 for any remaining Servo Actuators that may be used on other EC300 Controllers EC300 Marine Control System Installation Manual 1024168 129 Electrical Installation Twin Disc Inc
42. Electrical Installation Twin Disc Incorporated The following guidelines must be met when routing electrical wiring harnesses Keep the EC300 system harnesses away from antenna wires and AC power wires Do not route the EC300 control harnesses in the same trough or conduit as antenna or AC power wires Wiring harnesses must be located away from high current conductors and devices Harnesses must be at least 1 m 3 3 ft away from communications equipment antennas and associated wiring Wiring harnesses must be located away from hot surfaces or high risk fire areas Wiring harnesses 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 the harnesses Do not add additional wire to any harness Longer harnesses may require thicker conductors 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 Q Harnesses are available in varying lengths in 0 6 m 2 ft increments Wiring harnesses must be the minimum practical length Wiring harnesses should never be installed in a manner which results in more than 609 mm 24 in of excess length Wiring harnesses should have service drip loops at each connection point as required to m
43. Head 7 Ensure that the Dual Lever Control Head is firmly mounted 8 Route the Doubler to Station harness to the Station Doubler 9 Connect the Doubler to Station harness plug marked PORT into the receptacle marked STATION B on the PORT end of the Station Doubler 10 Connectthe Doubler to Station harness plug marked STARBOARD into the receptacle marked STATION on the STBD end of the Station Doubler EC300 Marine Control System Installation Manual 1024168 75 Electrical Installation Twin Disc Incorporated Doublers to EC300 Control 11 Connect the circular connector end of a Doubler to Control harness to the receptacle on the Station Doubler marked CONTROL 12 Route the harness marked PORT to the EC300 Port Control Note It is desirable especially on single station vessels to route the port and starboard harnesses as far apart as possible This minimizes the odds of both harnesses being accidently damaged at the same time allowing continued but reduced control of the vessel 13 Connect the Doubler to Control Harness plug to the J2 receptacle of the Port EC300 Control 14 Route the harness marked STARBOARD to the EC300 Starboard Control 15 Connect the Doubler to Control Harness plug to the J2 receptacle of the Starboard EC300 Control 16 lIfapplicable repeat steps 1 through 15 to connect two additional Dual Lever Control Heads through a second Station Dou
44. Installation Manual 1024168 127 Electrical Installation 128 Twin Disc Incorporated Do not connect the Servo Actuator s battery or power input directly to the engine or any of its electrical components Connect the servo power wires to the battery for the engine controlled by the Servo Actuator Port engine servos should be connected to the port battery Starboard engine servos 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 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 Servo Actuator 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Servo Actuator Harness Wiring Install the Servo Actuator Harness as follows See Figure 48 Refer to General
45. OTHERWISE SPECIFIED MACHINED DIMENSIONS X 20010 el EC300 0005 ALL ANGULAR TOLERANCES 31 GEDMETRIC TOLERANCING PER ASME Y14 5M 1994 NUTICH THUS PRINT CONTAINS PROPTETARY DE ORATION a D DISC INCOR INCORPORATE THIS NOTICE IS NOT INTENDED OR LIMIT RIGHTS GRANTED TD THE US Nt OR OT OTHERS BY CONTRACT NEGATIVE CONTROL LEADS MUST BE CONNECTED TO SAME SINGLE POINT FROM STBD BATT PORT BATTERY FUSE HOLDER SUPPLIED WITH ACTUATOR HARNESS 1022865 INSTALL NEAR BATTERY TO STBD BATT PRIMARY BATT AUXILIARY BATT OUND ACTUATOR 1022749 THROTTLE 1 STATION MECHANICAL ACTUATORS x ET CAUTION TO START MOTOR BATT SEE NOTE 4 1020553 5 8 18 1020929 we 10 nua neurscH 102124 w8 10 DEUTSCH WP_ 102125 3 4316 neurscwve Lwenes svete DEUTSCH wP LEGEND JUNCTION UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNECTOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END ALL POWER CONNECTIONS BATTERY AND NEUTRAL START gt SHOULD BE MADE USING 14 AWG WIRE A 14 AWG BO
46. Override Switch input wiring portion of the Bridge Signals harnesses as follows See Figure 44 Twin Disc Incorporated strongly recommends that the Manual Override Switch is properly wired if the transmission is equipped with a manual override valve Failure to properly wire the Manual Override Switch may cause catastrophic gear failure if the Manual Override Valve and the forward or reverse solenoid are inadvertently activated at the same time Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the customer supplied wire to either screw terminal on one of the manual override valve switches 2 Connect the other customer supplied wire to the other screw terminal on the manual override valve switch Note The manual override valve has screw terminals on both sides for two separate connections One side is for the J8 Manual Override switch connection and the other side for the J5 neutral start switch connection 3 Route the two wires to the EC300 Control Note EC300 Bridge Signals Harness J8 also may contain wiring for other features Route the harness to the most convenient location serving all the applicable connections 4 Remove the locking wedge from the Deutsch connector EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated 10 Electrical Installation Insert one of the wires into position 3 of the J8 connector Note Refer to the EC300 Sys
47. P Barn SIZE B A CONTROL STATION 1 r3 CONTROL STATION 1 CONTROL HEAD SHEET 1 CONTROL STATION 2 TRANSMISSION DISPLAY 1018791 GASKET 1020740 2 PLACES 1020690 INSERT SEALING PLUG CONTROL STATION 2 IN UNUSED CONTACT POSITIONS CONTROL HEAD CSHEET 1 CONNECTOR KIT 1020714 CONNECTOR KIT ECM PDWER SUPPLY THROTTLE SIGNAL POWER SUPPLY COMMON CUSTOMER SUPPLIED HARNESS ENGINE THROTTLE HARNESS WIRING 1020706 SERIES ENGINE SPEED SENSOR 45 1 SIGNAL RED GRN STRIPE J5 12 SENSOR RETURN GRN RED STRIPE ET a SPEED SENSOR SEE TABLE FOR ENGINE SPEED SENSOR TYPES IF NOT SUPPLIED WITH TRANSMISSION THIS CONNECTION USED WITH CAT ENGINE APPLICATIONS ONLY D J5 2 J5 3 REFER TO EC300 INSTALLATION MANUAL FOR INFORMATION ON VARIDUS ENGINE CONNECTIONS START SWITCH c 55 9 90 EL START MOTOR MANUAL DVERRIDE SWITCH J5 10 HARNESS WIRING 1020609 SERIES ENGINE ROOM ANALOG TRANS DIL TEMP SENSDR HARNESS WIRING 1020718 SERIES UN SHEET 1 1020720 SERIES J1939 CAN PWM DRIVERS temi 1020713 Nw TRANS OUTPUT J2 HARNESS SHOWN HARNESS WIRING SPEED SENSOR SEE NOTE 4 5 WIRING 1020718 SERIES J1939 CAN HARNESS WIRING 1020615 SERIES COMMUNICATION HARNESS SHOWN ON SHEET 1 CUST
48. REVERSE CLUTCH DRIVER DUTPUT PWM NEUTRAL CLUTCH RETURN FOR PWM 1 RETURN FOR PWM 2 RETURN FOR PWM 3 SIGNAL FROM IGNITION SWITCH CONTROLS CONTROLLER POWER IGNITION SWITCH OPTIONAL RETURN MANUAL OVERRIDE SWITCH MANUAL OVERRIDE SWITCH RETURN POWER SUPPLY FOR DIGITAL STATION 1 CONN COMM FOR DIGITAL STATION 1 CONN COMM FOR DIGITAL STATION 1 CONN COMM FOR CONTROLLER COMMS CONN 1 COMM FOR CONTROLLER COMMS CONN 1 SERVO POWER 211 1 1 4 2 SERVO POSITION q J11 2 J11 3 D OIL FILTER SWITCH INPUT OIL FILTER SWITCH RETURN TRANSMISSION OIL PRESSURE SWITCH PRIMARY POWER INPUT PIN 1 AUXILIARY POWER INPUT PIN 1 POWER COMMON PIN 1 g J2 1 J2 120 Je 2 J2 11 D gQ J2 3 10 D 4 Je 9 D g J2 5 Je 8 D 6 Je 7 D 1 3 1 J3 120 J3 2 J3 11 D Q J3 3 23 10 D q J3 4 J3 9 D 1 3 5 J3 8 D 23 6 J3 7 D Q J4 1 J4 18 D 4 2 J4 11 D Q J4 3 J4 100 4 4 J4 9 D Q J4 5 J4 8 D q J4 6 J4 7 D Q J5 1 J5 120 q J5 2 J5 11 O 1 5 3 J5 10 D J10 1 J10 4 O J10 2 J10 3 O q J12 1 J1e 6D q J1e e J12 50 OQ J12 3J12 40 J13 1 13 60 Q 213 2 13 5 0 13 3 13 40 NEGATIVE POWER UNUSED UNUSED THROTTLE LIMIT SINGLE LEVER SYNC MASTER SELECT SWITCH REVERSE SWITCH FORWARD SWITCH NEGATIVE POWER UNUSED UNUSED THROTTLE LIMIT SINGLE LEVER SYNC MASTER SELECT SWITCH REVERSE SWITCH FORWARD SWITCH NEGATIVE POWER UNUSED UNUSED T
49. Refer to the engine manufacturer s literature to resolve any discrepancies Table 14 Engine Connections at Caterpillar s TPS Connector EC300 Engine EC300 Signal Harness J5 Decsription Bm Power Supply A note 1 Switched Positive ECM Power TPS Connector Engine Signal Description pee Signal EE Primary Throttle Position Signal J5 Pin 3 ECM Power Supply B note 1 Negative Battery ECM Power Common The battery positive connection to J5 1 should be switched and from ECM wiring i The battery negative connection to J5 3 should be from ECM wiring not battery bus Table 15 Engine Connections at Caterpillar s Customer Connector EC300 Engine EC300 Signal Customer Harness J5 Decsription Connector ECM Power Supply Battery Positiove switched Engine Signal Description J5 Pin 3 ECM Power Supply Pin 2 Battery Negative Common EC300 Marine Control System Installation Manual 1024168 B 1 Appendix B Twin Disc Incorporated 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 outpu
50. SERIES 0416 MG518 SERIES 0459 MG6557SC SERIES 0461 MG6557RV SERIES 0465 MG 6619A SERIES 0473 MG 520 1HP SERIES 0441 MG 6650 00 SC SERIES 0446 MG 6848 00 SC SERIES 0478 MG 6690SC SERIES 0484 MGX 61500SC SERIES 0485 MGX 6650 SERIES 0487 MGX 6690SC SERIES 0488 MGX 6848SC SERIES 1721 MGX 6620SC SERIES 1737 MGX 6599A SERIES ecember 14 TDWP10099A rev gt NINIS 0450 MG340 SERIES PartOnly 0451 MG360 SERIES _ Part Only 0432 MG5010 amp MG5011 SERIES 10 0401 mG506 SERIES 710 0435 MG5050SERIES 10 0437 MG5061 amp MG5062V SERIES 10 0453 MG5055A SERIES 710 1706 MG5065A SERIES 10 1707 MG5065SC SERIES 10 0425 MG5085 SERIES 7 0 0442 MG5075A SERIES 7 0 0443 MG5075SC SERIES 710 0476 MG5082 SERIES 710 0419 MG5114 SERIES 70 0433 MG5090 SERIES 10 0489 MGX5114A SERIES 10 0490 MGX5114SC SERIES 10 0491 MGX5114IV SERIES 10 1719 MGX5095A SERIES 10 1728 MG5095A SERIES 70 1729 MG5095SC SERIES 10 0405 MG514 SERIES 10 0447 MG5145A SERIES 7 0 0448 MG5145SC SERIES 710 0492 MGX5135A SERIES 70 0494 MGX5145SC SERIES _ 10 1704 MG 5135A SERIES 7 0 0426 MG516 amp MG5170 SERIES 10 0477 MG5170 SERIES 70 0412 MG5200 SERIES 10
51. The options below depict the various wiring options for these outputs Refer to you enginie throttle interface specifications to see if these functions are compatable with your engine These functions are set up by an Authorized Twin Disc Distributor or at the factory OPTION 1 EC300 T J5 4 DB J5 6 TO DRIVE DEVICE TRANSMISSION IN NEUTRAL SOURCING OUTPUT OPTION 3 EC300 J5 4 gt TO DRIVE DEVICE J5 6 D COMMON TRANSMISSION IN NEUTRAL SINKING OUTPUT OPTION 2 EC300 5 5 O J5 6 TO DRIVE DEVICE TRANSMISSION IN GEAR SOURCING OUTPUT OPTION 4 EC300 J5 5 O TO DRIVE DEVICE J5 6 0 COMMON TRANSMISSION IN GEAR SINKING OUTPUT Figure 91 Transmission State Signal Output Diagram EC300 Marine Control System Installation Manual 1024168 Appendix Twin Disc Incorporated B 12 EC300 Marine Control System Installation Manual 1024168 1024168 R2 4 08 TWIN DISC INCORPORATED RACINE WISCONSIN 53403 U S A 262 638 4000 262 638 4482 FAX WWW TWINDISC COM
52. and lock washers Note Use 6 35 mm 0 25 in diameter fasteners and place lock washers under the mounting screw heads 4 Install the push pull cable Refer to Push Pull Cable Installation for cable installation EC300 Marine Control System Installation Manual 1024168 47 Component Installation Twin Disc Incorporated Push Pull Cable Installation Guidelines Correct push pull cable installation will aid in trouble free operation of the control system Different installation kits are available Where possible quick disconnect ball joints should be used to assist in push pull cable adjustments Push pull cable installation should meet the following guidelines 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 required Refer to cable manufacturer specifications Cables should not be routed near hot surfaces Ll Cables should not be routed in service or access areas 48 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component 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 17 and Figure 18 The dual kit accommodates one end of two cables The single kit accommodates one end of on
53. at the engine transmission using a mounting arrangement which allows for a cable travel within the 1 5 3 5 inch 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 inch 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 inch range and tighten the engine transmission end Leave the Servo Actuator end loose Proceed to the push pull cable adjustment section for either the mechanically shifted transmission mechanically controlled throttle or mechanically controlled troll valve to perform the initial push pull cable adjustment EC300 Marine Control System Installation Manual 1024168 53 Component Installation Twin Disc Incorporated Push Pull Cable Adjustment for Mechanically Shifted Transmission The transmission s gear select actuator is a three position device 45 degree left center and 45 degree right See Figure 23 The control will drive the Servo Actuator to these positions as commanded by ahead neutral or astern commands from the control head The push pull cable positions the gear select lever in the desired position NEUTRAL NEUTRAL ASTERN AHEAD N TRANSMISSION SERVO ACTUATOR ENGINE Figu
54. 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 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 J13 pin 1 and Earth or Bonding System e J13 pin 2 and Earth or Bonding System J13 pin 3 and Earth or Bonding System 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 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
55. continued but reduced control of the vessel 70 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Split Single Lever Control Head Stations in Twin Engine Installations Some dual engine installations use split Single Lever Control Heads at control stations rather than Dual Lever Control Heads For such installations one split lever harness and one dual lever harness are used See Figure 32 TO EC300 STARBOARD CONTROL Le 1020617 HARNESS WIRING DUAL LEVER TO EC300 V oh NC 1021458 PORT CONTROL Ne HARNESS WIRING SPLIT LEVER Figure 32 View of Split Single Lever Harness Wiring Install the Control Head harnesses as follows Note The Control Heads may be removed from the dash if this facilitates making the connection If they are removed then reinstall them after the connections have been made Note Provide enough length in the harness to allow removal of the Control Heads in the future EC300 Marine Control System Installation Manual 1024168 71 Electrical Installation Twin Disc Incorporated Refer to General Electrical Installation Guidelines for harness routing criteria 1 Connect the female circular connector end of the S
56. diagram provided for the system Shorten the harness on the end identified by the scissors icon Twin Disc Incorporated provides harnesses in the following configurations Fully prefabricated wiring harnesses with connectors installed on both ends Prefabricated wiring with connectors installed only on the EC300 end of the harness The equipment end of the harness is fabricated by the installer at the time of installation with components provided by the customer Prefabricated wiring harnesses with connectors installed on the equipment end and terminals installed on the EC300 end of the harness The terminals on these harnesses will be installed into the EC300 connector provided by Twin Disc Incorporated Q For Non Twin Disc components the wiring harness and equipment end connectors are supplied by the customer with the EC300 connector being supplied by Twin Disc Incorporated Kits are available from Twin Disc Incorporated which provide the contact sockets and sealing plugs used in the EC300 connectors EC300 Marine Control System Installation Manual 1024168 59 Electrical Installation Twin Disc Incorporated General Electrical Installation Guidelines Ensure that the EC300 Control Power and Grounding Harness J13 connector is disconnected before proceeding with the installation of all other harnesses When making the electrical connections described in this section ensure that the associated power source
57. identified on the existing tachometer sender The tachometer 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 tachometer signal generator as per the manufacturer s instructions Reference Engine Control Harness J5 Installation and Engine Room Harness J6 Installation in the Electrical Installation Section of this manual for complete speed sensor wiring information EC300 Marine Control System Installation Manual 1024168 43 Component Installation Twin Disc Incorporated Station Doubler Installation Station Doublers are used for installations requiring four 4 or five 5 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 Note The J1 connection will not support a station doubler and must be connected directly to a Control Head TRI 127 0 ELM MINIMUM i RECOMMENDED mimmmimmi MAINTENANCE CLEARANCE L Figure 15 Station Doubler Top Side Views 44 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated 5 Component Installation Locate a solid flat surface where the mounting pads contact and are parallel to the mounting surface Note All mounting hardware must be corrosio
58. is turned off The following general electrical installation points apply to all electrical installations Read the following guidelines before making any installations and connections The installer must follow the 00 installation diagram provided for the system The following guidelines must be met when fabricating electrical harnesses Electric harness are to be flame retardant and must comply with the following requirements as applicable e Harnesses 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 Harnesses constructed to IEEE 1580 2001 are to comply with the flammability criteria contained therein e Harnesses 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 harnesses which have not passed the bunched harness flammability criteria as per IEC Publication 60332 3 may be considered provided that the harness is treated with approved flame retardant material or the installation is provided with approved fire stop arrangements 60 EC300 Marine Control System Installation Manual 1024168 Electrical Installation Twin Disc Incorporated Maximum current carrying capacities of harnesses conforming to IEC Publication 60092
59. locations with the template Remove any splinters or sharp edges from the holes Check the fit by carefully placing the Control Head in the hole Remove the Control Head from the cutout Correct the fit as necessary Set drag per Control Head Lever Drag Adjustment See Control Head Lever Drag Adjustment 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 Install and mount the Control Head using the supplied gasket and four 4 oval head 10 screws or equivalent 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 Torque the fasteners to 1 13 Nm 10 Ib in maximum 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 Ib in maximum Reference Control Head Harness J1 J2 or J3 Installation for cable installation EEC300 Marine Control System Installation Manual 1024168 31 Component Installation Twin Disc Incorporated Side Mount Control Head Assembly Binnacle Console Station The side mount Control Head Assembly consists of a Lever
60. present the EC300 must be grounded to the engine block BONDING SYSTEM BOND WIRE WITH RING LUG MOUNTING FOOT PLACES O J1 J2 J3 J4 J5 J6 J7 e e o o suoni ooo o o o o o o o o o o o o o o 2 up 9999 ooo J8 J9 120 J130 Nu Figure 55 EC300 Control Bond Connection Diagram 3 EC300 Marine Control System Installation Manual 1024168 Install a ring lug on the control end of the wire Note The ring lug must be properly sized for both the wire and the mounting fastener 149 Electrical Installation Twin Disc Incorporated 4 Remove the mounting fastener at the bonding connection 5 Remove any paint at the mounting connection in order to ensure electrical contact 6 Insert the bonding wire s ring lug on the EC300 Control 7 Reinstall and tighten fasteners up to 1 13 Nm 10 Ib in maximum 150 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Engineering Drawings 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 and are supplied separately Note Any part numbers listed in the following enginee
61. 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 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 Bonding Requirements The EC300 Control must be bonded If used the Servo Actuator and accessories must also be bonded Note EC300 Control System components including Controllers Servo Actuators and Accessories that have designated bond points should be mounted on isolating platforms like plywood starboard PVC boxes etc 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 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 Control s bond connection should also be to the battery neg
62. s collar until the engagement snap is felt 2 Ensure that the Single Lever Control Head is firmly mounted 3 Route the Control Head harness to the EC300 Control 4 Connect the Control Head Harness plug to the J1 receptacle of the EC300 Control 5 If applicable repeat Steps 1 through 4 for connecting additional Control Stations using J2 for the second Control Head and J3 for the third Control Head 6 If J2 and or J3 are not used install a connector kit into these receptacles to seal the connector See System Drawing for Connector Plug Kit p n 7 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Multi Station Dual Lever Control Head Wiring Installation This section is applicable to dual engine applications with up to three Dual Lever Control Heads See Figure 31 CONTROL STATION 1 CONTROL STATION 2 CONTROL STATION 3 PORT STBD PORT STBD PORT STBD SN HARNESS WIRING PORT LEVER d 3 PLACES e PORT CONTROL e STARBOARD CONTROL 0 9 NG CONNECTOR pm we 20 013
63. wiring harnesses may be installed as one harness standard or individual harnesses If your installation includes individual harnesses proceed to the installation instructions for each harness When completed with the Transmission Harness installation proceed to the J9 Harness installation procedure and omit the J12 installation procedure The Transmission Harness is a fully prefabricated harness that combines the wiring for the J5 J6 J7 J8 and J12 harnesses and connections It consists of 2 separate harness assemblies A Control to Bracket Harness Figure 35 and a Bracket to Transmission Harness Figure 36 Various harness options are available to accommodate different transmission and control system options The Control to Bracket harness connects to the EC300 and is routed to the mating circular connector mounted on the transmission bracket The transmission is supplied with the Bracket to Transmission harness prewired The J5 wiring for engine throttle is available at the bracket and must be fabricated and wired by the customer The Transmission Harness connectors contain all contacts and sealing plugs that are required to fill the connector contact positions Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector Refer to General Electrical Installation Guidelines for harness routing criteria before proceeding with this section This section contains the followin
64. 0806396 210206356 CUSTDMER SUPPLIED HARNESS 15 3 TO x9 10 ENGINE THROTTLE NU CONNECTOR KIT NOTE 1020714 C ALL MAN CONNECTIONS WITHIN DASHED 14 AWG J5 9 TD x9 7 OUTLINES ARE UNCONTROLLED AND FOR REFERENCE ONLY CONSULT ENGINE MANUFACTURER FOR V TION X conector x MANUAL OVERRIDE ANUFA ERIFICATION 10207 HARNESS WIRING 14 AWG J5 10 TD x9 8 1080706 SERIES DISPLAY 1018791 ENGINE SPEED SENSOR GASKET 1020740 INSERT WIRE IN 2 PLACES INSERT WIRE IN y J5 11 SIGNAL RED GRN STRIPE X9 3 FROM J8 D CENTACT POSITION trop JS 12 RETURN GRN RED STRIPE FROM CONTROL STATION 1 020706 SPEED SENSOR STBD DISPLAY AY SHEET 2 07 gt lt SEE TABLE ENGINE N SPEED SENSUR TYPES X HARNESS WIRING sums PaA Ea BAEO 24 CONTACT POSITION 2 1020617 SERIES DUAL LEVER ENGINE ROOM ANALOG TRANS GIL CIRCULAR DUAL LEVER oa TEMP SENSOR CONNECTOR o h O J2 OF STBD 72 CONTROL c TO Ji OF STBD SHEET 2 TRANS OUTPUT Sede CONTROL Br HARNESS WIRING A MO IRANS guTRUT r SHEET 2 SN A 1020720 SERIES c t E PWM DRIVERS F KS 7 1020720 TVWA SEE NOTE 4 S lt REVS NC veia COMMUNICATION CABLE CONNECTOR KIT PLACEMENT CABLE END MAY 102169 BE PLACED ANY CONTROL 1 CONTROLLER EC300 STATION OR OTHER LOCATION 1 6A OPTIONAL 1020615 THAT ALLOWS ACCESS TO THE PORT CONTROL ENGINE SPEED SENSORS FOR REFERENCE ONLY COMMS INTERFACE CONNECTOR AT OR NEAR A H
65. 3 13 07 SCALI NONE INCORPORATED RACINE WI 53403 USA WIRING DIAGRAM Twin Disc Incorporated Appendix A Appendix A Environmental Specifications Table 13 Environmental Specifications Supply Voltage 10 5 Volts 30 0 Volts Operating Temperature 18 C 0 F 70 C 158 F Storage Temperature 40 C 40 F 80 C 176 F Vibration 759 220 000 Hz The EC300 meets or exceeds ABS requirements and ABYC recommendations for electrical transients electromagnetic compatibility chemical resistance flame resistance corrosion resistance submersion in liquids dust tolerance and electrostatic discharge EC300 Marine Control System Installation Manual 1024168 A 1 Appendix Twin Disc Incorporated 2 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B Appendix B Engine Connection Requirements Caterpillar Engine Connection Requirements This throttle signal configuration is known as a PWM or Duty Cycle The EC300 sets the throttle signal duty cycle 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 14 and Table 15
66. 3 ENGINE SPEED SENSOR SEE ENGINE SPEED SENSOR HARNESS INSTALLATION SECTION f 7 STARTER SOLENOID CONNECTOR KIT ENGINE THROTTLE E P 1 EU 42 J3 J4 J7 o E 1 o o o o 1 o o o 45 4 69 69 6 5 10 o 2 13 O USED WHEN STARTER RELAY SOLENOID IS 5 AMPS DC OR GREATER ENGINE CONTROL MODULE SEE ENGINE CONTROL HARNESS INSTALLATION SECTION START SWITCH NEUTRAL START RELAY CONTACT N O 14 AWG Js HARNESS WIRING ENGINE THROTTLE CUSTOMER SUPPLIED MANUAL OVERRIDE SWITCH NEUTRAL START RELAY CONTACT 14 AWG 2540 BATT v STARTER SOLENOID CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 TO J5 1 HARNESS WIRING ENGINE SPEED SENSOR f SEE ENGINE SPEED SENSOR HARNESS INSTALLATION SECTION CONNECTOR KIT ENGINE THROTTLE 000000 000000 000000 o o o 9000 o o 2 2 Ce o o m NEUTRAL START WITHOUT RELAY USED WHEN STARTER RELAY SOLENOID IS LESS THAN 5 AMPS DC Figure 40 Neutral Start Interlock Schematic J5 Harness 92 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 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 start
67. 300 Marine Control System Installation Manual 1024168 135 Electrical Installation Twin Disc Incorporated Transmission Oil Pressure Switch Wiring Installation Install the wiring connections for a Transmission Oil Pressure Switch as follows See Figure 49 Note The Transmission Oil Pressure Switch cable is part of the Engine Room Switch harness Cable ties may be removed for routing purposes Refer to General Electrical Installation Guidelines before proceeding with this section 1 If not already completed align the harness connector with the J12 receptacle of the EC300 Control and push it in until it snaps into place If not already completed route the Engine Room Switch Harness to the Transmission Oil Pressure Switch area Terminate the light blue with brown stripe OIL PRESSURE SWITCH J12 pin 3 wire to either screw terminal on the Transmission Oil Pressure Switch Terminate the brown with light blue stripe OIL PRESSURE SWITCH J12 pin 4 wire to the other screw terminal on the Transmission Oil Pressure Switch Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Note It may be desirable to complete any other terminations for this harness before securing the harness EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation EC300 Control Power and Grounding Harness J13 Installation The Control Power a
68. 4108 1 MODEL PAGE 1 4 15 08 11 31 12 AM ALK CONTROL STATION 1 TRANSMISSION 1020718 1080951 gy Q CONTROL STATION 2 1020951 SERIES DISPLAY POWER INSERT BLACK WIRE IN CONTACT POSITION 3 4 5 OR 6 FOR EACH DISPLAY POWER HARNESS INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS
69. 5 Pin4 Transmission State 1 solid state switch output that goes active when the transmission is in neutral This wire is used only for specific engines See page B 12 in Appendix B for additional information J5 Pin5 Transmission State 2 A solid state switch output that goes active when the transmission is not in neutral This wire is used only for specific engines See page B 12 in Appendix B for additional information J5 Pin6 Transmission State The return signal for the transmission state signal This wire is used itii Return only for specific engines See page B 12 in Appendix B for additional information EC300 Marine Control System Installation Manual 1024168 95 Electrical Installation Twin Disc Incorporated The EC300 Control System currently supports the following types of electronic engine controls Table 11 Engines Supported Uwe pum et mooo qucm e 00 m Ww pest rs 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 is performed by Twin Disc Incorporated or its local distributor Refer to Appendix B for detailed electrical installation requirements for the engines listed Harness Fabrication and Wiring Procedure Note The connector kit supplied for Engine Control Harness J5 has enough contacts and plugs necessary to fill the conn
70. 6 12SD P012 J 06 085 012 J7 DT06 12SC P012 J8 DT06 08SA P012 J9 DT06 06S P012 J10 DT06 04S P012 211 DT06 04S P012 Jie DT06 06S P012 J13 DT06 06S P012 TERMINALS 0462 201 16141 INDIVIDUAL PIN 1062 16 0122 REEL WEDGES 4 PIN W4S P012 6 PIN W6S P012 8 PIN W8S P012 12 PIN W12S P012 351 6 LA mw 101 7 47 7 REF MINIMUM RECOMMENDED MAINTENANCE CLEARANCE X 400 3258 7 6 THRU uu nee 3 PLACES 104 8 917 8 SOCKET CLEARANCE 142 9 AA 3 PLACES 314 3 Ml NOTE THERE IS NO PREFERRED MOUNTING ORIENTATION POSITIVE POWER NEUTRAL LED DRIVE LEVER POSITION MODE SELECT SWITCH COMMON POSITIVE POWER NEUTRAL LED DRIVE LEVER POSITION MODE SELECT SWITCH COMMON POSITIVE POWER NEUTRAL LED DRIVE LEVER POSITION MODE SELECT SWITCH COMMON TRANSMIT DATA TO RS 232 COMPUTER RECEIVE DATA FROM RS 232 COMPUTER COMMON FOR RS 232 COMMS SHIELD FOR RS 232 COMMS DIAGNOSTIC BOOT INPUT DIAGNOSTIC INPUT RETURN PWR SUPPLY FROM ECM THROTTLE TO ECM PWR SUPPLY COMMON FROM ECM TRANSMISSION STATE 1 TRANSMISSION STATE 2 TRANSMISSION STATE RETURN TRANSMISSION OIL TEMP TRANSMISSION OIL TEMP RETURN OIL PRESSURE SENSOR EXCITATION OIL PRESSURE SENSOR DRIVER DUTPUT PWM 1 FORWARD CLUTCH DRIVER DUTPUT PWM 2
71. AMP SHIM EC300 Marine Control System Installation Manual 1024168 153 Engineering Drawings Twin Disc Incorporated Servo Actuator Mounting Dimensions 260 10 232 136 52 38 RIGHT SID VIEW 210 8 29 188 117 4 625 m CI do EC300 Marine Control System Installation Manual 1024168 Engineering Drawings Twin Disc Incorporated Twin Disc Display Mounting Dimensions 1018791 52 7 2 07 REAR ENCLOSURE DIAMETER 8 32 THREAD 57 LABEL 2 24 24 b 0 94 ADJUSTABLE FOR 05 TU 20 002 TO 0 78 THICK MOUNTING PANELS 155 EC300 Marine Conirol System Installation Manual 1024168 Engineering Drawings Control Head Mounting Template Twin Disc Incorporated 334 5 24 REF ERE ES M dog ucc quA BH E t Ae Sp USE 15 64 UR Tp i 2 DRILI i 4 34 4 82 1445 i 55222 08 0 REE
72. B A CONTROLLER CONTROL STATION 1 TRANSMISSION CONTROL HEAD 1020635G DUAL LEVER INSERT WIRE IN CONTACT POSITION OF CIRCULAR CONNECTOR CONNECTOR KIT 1021169 NEEDED IF OPTIONAL 1020615 COMMS INTERFACE HARNESS IS INSTALLED HARNESS WIRING 1020718 SERIES J1939 CAN WARNESS WIRING 1020615 SERIES COMMS INTERFACE COPTIONALD CONTROL STATION 2 CONTROL HEAD 1020635G DUAL LEVER DISPLAY 1018791 GASKET 1020740 2 PLACES INSERT WIRE IN CONTACT POSITION J OF CIRCULAR CONNECTOR FROM CONTROL STATION 1 STBD DISPLAY SHEET 22 HARNESS WIRING 1020617 SERIES DUAL LEVER 1 D am TO J1 OF STBD ET CONTROL 0 E SHEET 2 INSERT WIRE IN CONTACT POSITION OF CIRCULAR CONNECTOR HARNESS WIRING 1020718 SERIES J1939 CAN TYPICAL COMMUNICATION CABLE PLACEMENT CABLE END MAY BE PLACED AT ANY CONTROL STATION OR OTHER LOCATION THAT ALLOWS ACCESS TO THE CONNECTOR AT OR NEAR A HELM HARNESS WIRING 1020951 SERIES DISPLAY POWER CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 5 1 NOTE NOT FOR USE WITH CAT ENGINE APPLICATIONS E INSERT SEALING PN OVERRIDE IGNITION WITCH lx pe m MANUAL DVERRIDE switch OPTION 1 TO BE USED WITH EC300 SOFTWARE VERSION 1 03 OR EARLIER HARNESS WIRING 1020615_ SERIES COMMUNICATION MANUAL OVERRIDE SWITCH OPTION 2 TO BE USED WITH EC300 1020613
73. CO CONTROL HEAD MIN JASH CUI MPLA ASTERN lt EEP RADIUS S4 Geo R LESS Y gt CM N E A NAN A N p iaa 6 C30 RAD T 4 50 Z 100mm USE 4 100mm LINES VERIFY SCALE 156 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Engineering Drawings Side Mount Lever Mounting Template 50 80 38 10 a 2 00 1 50 Rew 58b ma a UN 38 10 n 1 50 347 53 uc A a gt RY P AL 220 40 803 P 220 90 2 823 gi 2 50 24 75 0187 25 33 8 210 A PLACES N E BDX INE OR REFERENCE ONL 4 USE 4 OR 100mm LINES ERIFY 11 SCALE EC300 Marine Control System Installation Manual 1024168 157 Engineering Drawings Twin Disc Incorporated Side Mount Selector Assembly Mounting Template 106 68 4220 OO C375 el Ne 64 75 0 1872 05 33 0 0100 10 SCR ARANCE 6 84 CUT Ol 4 60 DE 20 65 4 75 PANEL OUTLINE FOR REFERENCE ONLY 1 8 X 4 n ji 100mm USE 4 GR 100mm S TO VER 11 SCA 158 EC300 Marine Control System Installation Manual 1024168 PER MATING CONNECTOR PARTS DEUTSCH CONNECTORS J1 DT06 12SA P012 Je 06 125 012 J3 DT06 12SA P012 J4 06 125 012 JS DT0
74. Customer OEM Engine Signal Description Harness J5 Decsription Connector g g P J5 Pin 1 J5 Pin 2 J5 Pin 3 puse Signal DD Pin B Throttle Position Throttle ECM Power Supply DD Pin A V Throttle Return GND Common Note Not all QSK Throttle Pot Connectors are DD Table 18 Engine Connections at the Cummins Quantum QSM 11 Engine with Voltage Control EC300 Engine EC300 Signal OEM Connector Engine Sianal Description Harness J5 Decsription QSM 11 9 9 5 1 CM Power Supply DD Pin C V Throttle VTP J5 Pin 2 Throttle Signal DD Pin B Throttle Position Throttle J5 Pin 3 ECM Power Supply DD Pin A V Throttle Return GND Common EC300 Marine Control System Installation Manual 1024168 B 3 Appendix B Twin Disc Incorporated Detroit Diesel Frequency Engine Connection Requirements for Frequency Control Table 19 Engine Connections at the Detroit Diesel Engine EC300 Engine EC300 Signal _ Engine Connector Engine Signal Description J5 Pin 1 ECM Power Supply J8 Pin 2 J5 Pin 2 Throttle Signal MIM Plug Series 60 Wiper NENNEN CIEN J5 Pin 3 ECM Power Supply MIM Plug Series 60 RTN pet mmm Detroit Diesel Voltage Engine Connection Requirements for Voltage Control Table 20 Engine Connections at the Detroit Diesel Engine EC300 Engine EC300 Signal er E t E ID t Harness J5 Decsription ngine Connector ngine Signal Description J5 Pin 1 ECM Power Supply J8 Pin 2 J5 Pin 2 Throttle Sign
75. E NOTE 4 757 TROLL CLUTCH J7 10 B 4728 SHAFT BRAKE CLUTCH J7 11 B CONTROLLER EC300 1020676 STBD CONTROL FUSE HOLDER SUPPLIED WITH CONNECTOR KIT 1020618 INSTALL NEAR BATTERY 14 AWG gg J13 1 CUSTDMER SUPPLIED HARNESS POWER X HARNESS WIRING 1020695 ENGINE RODOM SWITCH CUSTOMER SUPPLIED POWER O ACTUATOR POWER HARNESS WIRING 1022865 SERIES ACTUATOR UNLESS OTHERWISE SPECIFIED MACHINED DIMENSI XXX ALL ANGULAR TOLERANCES 31 GEOMETRIC TOLERANCING PER ASME Y14 5M 1994 ANY AL TU THE TWIN DISC INCORPORATE FIRST USE 4 855 Mone 00 THIS PRINT CORTAIRS PRUPIETART DURER DW s POWER SUPPLY COMMON 1 POSITION SIGNAL POWER SIGNAL POWER SUPPLY COMMON POSITION SIGNAL POSITION SIGNAL REF ACTUATOR 1022749 TO VESSEL BONDING SYSTEM SINGLE POINT GND SEE SHEET 1 STBD BATTERY FUSE HOLDER SUPPLIED WITH ACTUATOR HARNESS 1022865 INSTALL NEAR BATTERY TO SINGLE POINT GROUND SEE SHEET 1 O TO PORT BATT 5 AMP DETAIL SEE NDTE 2 CONTROLLER BOND WIRE MOUNTING FOOT TO START MOTOR TRANS OIL TEMP SENSOR gt lt J6 1 J6 e n E B DH DH J12 1 A 51 B Ji2 4 B 2124 DH ENGINE SPEED SENSORS REFERENCE ONLY 1020553 S 8 18 SINGLE DEUTSCH 1020929 me 10 nua DEUTSCH 1021124 0 neurscvP ines 3 4316
76. EC300 HARNESS WIRING HM HIRSCHMAN SOFTWARE VERSION 104 OR LATER 1021010 SERIES WP WEATHER PACK CONNECTOR DISPLAY ADAPTER CUSTOMER SUPPLIED HARNESS PPR PULSES PER REVOLUTION POWER X NO CONNECTION ECM ENGINE CONTROL MODULE CONNECTOR CONNECTOR KIT lt IF NEEDED SHORTEN THIS END 1020716 1020711 J1939 TERMINATING RESISTOR NOTES 2 PLACES CONNECTOR KIT 1 ALL_POWER CONNECTIONS BATTERY AND 1020712 NEUTRAL START SHOULD BE MADE USING 14 i 8 14 AWG BOND WIRE TERMINATED AT ONE DF XS E A A L J10 HARNESS SHOWN DN SHEET 1 THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL 4 REFER TO THE INSTALLATION HARNESS WIRING INSERT WHITE WIRE IN CONTACT POSITION 1 2 7 0 E aaa ee N 1 2 7 OR 8 a v 1020951 SERIES INSERT BLACK WIRE IN CONTACT POSITION 3 4 5 OR 6 H jl POSSIBLE CUNNECTION CONFIGURATIONS REFER TO INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS AE SEES MENE MANDAG ROS MORE VINE DRM ON PROFILE MODULES MUST Be DISCONNECTED AND M INNECTED A CONTROLLER PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER 5 HARNESSES BE INSTALLED AND MAINTAINED CONNECTOR BOND WIRE MOUNTING FOOT PER TWIN DISC STANDARD S822A 1080615 1020717 ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG J1939 T CONNECTOR UNLESS OTHERWISE SPECIFIED 2 PLACES TO VESSEL j DATE HARNESS WIRING BONDING SY
77. ELM o PART NUMBER THREAD OUTPUT CONNECTOR HARNESS IS CUSTOMER SUPPLIED WIRE o s 94 1020553 5 8 18 SINGLE DEUTSCH INSTALLED CONNECT ONE WIRE ECM POWER surety NI 1020927 3 4 16 SINGLE DEUTSCH NN NE M J8 J5 1 o 1020805 344 16 DUAL DEUTSCH CONNECT THE OTHER WIRE FROM J8 6 TO J5 3 2 SUM uu M CONNECTOR KIT 1020928 578 18 DuAL DEUTSCH o o 1020929 M18 1 0 DUAL DEUTSCH CONNECTOR IT 8 e o IN UNUSED CONTACT POSITIONS 10 DUAL DEUTSCH WP of Jo 1021125 3 4 16 DEUTSCH WP HARNESS WIRING INSERT SEALING PLUG 9 NEGATIVE CONTROL LEADS 1081126 5 8 18 DUAL DEUTSCH WP 41939 CAN IN UNUSED CONTACT POSITIONS MUST BE CONNECTED TO n t FUSE HDLDER SUPPLIED SAME SINGLE POINT TH STBD CONTROL i WITH CONNECTOR KIT FROM STBD BATT LEGEND 1020618 e JUNCTION INSTALL NEAR BATTERY x UNUSED CONTACTS NOT SHOWN bs prc d LORS ER NN SIRE NOTE _ ALL MAN CONNECTIONS WITHIN DASHED MANUAL OVERRIDE J81 15 Kip 7 SHIELD QUTLINES ARE UNCONTROLLED AND FOR 58 3 Cre TWISTED LEADS REFERENCE ONLY CONSULT ENGINE P 8 E pul o MANUFACTURER FOR VERIFICATION OG 8 a 8 STBD CONTROL lt OPTIONAL gt Se PORT CPC CIRCULAR PLASTIC CONNECTOR AUXILIARY BATT 113 020 BATTERY DH DEUTSCH CONNECTER D SUB D SUB MINIATURE CONNECTOR MB MOLDED BULLET CONNECTO
78. ENCE ONLY Sp MON STBD CONTROL PART NUMBER THREAD OUTPUT TYPE CONNECTOR TYPE o mpe CONNECT ONE WIRE FROM J8 2 TO J5 1 2 2 24 6 CE ii Seir TENSE 9 9 h H CONNECT THE OTHER WIRE FROM J8 6 TO J5 3 connector KIT 1020805 3 4 16 DUAL DEUTSCH 5 2 w 1020618 1020928 5 8 18 DUAL DEUTSCH INSERT SEALING PLUG 1080929 MI8 1 0 DUAL DEUTSCH CONNECTOR KIT J8 Je 1o Mo IN UNUSED CONTACT POSITIONS 102124 18 10 DEUTSCH WP 1020613 N 960 0 90 1081125 3 4 16 DUAL DEUTSCH WP INSERT SEALING PLUG 9099 eoo C M 1021126 5 8 18 DUAL DEUTSCH WP IN UNUSED CONTACT POSITIONS BIN a o h 90 FUSE HOLDER SUPPLIED O i WITH CONNECTOR KIT LEGEND 1020618 1 W INSTALL NEAR BATTERY UNUSED CONTACTS NOT SHOWN TD X9 3 14 AWG TWIN DISC SUPPLIED COMPONENT NOTE 14 did SINGLE CHASSIS OR FRAME CONNECTION ALL MAN CONNECTIONS WITHIN DASHED MANUAL OVERRIDE SIT Eg POINT GND SHIELD OUTLINES ARE UNCONTROLLED AND FOR SWETECH J8 3 12 AMP SEE SHEET 1 CO TWISTED LEADS REFERENCE ONLY CONSULT ENGINE 8 x AMP CONNECTOR 8 Ma DRE RIDES ee Sor es 8 TO PORT CONTROL OPTIONAL STBD ee eet Mrs AUXILIARY BATT Ji3 2 15 BATTERY DH DEUTSCH CONNECTOR D SUB D SUB MINIATURE CONNECTOR mes MB MOLDED BULLET CONNECTOR 13 2 MP METRI PACK CONNECTOR Meat eee J FROM PORT BATT OPTIONAL Ms ri CONNECT BE USED WITH
79. HRBTTLE LIMIT SINGLE LEVER SYNC MASTER SELECT SWITCH REVERSE SWITCH FORWARD SWITCH SHIELD FOR DIGITAL NMEA 2000 CONN COMMON FOR DIGITAL NMEA 2000 CONN COMM SIGNAL FOR NMEA 2000 CONN COMM SIGNAL FOR NMEA 2000 CONN POWER SUPPLY FOR NMEA 2000 CONN UNUSED ENGINE SPEED SENSOR RETURN ENGINE SPEED NEUTRAL START RELAY CONTACT COM NEUTRAL START RELAY CONTACT ND UNUSED UNUSED PROPELLER SPEED SENSOR RETURN PROPELLER SPEED PROPELLER SPEED SENSOR EXCITATION DIL PRESSURE SENSOR RETURN RETURN FOR PWM 6 RETURN FOR PWM 5 RETURN FOR PWM 4 DRIVER OUTPUT PWM 6 SHAFT BRAKE CLUTCH DRIVER DUTPUT PWM 5 PTO CLUTCH STABILIZER DISABLE TROLL ENABLE DRIVER DUTPUT PWM 4 TROLL CLUTCH ALARM RELAY CONTACT COM ALARM RELAY CONTACT NC TACHOMETER RETURN TACHOMETER A OUTPUT SHIELD FOR DIGITAL STATION 1 CONN COMMON FOR DIGITAL STATION 1 CONN NEUTRAL VALIDATION FROM DIGITAL STATION 1 CONN SHIELD FOR DIGITAL CONTROLLER COMMS CONN 1 COMMON FOR DIGITAL CONTROLLER COMMS CONN 1 SERVO POWER SUPPLY COMMON SERVO POSITION REFERENCE SHAFT BRAKE SWITCH RETURN SHAFT BRAKE SWITCH TRANSMISSION DIL PRESSURE SWITCH RETURN POWER COMMON PIN 2 AUXILIARY POWER INPUT PIN 2 PRIMARY POWER INPUT PIN 2 CONTROL STATION 1 THIS CONNECTION USED WITH CAT ENGINE APPLICATIONS ONLY TRANSMISSION ECM POWER SUPPLY CONTROL HEAD THROTTLE SIGNAL ECM PDWER SUPPLY CDMMUN peer ees CUSTOMER SUPPLIED HARNESS 5 3 DISPLAY
80. ING PLATE MOUNTING PLATE 32 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation 3 Cut out the Interface Assembly Mounting Template and Selector Assembly Mounting Template from the Engineering Drawings and tape in the selected positions Note For twin engine applications the template to mount the Starboard Interface Assembly is flipped over and then rotated 90 degrees counterclockwise from the Port Interface Assembly See Figure 5 4 Use the scale marks on the template to verify that the template is the correct size Scale 1 1 5 Using the templates mark all necessary holes and cutouts Port 74 d Locate in Upper Front Corner of Console E Locate in Upper Front Corner of Console Starboard Drawing Not To Scale Figure 5 Side Mount Interface Assembly Mounting Template Position 6 Drill and cut the holes using the template markings 7 Check the hole locations with the template 8 Remove any splinters or sharp edges from the holes EC300 Marine Control System Installation Manual 1024168 33 Component Installation Twin Disc Incorporated 9 Check the fit of the holes by carefully inserting the Interface and Selector assemblies 10 Correct the fit as necessary pz 157 10 L
81. 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 2 Locate a position on the top or front surface of the console which provides unrestricted access to the Selector Assembly Confirm that the desired location will allow the Interface Harness to reach between the Interface Assembly and the Selector Assembly HARNESS WIRING SELECTOR ASSY HARNESS WIRING SIDE MOUNT DUAL SIDE MOUNT SIDE MOUNT P me 3 LEVER PORT STATION STD H B a E d XN INTERFACE ASSY INTERFACE ASSY P HARNESS WIRING DUAL LEVER 2 TO PORT CONTROL EE TO STBD CONTROL Figure 4 Side Mount Control Head Assembly LEVER 0206 MOUNT
82. Je CUSTDMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 TO J5 1 IGNITION SWITCH 12 24 VDC BATT O 0 J8 1 MANUAL OVERRIDE SWITCH J8 4 CUSTDMER SUPPLIED HARNESS MISC BRIDGE SIGNALS HARNESS WIRING 1020617 SERIES DUAL LEVER CONNECTOR KIT KIT 1020613 HARNESS WIRING 1021010 SERIES DISPLAY ADAPTER HARNESS WIRING 1020614 SERIES CONTROLLER COMMS HARNESS WIRING 1022865 SERIES ACTUATOR WEIGH FIRS UNLESS OTHERWISE SPECIFIED T Use MACHINED DIMENSIONS usat one EC300 PRINT CONTAINS PROPTETARY Fe ORATION Ta s VIN D DISC INC INCORPORATE CONNECTOR KIT 1020690 HARNESS WIRING 1020706 IF NOT SUPPLIED WITH TRANSMISSION ENGINE SPEED SENSOR HARNESS WIRING 1020609 SERIES ENGINE ROOM ANALOG 55 DRIVERS SENSOR RETURN JA FDRWARD CLUTCH J7 4 dire REVERSE CLUTCH J7 5 B NEUTRAL CLUTCH J7 6 B SEE NOTE 4 2127 TROLL CLUTCH J7 10 B 78 SHAFT BRAKE CLUTCH 47 11 B CONTROLLER EC300 1020676A PORT CONTROL FUSE HOLDER SUPPLIED WITH CONNECTOR KIT 1020618 INSTALL NEAR BATTERY 14 AWG gg J13 1 CONNECTOR KIT 1020618 CUSTDMER SUPPLIED HARNESS POWER HARNESS WIRING 1020695 ENGINE ROOM SWITCH CUSTOMER SUPPLIED HARNESS ACTUATOR POWER POWER SUPPLY COMMON POSITION SIGNAL POWER SIGNAL POWER SUPPLY COMMON
83. Meters 295 Feet 2001 L1 Russian Maritime Registry Service s RMRS Rules for the Classification and Construction of Sea Going Ships Part XI Electrical Equipment Part XV Automation Russian Maritime Registry Service s RMRS Rules for Technical Supervision During Construction of Ships and Manufacture of Materials and Products for Ships Part IV Technical Supervision During Manufacture of Products 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 the typical installation of a single or twin engine system with one two or three control stations as standard equipment Additionally these instructions cover installation of up to eight engine systems with optional accessories and cables The EC300 Control System is supplied in response to customer 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 Restriction Notice This document contains proprietary Twin Disc Incorporated information Neither receipt nor possession thereof confers any rights to reproduce use or disclose in whole or in part any such information without express written authorization from the Corporate Engineering Control Systems
84. ND SEE SHEET D ALL POWER CONNECTIONS BATTERY AND SOFTWARE VERSION 1 04 TO PORT BATT NEUTRAL START SHOULD BE MADE USING OR LATER 14 AWG WIRE 14 AWG BOND WIRE TERMINATED AT ONE OF J10 HARNESS SHOWN UN SHEET 1 THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL REFER TD THE INSTALLATION MANUAL FOR MORE INFORMATION J13 3 TO SINGLE 14 AWG 3 1 POINT GND SEE SHEET 1 STBD BATTERY PRIMARY BATT CUSTOMER SUPPLIED HARNESS QUO BATT ACTUATOR POWER THE COMMUNICATION BUS HAS OTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION CAUTION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESSES BE INSTALLED AND MAINTAINED MOUNTING PER TWIN DISC STANDARD S822A HARNESS WIRING ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG 1022865 SERIES UNLESS OTHERWISE SPECIFIED TO VESSEL ACTUATOR ACTUATOR BONDING SYSTEM 1022749 TWIN ENGINE 1 STATION MECHANICAL ACTUATORS e ET XXX 420 SYSTEM 3 THROTTLE ALL ANGULAR TOLERANCES 1 USED IN ANY MANER DETRIMENTAL TO TIE INTEREST OF DEAE NANE MIN D DISC INCOR INCORPORATE ae O peer syste coment ecw eee B eran 2 CONTROLLER BOND WIRE REVIEW 00 102
85. ND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION THE COMMUNICATION BUS HAS OTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES TA MEME ED AND PERMANENTLY THE TRANSMISSION PRIOR TO CONNECTING THE C300 CONTROLLER HARNESSES TO BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TD BE 18 AWG UNLESS OTHERWISE SPECIFIED TWIN DIS SYSTEM 3 D MELE SIMILAR TO 2 21 SS Ee eS SF ER a ISIZEI B A CUSTDMER SUPPLIED HARNESS ENGINE THROTTLE START SWITCH L HARNESS WIRING 1020706 SERIES 55 9 0 O BATT CONNECTOR KIT ENGINE SPEED SENSOR 1020690 45 SIGNAL RED GRN STRIPE Fs START MOTOR INSERT SEALING PLUG J5 18 SENSOR RETURN GRN RED STRIPE 2i IN UNUSED CONTACT POSITIONS BATT per CE SPEED SENSOR SEE TABLE FOR ENGINE MANUAL OVERRIDE SWITCH 1020714 CONNECTOR KIT SPEED SENSOR TYPES IF NOT SUPPLIED WITH TRANSMISSION 1020713 CONNECTOR KIT CONNECTOR KIT 1021062 1020713 X HARNESS WIRING 1021535 SERIES E Jl HARNESS SHOWN PWM DRIVERS 1 p aS messss svete SINGLE DE
86. OMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 2 TO J5 1 NOTE NOT FOR USE WITH CAT ENGINE APPLICATIONS 1020613 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS IGNITION aaa OVERRIDE SW SWITCH ITCH BATT ol a ERG VUA WITCH MANUAL OVERRIDE SWITCH OPTION 1 TO BE USED WITH EC300 L SOFTWARE VERSION 1 03 OR EARLIER zd eS cui X CONTROLLER EC300 1020676A STBD CONTROL CONNECTOR KIT 1020618 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS FUSE HOLDER SUPPLIED WITH CONNECTOR KIT 1020618 INSTALL NEAR BATTERY 14 AWG 14 AWG J13 3 J13 1 TO PORT CONTROL lt OPTIONAL AUXILIARY J13 2 15 14 AWG STBD BATTERY ENGINE SPEED SENSORS FOR REFERENCE ONLY PART THREAD QUTPUT CONNECTOR DEM ETE 3 4 16 mero nunc ursi 10224 w 10 DEUTSCH wP 1021125 3 416 DuaL peuTsc VP 102126 s e 18 peurscw wP LEGEND JUNCTION UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR TU SINGLE PUINT GND SEE SHEET 1 413 2 FROM PORT BATT OPTIONAL MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNEC
87. R MANUAL OVERRIDE SWITCH HARNESS WIRING 14 AWG _ MP METRI PACK CUNNECTUR BE USED WITH EC300 1021010 SERIES Ji3 e FROM STBD BATT OPTIONAL MS MIL SPEC CONNECTOR SOFTWARE VERSION 104 OR LATER DISPLAY ADAPTER HM HIRSCHMAN WP WEATHER PACK CONNECTOR CUSTOMER SUPPLIED HARNESS PPR PULSES PER REVOLUTION BOWER X NO CONNECTION ECM ENGINE CONTROL MODULE S lt IF NEEDED SHORTEN THIS END CONNECTOR KIT 2d 5 1020711 HARNESS WIRING INSERT WHITE WIRE IN CONTACT POSITION 1 2 7 DR 8 NOTES ALL POWER CONNECTIONS BATTERY AND NEUTRAL START SHOULD BE MADE USING 14 AWG WIRE A 14 AWG BOND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION THE COMMUNICATION BUS HAS OTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESSES TO BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG UNLESS OTHERWISE SPECIFIED DATE 4 15 08 SCALES TAUN DISS INCORPORATED NSTALL REV ZONE CH ND DATE UNLESS OTHERWISE SPECIFIED MACHINED DIMENSIONS 0030 ex 0010
88. RAL J7 5 PURPLE YELLOW STRIPE E J7 2 X YELLOW PURPLESTRIPE X REVERSE 07 4 GREEN RED STRIPE E X RED GREEN STRIPE X A FORWARD S J7 7 EX o w J7 10 X gt J7 8 X J7 11 EX 7 9 X J7 12 HARNESS WIRING PWM DRIVERS PURPLE YELLOW STRIPE 25 X YELLOW PURPLE STRIPE X REVERSE GREEN RED STRIPE B 0 X RED GREEN STRIPE X AP FORWARD x EX PURPLE YELLOW STRIPE X YELLOW PURPLE STRIPE X REVERSE GREEN RED STRIPE X RED GREEN STRIPE X ap FORWARD LX 2n 4 1 Lx EX t pn LX EX J712 X 5 J6 J7 6 Jr6 Fx o o J7 3 EX 9 o o o PURPLE YELLOW STRIPE 25 o o o o X YELLOW PURPLE STRIPE X o REVERSE 9 0 GREEN RED STRIPE E 1 wg 12 RED GREEN STRIPE FORWARD LIGHT BLUE BROWN STRIPE X BROWN LIGHT BLUE STRIPE X Ng TROLL EX n o o L x H X J12 0 J130 EX O PW 17 9 RED SS K 07 12 X BLACK X SHAFT BRAKE FAA 278 gt BED STABILIZER E 37 11 BLACK amp DISABLE PO RED Avv 47 8 TROLL 7 11 BLACK amp ENABLE Figure 43 PWM Driver Harness Wiring Diagram EC300 Marine Conirol System Installation Manual 1024168 105 Electrical Installation Twin Disc Incorporated Two Solenoid Transmission Clutch Control Wiring Installation Install the wiring for a two solenoid transmission as follows See Figure 43 Note Refer to the transmission manufacturer s technical manual as required to ident
89. RED BATT PIN C BLANK WIRE Ct STARTER SOLENOID BATT NEUTRAL START WITH RELAY USED WHEN STARTER RELAY SOLENOID IS 5 AMPS DC OR GREATER BRACKET TO TRANSMISSION HARNESS O MANUAL OVERRIDE T O O MANUAL OVERRIDE START SWITCH O NEUTRAL START RELAY CONTACT N O 14 AWG 04 YELLOW RED o o BATT PINA WIRE mw PINB NEUTRAL START RELAY CONTACT COM 14 AWG TV INC BLANK YELLOW RED AAAS Y Y d WIRE STARTER SOLENOID NEUTRAL START WITHOUT RELAY USED WHEN STARTER RELAY SOLENOID IS LESS THAN 5 AMPS DC Figure 37 Neutral Start Interlock Schematic Bracket to Transmission Harness 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 Control s neutral start interlock contacts and any hardwired transmission neutral interlock must be wired in series with the vessel s starting circuit If a hardwired transmission neutral start switch is present then modify the following installation procedures to accommodate the switch 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 customer s existing wiring The following steps assume that the Ignition Sw
90. STEM 4 15 08 TWIN 9086 1020615 SERIES INCORPORATED COMMUNICATION UNLESS GTLERUISE EE ome Wee FIRST USE MATERIAL HEAT TREAT NONE RACINE WI 53403 USA MACHINED DIMENSIONS m ASSY T N E H WR u m err emo 00 mv 102410 XXXX 0 005 NGTICE THIS PRINT CONTAINS PROPIETARY INFORMATION AND IS NUT TO BE SIMILAR TO NAME RC A e o MF rm Svsrew cowtea eca00 220770 PER ASME 145 1994 THE US GOVERNMENT OR OTHERS BY CONTRACT D MAND REG 299 e av 7 C B A Ex STBD ACTIVE CONTROL HEAD CONTROL STATION 1 SHEET STBD POWER AUXILIARY STBD ACTIVE CONTROL HEAD CONTROL STATION 2 FROM SHEET 3 STBD PDWER AUXILIARY THROTTLE SIGNAL THROTTLE COMMON REFER TO EC300 INSTALLATION MANUAL FOR INFORMATION ON VARIOUS ENGINE CONNECTIONS COMMON THROTTLE JOYSTICK AXIS 1 FORWARD SWITCH ENGAGE REVERSE SVITCH DISENGAGE NEUTRAL LED DRIVE CONTROL HEAD SELECT SWITCH 1020635 SERIES Ni DUAL LEVER PUWER CONTROL STATION 1 COMMON THROTTLE JOYSTICK AXIS 1 FORWARD SWITCH ENGAGE i REVERSE SVITCH DISENGAGE COMMON THROTTLE JOYSTICK AXIS 1 FORWARD SWITCH ENGAGE REVERSE SWITCH DISENGAGE NEUTRAL LED DRIVE CONTROL HEAD SELECT SWITCH 1020635 SERIES N DUAL LEVER POWER CONTROL STATION 2 i COMMON THROTTLE JOYSTICK AXIS 1 FORWARD SWITCH ENGAGE i REVERSE SWITCH DISENGAGE START SVITCH e 35 9 0 o BATT MANUAL OVERRIDE SWITCH CUS
91. Sd qv Ge J9 no 19 120 J130 9 rel CONNECTOR TERMINATING RESISTOR 2 PLACES 0 HARNESS WIRING 0 0 Mq CONTROLLER COMMS RECEPTACLE T CONNECTOR J1939 HARNESS WIRING A 2 PLACES 2 PLACES COMMUNICATION Figure 31 Dual Engine Dual Lever Control Head Wiring Install the Control Head harnesses as follows Note Each dual lever harness consists of two separate harnesses joined together at the Control Head end At the EC300 end one harness end is marked PORT and the other harness end is marked STARBOARD The harness end s marked PORT must route to the port control The STARBOARD harness 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 EC300 Marine Control System Installation Manual 1024168 69 Electrical Installation Twin Disc Incorporated 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 Refer to Ge
92. Sensor Installation 38 Installation Magnetic Pick Up Engine Speed Sensor 40 Installation Hall Effect Pick Up Output Speed Sensor 42 Installation Tachometer Signal Generator 43 Station Doubler Installation 44 Servo Actuator Installation ceres essere 46 Servo Actuator Mounting 47 Push Pull Cable Installation Guidelines 48 Push Pull Cable Installation Kits for Conductive Vessels 49 Push Pull Cable Installation Kits for Nonconductive Vessels 50 Push Pull Cable Mounting Bracket and Cable Installation 52 Push Pull Cable Adjustment for Mechanically Shifted Transmis EC me 54 Push Pull Cable Adjustment for Mechanically Controlled 55 Push Pull Cable Adjustment for Mechanically Controlled Valve 56 Push Pull Cable Final Adjustment 57 EC300 Marine Control System Installation Manual 1024168 9 Table of Contents Twin Disc Incorporated Electrical Installation 59 General Electrical Harness Information 59 Gener
93. T 15 a BATTERY XU J13 2 J13 3 NEGATIVE CONTROL LEADS gt ns i e EESUU CONTROLEER MUST BE CONNECTED TO J13 6 MEUM SAME SINGLE POINT A 15 AMP LN J13 Y AUXILIARY POWER INPUT 4 AWO NS s NS STBD NN A DV NN PETES N FUSE AND HOLDER ARE SUPPLIED WITH CONNECTOR KIT 2 PLACES INSTALL AS CLOSE TO BATTERY AS POSSIBLE AUXILIARY POWER COMMON 14 AWG gt _ Figure 53 Redundant Power Distribution Note Some applicable codes and standards notably RMRS require completely redundant wiring between the EC300 controller and the auxiliary power supply Figure 53 shows the connections for redundant power distribution 144 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Refer to General Electrical Installation Guidelines before proceeding with this section 1 Install two fuses or circuit breakers at the battery positive or engine controller power distribution connections 2 Route power wiring to the fuses or circuit breakers 3 Temporarily remove the fuses or open the circuit breakers Note Power wiring must be a twisted pair of 14 AWG stranded copper wire 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
94. T ENGINE APPLICATIUNS 1020618 Sd Bum CONNECTOR IN UNUSED CONTACT POSITIONS 1020716 CONNECTOR KIT 1080929 10 DuaL__ s DEUTSCH J1939 T CONNECTOR 1020613 o i mensa mua nursci ve 2 PLACES INSERT SEALING PLUG i 102125 3 446 pua 5 IN UNUSED CONTACT POSITIONS 102126 578 16 nua DEUTSCH WP__ FUSE HOLDER SUPPLIED WITH CONNECTOR KIT P 2 1020618 IGNITIUN MANYAS I PRIDE INSTALL NEAR BATTERY NEGATIVE CONTROL LEADS LEGEND SWITCH MUST BE CONNECTED TO JUNCTION BATT M 14 AWG SAME SINGLE POINT UNUSED CONTACTS NOT SHOWN _ J13 3 MANUAL OVERRIDE 14 AWG SWITCH TWIN DISC SUPPLIED COMPONENT n 213 1 MANUAL OVERRIDE SWITCH E OPTION 1 L _ CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS BE USED WITH EC300 SOFTWARE VERSION 1 03 OR EARLIER AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNECTOR PULSES PER REVOLUTION CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END CUSTOMER SUPPLIED HARNESS POWER MANUAL OVERRIDE SWITCH OPTION 2 BE USED WITH EC300 SOFTWARE VERSION 1 04 Harness WIRING CONNECTOR KIT HARNESS WIRING LATER 1021010 SERIES 1020951 SERIES DISPLAY ADAPTER CONNECTOR KIT 1020712 X CONNECTOR KIT NOTES
95. TOMER SUPPLIED HARNESS ENGINE THROTTLE 2 lt py 45 1 A ENGINE J5 12 i B SPEED SENSUR SEE TABLE F R ENGINE SPEED SENSOR TYPES SIGNAL SENSUR RETURN TO START MOTOR NEUTRAL LED DRIVE 1 SELECT SWITCH TO SHEET 3 HARNESS WIRING 1020951 SERIES DISPLAY POWER HARNESS WIRING 1020718 SERIES us CAN 4 lt iL wot DHA BC C B DH ABC C BA HARNESS WIRING 1020615 SERIES COMMUNICATION LARNESS WIRING _ 1020614 SERIES CONTROLLER COMMS ONNECTUR 1020717 J1939 TERMINATING RESISTUR 4 PLACES STBD COMMUNICATIONS J10 gt TO SHEET 3 DH STBD CONTROL Ji 12 24 VDC POWER BATTERY GROUND BACKLIGHT CONTROL NOT FOR CUSTOMER USE STATION ACTIVE NOT FOR CUSTOMER USE J1939 CAN SHIELD J1939 CAN L J1939 CAN H HARNESS WIRING 1020951 SERIES DISPLAY POWER 12 24 VDC POWER BATTERY GROUND BACKLIGHT CONTROL NOT FOR CUSTOMER USE STATION ACTIVE NOT FOR CUSTOMER USE J1939 CAN SHIELD J1939 CAN L J1939 CAN H HARNESS WIRING 1020718 SERIES J1939 CAN HARNESS WIRING 1020617 SERIES DUAL LEVER TRANSMISSION 1018791 1020740 1018791 1020740 HARNESS WIRING 1020615 SERIES COMMUNICATION X HARNESS WIRING 1020615 SERIES COMMUNICATION CONNECTOR 1020716 J1939 T CONNECTOR 5 PLACES NEUTRAL LED DRIVE 1 SELECT SWITCH 2 lt SHEET 3 STBD CONTROL
96. TOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END MANUAL OVERRIDE SWITCH OPTION 2 TO BE USED WITH EC300 SOFTWARE VERSION 1 04 OR LATER WIRING 1021010 SERIES DISPLAY ADAPTER CUSTDMER SUPPLIED HARNESS POWER CONNECTOR CONNECTOR KIT HARNESS WIRING 1020716 1020711 1020951 SERIES J1939 TERMINATING RESISTOR NOTES DISEEAT POWER 2 PLACES cowvecror KIT ALL POWER CONNECTIONS BATTERY AND 10207 NEUTRAL START SHOULD BE MADE USING 14 AWG WIRE A 14 AWG BOND WIRE TERMINATED AT ONE OF THE MOUNTING FEET OF THE CONTROLLER MUST BE CONNECTED TO THE VESSEL BONDING SYSTEM SEE DETAIL A REFER TO THE INSTALLATION MANUAL FOR MORE INFORMATION THE DISPLAY COMMUNICATION BUS HAS DTHER POSSIBLE CONNECTION CONFIGURATIONS REFER TD THE INSTALLATION MANUAL FOR MORE INFORMATION CAUTION ALL CONTROLS INCLUDING TROLL AND PROFILE MODULES MUST BE DISCONNECTED AND PERMANENTLY REMOVED FROM THE TRANSMISSION PRIOR TO CONNECTING THE EC300 CONTROLLER HARNESSES TD BE INSTALLED AND MAINTAINED PER TWIN DISC STANDARD S822A ALL CUSTOMER SUPPLIED WIRING TO BE 18 AWG UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED TWIN ie MEI CA c EC eum SYSTEM 2 XX IN ANY MANER INTEREST OF as mares ge DETAIL J10 HARNESS SHOWN ON SHEET 1 li SEE NUTE 2 HARNESS WIRING 1020951 SERIES DISPLAY POWER INSERT
97. TRAL START RELAY CONTACT N O 14 AWG jS 5 16 SBATTL EET c ENGINE T SNC AJ NEUTRAL START RELAY CONTACT COM 14 AWG 45 10 Y 1 STARTER SOLENOID 1 1 1 ENGINE SPEED SENSOR Lo TO START MOTOR CUSTOMER SUBB IEDWIEE SEE ENGINE SPEED SENSOR HARNESS INSTALLATION SECTION m 9 9 ECM POWER SUPPLY CONNECT FROM J8 2 TO J5 1 ENGINE SPEED SENSOR CONNECTOR KIT ENGINE THROTTLE Figure 39 Engine Control Harness J5 90 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Neutral Start Interlock Wiring Installation The EC300 Control is designed to ensure that a control head is in command and that the lever is in the neutral detent position before an engine can be started 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 The relay contact closes only when the system ignition is turned on a Control Head is selected and the lever for the selected Control Head is in the neutral position Neutral Start Interlock Wiring Requirements Normally the boat wiring routes the start command wire from the key switch or engine control panel through the EC300 Control s Neutral Start Interlock If a bypass or override switch i
98. UTSCH CONTROLLER EC300 menses fme uM oeurscH 1020676 mene we 10 uM DEvTscH WP STBD CONTROL meus arate ua DEUTSCH WP wanes muar DEuTscH vP SEE NOTE 4 CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY CONNECT FROM J8 8 TO 5 1 NOTE NOT FOR USE WITH CAT ENGINE APPLICATIONS CONNECTOR KIT 1020618 INSERT SEALING PLUG LEGEND IN UNUSED CONTACT POSITIONS Wari UNUSED CONTACTS NOT SHOWN TWIN DISC SUPPLIED COMPONENT CHASSIS OR FRAME CONNECTION SHIELD TWISTED LEADS AMP CONNECTOR CINCH CONNECTOR CIRCULAR PLASTIC CONNECTOR DEUTSCH CONNECTOR D SUB MINIATURE CONNECTOR MOLDED BULLET CONNECTOR METRI PACK CONNECTOR MIL SPEC CONNECTOR HIRSCHMAN WEATHER PACK CONNECTOR PULSES PER REVOLUTION NO CONNECTION ENGINE CONTROL MODULE IF NEEDED SHORTEN THIS END 1020613 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS FUSE HOLDER SUPPLIED WITH CONNECTOR KIT ur E 1020618 IGNITION INSTALL NEAR BATTERY SWITCH BATT o 14 AWG MANUAL OVERRIDE 5 SWITCH d MANUAL OVERRIDE SWITCH E cci OPTION 1 TO BE USED WITH EC300 7 SOFTWARE VERSION 1 03 CUSTOMER SUPPLIED HARNESS OR EARLIER POWER CONNECTOR ASSY FUSE HOLDER SUPPLIED 1021 553 WITH ACTUATOR HARNESS T PLUG CONNECTOR KIT 1022865 MANUAL OVERRIDE SWITCH 1020711 INSTALL NEAR BATTERY OPTION 2 NOTES TO BE USED WITH EC300 TO SINGLE POINT GROU
99. WHITE WIRE IN CONTACT POSITION 1 2 7 UR 8 INSERT BLACK WIRE IN CONTACT POSITION 3 4 5 OR 6 IR EACH DISPLAY POWER HARNESS Fol CONTROLLER INSERT SEALING PLUG IN ALL UNUSED CONTACT POSITIONS BOND WIRE CONNECTOR B TH VESSEL 1020717 JI939 T CONNECTOR BONDING SYSTEM 3 PLACES HARNESS WIRING 1020615 SERIES COMMUNICATION X CONNECTOR KIT 1021169 NEEDED IF OPTIONAL 1020615 COMMS INTERFACE CONTROL STATION 1 CONTROL HEAD 1020635C DUAL LEVER HARNESS WIRING 1020617 SERIES DUAL LEVER bati TYPICAL COMMUNICATION CABLE PLACEMENT CABLE END MAY BE PLACED AT ANY CONTROL STATION OR OTHER LOCATION THAT ALLOWS ACCESS TO THE CONNECTOR AT OR NEAR A HELM TO Ji OF STBD CONTROL SHEET 2 eo CUSTOMER CONNECTOR KIT 1020690 INSERT SEALING PLUG IN UNUSED CONTACT POSITIONS CONNECTOR KIT 1080714 X CONNECTOR KIT 1020713 CUNNECTUR KIT 1020713 SUPPLIED HARNESS ENGINE THROTTLE START SWITCH atl 559 0 o BATT MANUAL DVERRIDE SWITCH HARNESS WIRING 1020706 SERIES ENGINE SPEED SENSOR JS 11 SIGNAL RED GRN STRIPE 45 12 SENSOR RETURN GRN RED STRIPE ENGINE 1 20705 TN SBE sensor SEE TABLE FOR ENGINE SPEED SENSOR TYPES IF NOT SUPPLIED WITH TRANSMISSION CONNECTOR KIT 1021062 WIRING 1081535 SERIES e RH 7 3 FWI 4 CONTROLLER EC300 HARNESS IS INSTALLED
100. a vibration damped plate Choose a location that meets the following criteria 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 L L5 LJ BJ DO It is a minimum of 1 m 3 3 ft away from alternators generators communications equipment and associated wiring Q It is away from high vibration It provides easy access for routing connecting and adjusting the push pull cable if used It is convenient for accessing the electrical connections Control equipment and displays 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 EC300 Marine Control System Installation Manual 1024168 25 Component Installation Twin Disc Incorporated 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 Cables should be minimum length possible Any cable bends should have no sharp bends Install with the maximum possible bend radius Refer to cable manufacturer s specifications Cables must be located away from hot surfaces Cables mus
101. act P N 0462 209 16141 using the Deutsch HDT crimp tool P N HDT 48 00 and insert it into pin B of the Neutral Start connector B Route this wire to the start relay solenoid and terminate it at the start relay solenoid using an appropriate connector 4 When both pins and the seal plug have been inserted in the connector body then insert the locking wedge 5 Align the harness connectors and push it in until it snaps into place 6 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 84 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Engine Throttle Wiring Installation These signals interface with the engine Electronic Control Module s ECM s throttle input 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 Bracket to Transmission Harness has three pins for throttle control Table 8 lists the pin functions Table 8 Engine Control Pin Functions ECM Power Supply Power supply for the Throttle Signal It is most often a power supply coming from J8 pin 2 In some cases it may be power coming from the ECM This signal is to be used as the power source for the throttle signal output
102. ag adjustment screw s until the desired drag is obtained over the full lever travel Note 0 45 to 0 91 kg 1 to 2 lb average drag is normally desirable DRAG ADJUSTMENT DRAG ADJUSTMENT Figure 7 Drag Adjustment Screws for Single Dual Lever Control Head E REMOVE SCREW TO ACCESS DRAG ADJUSTMENT Figure 8 Drag Adjustment Screws for Side Mount Control Head Assembly EC300 Marine Control System Installation Manual 102416 35 Component Installation Twin Disc Incorporated Twin Disc Display Installation Figure 9 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 Locate a position on the dash or control panel for the display 2 Using the appropriate cutting tools cut a 54 mm 2 125 in hole 3 Round off any sharp edges and remove any burrs 4 Remove the mounting bracket and nuts from the rear of the display 5 Ensure that the display will fit i
103. al Electrical Installation Guidelines 60 Control Head Harness J1 J2 or J3 Installation 66 Multi Station Single Lever Control Head Wiring Installation 67 Multi Station Dual Lever Control Head Wiring Installation 69 Split Single Lever Control Head Stations in Twin Engine Installa HONS mb T n 71 Multi Station Dual Lever Control Head Wiring Instllation Using sirjje WB 73 Service Connector 78 Transmission Harness J5 J6 J7 J8 and J12 Installation 78 Control to Bracket Wiring Installation 79 Bracket to Transmission Wiring Installation 81 Neutral Start Interlock Wiring Installation 82 Engine Throttle Wiring Installation 85 Prewired Connection 2 88 Engine Control Harness J5 Installation 89 Neutral Start Interlock Wiring Installtion 91 Electronic Control Module Throttle Wiring 95 Engine Speed Sensor Harness Installation 99 Engine Room Analog Harness J6 Installation 101 Transmissi
104. al MIM Plug Series 60 Wiper pee EI T _ J5 Pin 3 ECM Power Supply MIM Plug Series 60 RTN pene emm o B4 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B Deutz Type 1 Engine Connection Requirements for Voltage Control Table 21 Engine Connections at the Deutz Type 1 Engine EC300 Engine EC300 Signal Enaine Connector Engine Signal Description Harness J5 Decsription g DSC 1005 60V J5 Pin 1 ECM Power Supply J8 Pin 2 n Signal EE Pin 81 note 1 Signal ECM Power Supply A7 X4 Pin 82 note 1 Ground Common 1 Remove wiring from signal input range transformer Deutz Type 2 Engine Connection Requirements for 4 20mA Loop Control Table 22 Engine Connections at the Deutz Type 2 Engine EC300 Engine EC300 Signal Endine Connector Engine Signal Description Harness J5 Decsription 9 W RSC 671 J5 Pin 1 ECM Power Supply Terminal F of Gov From 5550 5570 Governor via Diode J5 Pin 2 Throttle Signal Terminal 4 of Speed From 671 Speed Control HUN RUNE NE J5 Pin 3 ECM Power Supply Terminal 5 of Speed From 671 Module 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 EC300 Marine Control System Installation Manual 1024168 B 5 Appendix B Twin Disc Incorporated Iveco PWM Engine Connection Requirements for Pulse Width Modulation Control Table 23 Engine Connections at the I
105. al Oil Filter Differential and Oil Pressure Switches used to trigger a fault condition when active EC300 Marine Control System Installation Manual 1024168 21 Introduction Twin Disc Incorporated Table 3 Typical Speed Sensor Types Single Output Magnetic Pickup Sensors are available with various thread sizes and connectors Dual Output Magnetic Pickup Sensors are available with various thread sizes and connectors Tachometer Generator with Drive Tang One input speed sensor is required for each engine and one shaft speed sensor is required per transmission On a dual output speed sensor 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 Note On multiple engine vessels each engine must use speed sensors of the same type model and part number Table 4 Communications Harness Components for Twin Engine Basic Systems Communications Harness Components i Supplied by E eneral Drawin mponent Name i i Controller Communications Harness SONNESTOR Communications TERMINATING RESISTOR Harness 1939 T Connector Receptacle HARNESS WIRING HARNESS WIRING CONTROLLER COMMUNICATIONS COMMUNICATIONS 2 PLACES z z Terminating Resistor Plu
106. als not exceeding 2 m 6 6 ft in order to prevent the release of wire harnesses during a fire Do not use wire staples EC300 Marine Control System Installation Manual 1024168 63 Electrical Installation Twin Disc Incorporated Where wire harnesses 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 harness 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 Wiring harnesses to be installed behind or imbedded in structural insulation They may however pass through such insulation at right angles Wiring conduit or recesses integral with B or C class fire walls may be used for installing harnesses if the fire walls are of an approved type and the installation prevents the propagation of smoke through the conduit When harnesses pass through non watertight bulkheads decks or structural members the length of the bearing surface for the harness is to be at least 6 4 mm 0 25 in All burrs and sharp edges are to be removed No harness is allowed to penetrate the collision bulkhead To avoid possible signal interference signal w
107. ation Tachometer Signal Generator EC300 Marine Control System Installation Manual 1024168 39 Component Installation Twin Disc Incorporated Installation Magnetic Pick up Engine Speed Sensor Note Some transmissions have pre drilled and plugged sensor holes above the primary or secondary shaft transfer gear Note Some engines have pre drilled and plugged sensor mounting plates in the flywheel housing Consult the engine manufacturer if a mounting hole must be added Additionally some engines may already have Speed Sensors 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 additional holes 1 Bump the engine starter until the crown top of a gear tooth is visible in the center of the hole See Figure 11 Crown of Gear in Center of Hole Direction of Rotation Engine Flywheel Housing Figure 11 View of Tooth Crown through Speed Sensor Mounting Hole 40 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation 2 Thread the lock nut onto the sensor and apply anaerobic sealant equivalent to MA908 Loctite 242 to the threads of the engine speed sensor near the end away from the wires See Figure 12 APPLY SEALANT TO THREADS Figure 12 View of Typical Single and Dual Output Speed Sensors 3 Thread the sensor into the sensor open
108. ative If the vessel or engine has an independent bonding system then the control should be bonded to the independent bonding System EC300 Marine Control System Installation Manual 1024168 147 Electrical Installation Twin Disc Incorporated Bond wires must be connected to one of the unpainted mounting surfaces of the EC300 Control the Station Doubler and 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 bonding conductor must be 14 AWG stranded copper wire with insulation that is colored green with yellow stripe preferred or green to comply with ABYC standards Install the EC300 Control bonding connection as follows See Figure 54 and Figure 55 1 If EC300 is used with Twin Disc Transmission and the Transmission Harness Series connect green chassis wire from the transmission harness to one of the unpainted mounting feet of the EC300 1022894 CHASSIS Figure 54 Master Control Harness J5 J6 J7 J8 J12 and Chassis Wire Diagram 148 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation If the EC300 is not wired with transmission harness series route a bond wire connected to the vessel bonding system to one of the unpainted mounting feet of each of the EC300 controls Note If no vessel bonding system is
109. ator Harness Wiring eere 129 Engine Room Switch Harness J12 Installation 133 Transmission Oil Filter Differential Pressure Switch Wiring Instal t 135 Transmission Oil Pressure Switch Wiring Installation 136 EC300 Control Power and Grounding Harness J13 Installation 137 EC300 Control Power Wiring eese eee 138 EC300 Control Bonding Installation 147 Engineering Drawings 151 List of Engineering Drawings eeeeeeeeeeee 151 Morse 33 Series Cable Mounting Dimensions 153 Servo Actuator Mounting Dimensions 154 Twin Disc Display Mounting Dimensions 1018791 155 Control Head Mounting Template 156 Side Mount Lever Mounting Template 157 Side Mount Selector Assembly Mounting Template 158 EC300 Control Mounting Dimensions 159 EC300 Control Pin Assignments 160 System 1 Single Engine 1 Station 161
110. audible device The EC300 station transfer signal output can drive up to one amp of current at a voltage approximately equal to the controller power supply If the audible device requires higher current or a different voltage an appropriately sized customer supplied relay must be used Install the station transfer signal output wiring harnesses as follows See Figure 49 Note this installation guide covers only direct connection of the audible device to the EC300 controller 1 Connect one customer supplied wire to the positive signal input of the audible device 2 Connect the other customer supplied wire to the negative signal input of the audible device 3 Route the two wires to the EC300 Control 4 Remove the locking wedge from the J11 Deutsch connector 5 Insert the wire for the positive signal input of the audible device into pin 1 ofthe J11 connector 6 Insert the wire for the negative signal input of the audible device into pin 4 ofthe J11 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information 7 When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body EC300 Marine Control System Installation Manual 1024168 131 Electrical Installation Twin Disc Incorporated 8 Ensure that sealing plugs are installed in all empty connector positions 9 Align the harness connecto
111. batteries if multiple batteries are used so as not to exceed the voltage limits for the EC300 Control EC300 Marine Control System Installation Manual 1024168 141 Electrical Installation Twin Disc Incorporated PORT CONTROL J1 J2 J3 J4 J5 J6 J7 o gs ies 5210 2 25 Lel ES gs ies 2125 22 8 29 suo Her 22 F JE 5 5 55 22 UE 2 o o o o o o o o 3 9 4 cane P 5755 D 4m D J8 J9 J109 J19 J120 J130 6 D CONNECTOR KIT 9 INSERT SEALING PLUG IN CONTACT POSITIONS 4 6 HARNESS WIRING POWER CUSTOMER SUPPLIED J13 3 POWER COMMON 14 AWG PRIMARY POWER INPUT 14 AWG J13 1 PORT BATTERY NEGATIVE CONTROL LEADS FUSE AND HOLDER ARE SUPPLIED MUST BE CONNECTED TO WITH CONNECTOR KIT SAME SINGLE POINT INSTALL AS CLOSE TO BATTERY AS POSSIBLE 15 AMP J43 2 AUXILIARY POWER INPUT 14 AWG FROM STARBOARD EC300 CONTROL n n IF USED STBD BATTERY HOOKING UP PORT CONTROL EP i TO STARBOARD BATTERY IS OPTIONAL TO STARBOARD EC300 CONTROL IF USED Figure 51 Power Wiring Diagram for Unswitched Engine Powering Applications 142 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation e PORT CONTROL d ooooool d ooooool N99999oy o o o
112. be sealed using heat shrink tubing in combination with insulating compound or sealing devices The installer must provide suitable wire harness and crimping tools An appropriate tool for Deutch contacts is the Deutsch crimper P N HDT 48 00 Use all tools and materials in accordance with manufacturer s instructions Crimps must be made with a tool designed to operate with the lug contact Crimps shall be able to hold 13 6 kg 30 Ib 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 Any friction connectors or soldered connectors at components must meet the component manufacturer s 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 interference caused by circulating currents the conductive shield and wire harness armor of signal harnesses is to be grounded only at one end of the wire harness To connect a harness to an EC300 Control align the plug orientation keys with the EC300 Control s receptacle and push the plug in until it snaps in place EC300 Marine Control System Installation Manual 1024168 65 Electrical Installation Twin Disc I
113. bler to the J3 receptacles of the EC300 Port and Starboard Controls 17 IfJ2and or J3 are not used install a connector kit into these receptacles to seal the connector See System Drawing for Connector Plug Kit p n 18 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 76 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Bonding Wire 19 20 21 22 23 24 Electrical Installation Route a bond wire from the vessel bonding system to the selected mounting pad on each Station Doubler See Figure 33 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 a ring lug on the doubler end of the wire Note The ring lug must be properly sized for both the wire and the mounting fastener Remove the mounting fastener at the bonding connection Remove any paint at the mounting connection in order to ensure electrical contact Insert the bonding wire s ring lug on the Station Doubler Reinstall and tighten fasteners up to 1 13 Nm 10 Ib in maximum EC300 Marine Control System Installation Manual 1024168 77 Electrical Installation Twin Disc Incorporated Service Connector J4 Factory Use Only Transmission Harness J5 J6 J7 J8 and J12 Installation 78 Note The J5 J6 J7 J8 and J12
114. 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 equal 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 customer s and subsequent purchaser s 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 manufactur
115. ctor with the J9 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 EC300 Marine Control System Installation Manual 1024168 121 Electrical Installation Twin Disc Incorporated Communication Harness J10 Installation The Communications Harness J10 provide the main interface between two or more EC300 Controllers The vessel may have one or more EC300 Controllers located in or near the engine room The Communication Harnesses J10 are fully pre fabricated and plug into the J10 connector at each EC300 The J10 connectors contains all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector Cruise mode and Express mode support a feature in which the speed of all engines in the system can be synchronized For the synchronization feature to function information must be passed between all controllers in the system A communication harness assembly is required to be connected between all EC300 Controls Atypical harness assembly consists of 2 controller harnesses 1 communication harness 2 T connector receptacles and 2 terminating resistors The harnesses are available in various lengths and are terminated with the proper connectors This section contains the following sub section
116. del 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 options such as Engine Sync Trolling Shaft Brake Mechanical Actuator Output Transmission Oil Pressure and Oil Temperature Monitoring and Helm Display The following installation instructions provide the necessary information on Component Installation Electrical Installation and Configuration 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 The installation procedure is as follows 1 Read and understand this manual Contact the supplier of the system your local Twin Disc Distributor or the Twin Disc Incorporated website for help http Awww twindisc com 2 Locate desired positions for Control Heads Controls and general routing of interconnecting harnessing 3 Identify locations for vessel interconnections such as Ignition Power Wiring Electronic Throttle Electric Shi
117. e Control Head and the Station Doubler The Doubler to Control Harness routes between the Station Doubler and the EC300 Control J2 or J3 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Note Provide enough length in the harness to allow removal of the Control Head in the future Refer to General Electrical Installation Guidelines for harness routing criteria Control Station 1 1 Connect the circular connector end of a Doubler to Station harness to the Dual Lever Control Head Note For each Control Head connector align the large connector key with the large keyway and push the connector into place Then turn the connector s collar until the engagement snap is felt 2 Ensure that the Dual Lever Control Head is firmly mounted 3 Route the Doubler to Station harness to the Station Doubler 4 Connect the Doubler to Station harness plug marked PORT into the receptacle marked STATION A on the PORT end of the Station Doubler 5 Connect the Doubler to Station harness plug marked STARBOARD into the receptacle marked STATION A the STBD end of the Station Doubler Control Station 2 6 Connect the circular connector end of a Doubler to Station harness to the Dual Lever Control
118. e The original customer and subsequent purchasers will not use 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 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 December 14 2007 TDWP10099 rev 2008 FLAT RATE SCHEDULE FOR MARINE PLEASURE CRAFT TRANSMISSION Hourly Labor Rate Must be Acceptable to Twin Disc Incorporated at Clutch Unit Repair R amp R R amp R Rebuild Product Code Model Series R amp R Rebuild Valve Valve 0450 MG340 SERIES Part Only 0451 MG360 SERIES Part Only 0432 MG5010 amp MG5011 SERIES 0401 MG506 SERIES 0435 MG5050 SERIES 0437 MG5061 amp MG5062V SERIES 0453 MG5055A SERIES 1706 MG5065A SERIES 1707 MG5065SC SERIES 0425 MG5085 SERIES 0442 MG5075A SERIES 0443 MG5075SC SERIES 0476 MG5082 SERIES 0419 MG5114 SERIES 0433 MG5090 SERIES 0489 MGX5114A SERIES 0490 MGX5114SC SERIES 0491 MGX5114IV SERIES 1719 MGX5095A SERIES 1728 MG5095A SERIES 1729 MG5095SC SERIES 0405 MG514 SERIES 0447 MG5145A SERIES 0448 MG5145SC SERIES 0492 MGX5135A SERIES 0494 MGX5145SC SERIES 1704 MG 5135A SERIES 0426 MG516 amp MG5170 SERIES 0477 MG5170 SERIES 0412 MG5200
119. e 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 10 32 x 0 75 2 CLAMP MORSE P N 31509 SHIM MORSE P N 31538 NJAL 12 EXTERNAL TOOTH LOCK WASHER 2 RETAINER PLATE Figure 17 Installing Cable Clamp on Servo Actuator for Conductive Vessels MORSE BALL JOINT ASSY 0 218 ID NYLON FLAT WASHER pans ARM CM 0 218 ID NYLON FLAT WASHER MORSE LOCK WASHER Q ID MORSE NUT Figure 18 Installing Ball Joint Assembly for Conductive Vessels EC300 Marine Control System Installation Manual 1024168 49 50 Component Installation Twin Disc Incorporated 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 electrical interference that may affect the operation of the servo actuator or EC300 Control Most secondary current path sources of interference can be eliminated by insuring there are no loops through the engine block or transmission via push pull cables If isolation components are used on any component of the EC300 Control System they must be used on all components For nonconductive vessels isolating installation kits with cable clamps and terminal eye pins mus
120. e from the Deutsch connector EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Insert the wire into position 1 of the J8 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J8 connector is part of the Bridge Signals Harness When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body Ensure that sealing plugs are installed in all empty connector positions Align the harness connector with the J8 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 EC300 Marine Control System Installation Manual 1024168 113 Electrical Installation Twin Disc Incorporated Manual Override Switch Wiring The Manual Override switch is used to disable the forward and reverse solenoid drivers when the manual override valve is open The Manual Override switch is a normally closed contact In the event the manual override valve is manually activated the switch contacts will open and the EC300 control will go into a controller neutral condition and no longer power the forward and reverse solenoids If used the Manual Override Switch should be installed per Manual Override Switch Installation Install the Manual
121. e to the Full Slip Troll position 2 Position the transmission trolling lever to Full Slip Troll The attached push pull cable will move accordingly 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 4 Repeat steps 1 3 with the Control Head Mode Select Switch in CRUISE The Servo Actuator will move to the Lockup Cruise position Proceed to Push Pull Cable Final Adjustment 56 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Push Pull Cable Final Adjustment Final adjustments alignment of the push pull cable must be completed with power applied to a functioning control system All power wiring and Control System checks must be made prior to proceeding with the final adjustments alignment of the push pull cable Disconnect the quick connect on the push pull cable from the Servo Actuator lever to perform the power wiring and Control System checks 1 Power up the Control System and take command at a Control Head Use the Control Head closest to where the Servo Actuator is located or have one person operate the Control Head while another monitors and adjusts the push pull cable at the Servo Actuator Move the Control Head levers and the Mode Select Switch to shift the component the Servo
122. ector 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 96 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Install the Engine Throttle Wiring portion of the Engine Control harnesses as follows Refer to General Electrical Installation Guidelines for harness routing criteria 1 Identify the wiring requirements from the installation drawing and from appendix B for the specific engine installation Locate the necessary connecting points on the engine control module or engine control wiring circuits Make a suitable interface harness containing the necessary conductors Note The throttle signal wires must be 18 AWG stranded copper wire All other wires must be a minimum of 18 AWG stranded copper wire Connect the engine harness at the engine end Note It may be desirable to complete any other terminations for this harness before securing the harness Route the engine harness to the associated EC300 Control Crimp the supplied Deutsch pin P N 0462 209 16141 using the Deutsch HDT crimp tool P N HDT 48 00 for the Engine Control Harness J5 connector on the wires Remove the locking wedge from the Deutsch connector Insert the wires into the proper position in the J5 connector Note Refer to the EC300 System Installation Drawings in the Engineeri
123. ent 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 All information illustrations and specifications in this manual are based on the latest information at the time of publication The right is reserved to make changes at any time 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 Incorporated products contact any Twin Disc distributor or service dealer For a complete list of Twin Disc Distributors or Service Dealers please see our Corporate website at http www twindisc com For additional information you may contact Twin Disc Incorporated Product Service by e mail at service twindisc com or phone at 800 558 3208 ext 2727
124. er solenoid relay current is unknown or if no means to measure the current is available Note The EC300 Control s neutral start interlock contacts and any hardwired transmission neutral interlock must be wired in series with the vessel s starting circuit If a hardwired transmission neutral start switch is present then modify the following installation procedures to accommodate the switch 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 customer s existing wiring The following steps assume that the Ignition Switch start switch the Starter Solenoid and the Neutral Start Relay if used are already installed Refer to General Electrical Installation Guidelines for harness routing criteria This section assumes an existing connection between the engine starting switch atthe helm and the engine starting circuit If a connection does not exist it may be desirable to install this circuit before continuing 1 Disconnect the wire coming from the start switch at the helm from the start relay solenoid and connect it to J5 pin 9 2 Make a connection from J5 pin 10 to the start relay solenoid using 14 AWG wire 3 Route both yellow with a red stripe wires to the EC300 Control 4 For the yellow with a red stripe wire from the start switch at the helm crimp the supplied Deutsch contact P N 0462 209 16141 using the Deutsch HDT crimp tool P N HDT 48 00
125. ess J5 Decsription W SE4 ECU 9 9 J5 Pin 1 ECM Power Supply J8 Pin 2 pee pes Signal S1 Pin B Throttle Pot Wiper ECM Power Supply 51 PinA Sensor Return Common Note Connections should be made as close to the Engine Control Unit ECU as possible EC300 Marine Control System Installation Manual 1024168 B 7 Appendix B Twin Disc Incorporated MAN Current Engine Connection Requirements for 4 20mA Loop Control This throttle configuration is a current loop and is set to approximately 3 8 mA at idle and 20 3 mA at full throttle See the MAN engine manual for complete details on interconnections for throttle input to the engine harness engine control Table 26 Engine Connections at the MAN Engine with Current Control pesi p 1 Engine Connector Engine Signal Description p CM Power Supply J8 Pin 2 Ignition Return J5 Pin 3 Throttle Common X9 Pin 10 and to J8 4 20 MA Pin 6 Battery from T531 J Neutral Start Relay 9 Pin 7 Neutral Start Interlock Contact normally open J5 Pin 1 J5 Pin 2 Throttle Signal pe MA 5 Pin 9 5 Pin 10 B 8 J Neutral Start Relay X9 Pin 8 Neutral Start Interlock Contact common Table 27 Previous Engine Connection Diagram NOW OBSOLETE EC300 Engine EC300 Signal Engine Connector Engine Sianal Description Harness J5 Decsription note 1 g g P J5 Pin 1 CM Power Supply X9 Pin 7 Battery from T515 J5 Pin 2 Throttle Signal VON j MA J5 Pin 3 ECM Power Supply X9 Pin 10
126. ft Speed Sensing etc The engine manual transmission manual and vessel wiring diagrams may be needed for reference 4 Purchase fabricate any necessary Customer Supplied items or tools 5 Install system components 6 Install harnessing and wiring EC300 Marine Control System Installation Manual 1024168 13 Introduction 14 10 Twin Disc Incorporated Inspect and compare the installation against this manual and applicable system drawings Correct any discrepancies Record all component part numbers and serial numbers Document all customer supplied and connected wiring Include wire colors and location in document Test the system Complete any necessary troubleshooting and adjustments See configuration Manual Sea trial the vessel EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Introduction General Information This publication provides the information necessary for the installation of the Twin Disc Model EC300 Control System The components as supplied with the order meet the codes and standards that were applicable when the order was placed Applicable codes and standards include L1 American Boat amp Yacht Council ABYC Direct Current DC Electrical Systems on Boats Standard E 9 L1 American Bureau of Shipping s ABS Rules for Building and Classing Steel Vessels 2002 L1 American Bureau of Shipping s ABS Rules for Building and Classing Steel Vessels Under 90
127. g Required for multiple engine systems 1 Add one 1 additional component for each additional engine more than two 2 Quantity does not change regardless of the number of engines 22 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Introduction Additional Materials Installation requires the following supplies that are not furnished with the basic control system L1 Brackets fasteners and other hardware for mounting the components Note Use 6 35 mm 0 25 in maximum fastener diameter to mount the control s L1 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 L1 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 5 Note Table 5 provides color code requirements for those vessels subject to American Boat amp Yacht Council ABYC Standard E 9 requirements Table 5 Power Wire Color Codes as per ABYC Standard E 9 Color Code Yellow w Red Stripe Neutral Start Relay Contacts J5 pins 9 amp 10 Pupe Jsriion Switch US pin Yellow preferred or Black Battery Negative 013 pin 3 Batter
128. g sub sections Q Control to Bracket Wiring Installation Bracket to Transmission Wiring Installation e Neutral Start Interlock Wiring Installation e Engine Throttle Wiring Installation e Prewired Connection Inspection EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Control to Bracket Wiring Installation The Control to Bracket wiring provides wiring connections to interface the transmission and engine with the EC300 Control See Figure 35 6 74956 o B B d 9 2 o 2 o 9 o 2 o o o o 9 o o o o o o 1 2 9712168 17572 3 4 o mm PE e s 25 e 1 6 Jo 135 CHASSIS o 1 4 9 e000 p 8 5 J8 400 129 9 Figure 35 Control to Bracket Harness Assembly EC300 Marine Control System Installation Manual 1024168 79 Electrical Installation 80 Twin Disc Incorporated Refer to General Electrical Installation Guidelines for harness routing criteria 1 Align the J5 harness connector with the J5 receptacle of the EC300 Control and push it in until it snaps into place Align the J6 harness connector with the J6 receptacle of the EC300 Control and push it in until it snaps into place Align the J7 harness connector with the J7 receptacle of the EC300
129. he corresponding position SERVO ACTUATOR TRANSMISSION ENGINE Figure 24 Engine Throttle Actuator 1 Position Control Head lever at the Neutral Detent The Servo Actuator lever will move to the idle position 2 Position engine lever to Idle The attached push pull cable will move accordingly 3 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 4 Repeat with the Control Head lever in Full Throttle position The Servo Actuator lever will move to the full throttle position Proceed to Push Pull Cable Final Adjustment EC300 Marine Control System Installation Manual 1024168 55 Component Installation Twin Disc Incorporated Push Pull Cable Adjustment for Mechanically Controlled Troll Valve The transmission s troll valve is a two position device with nominal positions at 45 degree left and 45 degree right rotation See Figure 25 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 TROLLING VALVE SERVO ACTUATOR TRANSMISSION ENGINE Figure 25 Transmission Troll Valve Actuator 1 Position the Control Head lever at the Neutral Detent and the Mode Select Switch to TROLL The Servo Actuator will mov
130. he neutral start and engine throttle circuits The remaining connections have been completed at the factory based upon the options ordered Verify that the connections are securely connected and have not been damaged during transmission installation See Figure 38 z lt Ba Figure 38 Bracket to Transmission Harness Assembly To complete the wiring harness installation proceed to the Twin Disc Display Harness JQ Installation Communication Harness J10 Installation Servo Actuator Harness J11 Installation and EC300 Control Power and Grounding Harness J13 Installation Skip only those procedures that do not apply to your installation EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Engine Control Harness J5 Installation The Engine Control Harness J5 provides wiring connections for the Neutral Start Interlock Engine Throttle if applicable and Engine Speed Sensor The EC300 J5 12 pin Deutsch connector as well as the Engine Speed Sensor harness are supplied by Twin Disc Incorporated The Neutral Start Interlock and Engine Throttle harness are customer supplied field fabricated and plug into the J5 connector when not using the Twin Disc transmission harness The J5 connector kit contains all contacts and sealing p
131. ify the solenoids If the solenoids are not clearly identified make the connections on a temporary basis until testing can confirm the selection Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the PWM Driver harness to the forward and reverse solenoid connectors 2 Route the PWM Driver harness to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness 3 Ensure that sealing plugs are installed in all empty connector positions 4 Align the harness connector with the J7 receptacle of the EC300 Control and push it in until it snaps into place 5 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 106 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Three Solenoid Transmission Clutch Control Wiring Installation Install the wiring for a three solenoid transmission as follows See Figure 43 Note Refer to the transmission manufacturer s 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 Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the PWM Driver harness to the forward neutral and reverse solenoid connectors
132. ing until it just contacts tip of the gear tooth then back sensor out one full turn 4 Tighten the lock nut to 4 52 Nm 40 Ib in maximum while holding the Speed Sensor body in place 5 If using a dual output Speed Sensor reconnect the original signal cable to one of the sensor outputs EC300 Marine Control System Installation Manual 1024168 41 Component Installation Twin Disc Incorporated Installation Hall Effect Pick up Output Speed Sensor Note Some transmissions have predrilled and plugged sensor holes for the purpose of installing output speed sensors Note Some transmissions may need an output speed pick up wheel installed on the output flange and an output speed bracket installed on the transmission housing to facilitate the installation of an output speed sensor See Figure 13 Ga led 7 SPEED PICK UP WHEEL d TRANSMISSION OUTPUT FLANGE Figure 13 Output Speed Sensor Pick Up Bracket and Speed Wheel SPEED SENSOR SPEED PICK UP BRACKET SPEED PICK UP WHEEL CAP SCREWS 1 Turn the output shaft until the crown of the gear tooth or speed wheel tooth is centered in the sensor hole See Figure 11 2 Thread the lock nut onto the sensor Apply anaerobic sealant equivalent to MA908 Loctite 242 to the threads of the engine speed sensor near the end away from the wires See Figure 12 3 Install sensor until contacts tip of gear tooth and back senso
133. ingle Engine with One Station Required Components for Typical Applications Twin Disc Two Stations One Station Twin Engine with Two Stations i Single Engine with Twin Engine with lt lt EC300 Control Single Lever Control Head J1 J2 J3 lt Dual Lever Control Head J1 J2 J3 Single Lever Station Harness J1 J2 J3 8 Dual Lever Station Harness J1 J2 J3 Transmission Harness J5 J6 J7 J8 EC300 Control to Bracket N N EC300 Marine Control System Installation Manual 1024168 19 Introduction Twin Disc Incorporated Transmission Harness J5 J6 J7 J8 Bracket to Transmission J5 Engine Control Harness J5 Speed Sensor Harness J6 Engine Room Analog Harness Speed Sensors See Table 3 J7 PWM Driver Harness pum m J10 Communication Harness See Table 4 Nl Ce 1 The Control Head can be ordered with the lever on the left or right side 2 The Dual Lever Control Head can be replaced with optional Split Single Lever Control Heads or a Side Mount Control Head Assembly 3 Harness Assembly eliminating the need for individual harnesses Various harness options are available to accommodate diffferent transmi
134. inimize water drainage toward the connector Loops should be tied down so that they do not move freely when the boat is in motion Excess motion can cause the harnesses to fatigue and break Wiring harness bend radius should be at least eight harness diameters unless otherwise permitted RMRS requires greater than ten harness diameters Wiring harnesses to be secured in such a manner that stresses are not transmitted to the connector terminal 62 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Wiring harnesses must be supported or secured every 406 mm 16 in maximum with the appropriate hardware except if the harness is enclosed in rigid duct conduit or other enclosure The distance between harness supports are to be suitably chosen according to the type of harness and the degree of vibration the installation is likely to be subjected to For horizontal runs where harnesses 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 wiring harness runs on weather decks where forces from sea water washing over the deck is expected Alternatively harness support systems complying with a recognized standard other than IEC 60092 352 may be used where the installed harness mu
135. ion Oil Temperature Sensor Wiring Installation Transmission Output Speed Sensor Wiring Installation HARNESS WIRING ENGINE ROOM ANALOG y 7 E TRANS OIL TEMP SENSOR TRANSMISSION OUTPUT SENSOR Je6 v SENSOR EXCITATION RED IA TT 16 8 V SENSOR RETURN BLACK TRANSMISSION i 1 OUTPUT J67 l SIGNAL ORANGE TS lt J amp 33 x J64 X J65 X SIGNAL RED GRN STRIPE J6 zx TRANS OIL TEMP 4 945 16 2 5 SENSOR RETURN GRN RED STRIPE 8 Figure 42 Engine Room Analog Harness J6 Wiring Diagram EC300 Marine Control System Installation Manual 1024168 101 Electrical Installation Twin Disc Incorporated Transmission Oil Temperature Sensor Wiring Installation Install the wiring for a Transmission Oil Temperature Sensor as follows See Figure 42 Refer to General Electrical Installation Guidelines for harness routing criteria 1 Align the Engine Room Analog Harness connector with the J6 receptacle of the EC300 Control and push it in until it snaps into place Route the Engine Room Analog Harness to the associated transmission 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 Transmission Oil Temperature Sensor cab
136. ire harnesses occupying the same wireway or conduit with power harnesses are to be effectively shielded The following guidelines must be met when making wiring connections All electrical connections must be made within waterproof enclosures or shall be watertight Connections must be watertight if they can be immersed in water connectors 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 harness 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 Wire harnesses supplied by Twin Disc Incorporated will not include any unused wires 64 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Terminals 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 Wire harnesses stripped of insulation are to
137. itch start switch the Starter Solenoid and the Neutral Start Relay if used are already installed EC300 Marine Conirol System Installation Manual 1024168 83 Electrical Installation Twin Disc Incorporated Refer to General Electrical Installation Guidelines for harness routing criteria This section assumes an existing connection between the engine starting switch atthe helm and the engine starting circuit If a connection does not exist it may be desirable to install this circuit before continuing 1 Remove the locking wedge from the Neutral Start Deutsch connector Note The Neutral Start connector is provided in the Transmission harness connector kit Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information 2 Disconnect the wire coming from the start switch at the helm from the start relay solenoid A Remove any existing terminals from the end of the wire and crimp the supplied Deutsch contact P N 0462 209 16141 using the Deutsch HDT crimp tool P N HDT 48 00 Note The Deutsch 14 AWG contact P N 0462 209 16141 can be identified by a green band B Route the wire from the start relay solenoid to the Neutral Start connector of the Bracket to Transmission harness and insert it into pin A of the connector 3 Using 14 AWG wire make a connection from pin B of the Neutral Start connector to the start relay solenoid A Crimp a supplied Deutsch cont
138. l Lever Control Head With Levers in Neutral EC300 Marine Control System Installation Manual 1024168 29 Component Installation Twin Disc Incorporated 2 Cut out the Control Head Mounting Template in Engineering Drawings in the back of this manual and tape it in the desired location Note The template provided with the control 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 3 Ensure that the control head location provides clearance for the operator s hands over the full range of lever travel ASTERN DETENT POSITION AHEAD DETENT POSITION 159 15 ASTERN 0 559 v 25 4 25 4 1 0 gt gt 22 1 0 CLEARANCE REQUIRED TO AVOID PINCH POINTS ia BOTH SIDES T 127 5 0 MINIMUM RECOMMENDED MAINTENANCE CLEARANCE M Figure 3 Side View of Control Head With Lever Clearance Shown 4 Center punch the four 4 mounting holes and scribe the base cutout outline 30 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated 10 11 12 13 14 15 16 Component Installation Remove the template Note The hole cannot be smaller than shown on the template and must be properly aligned with the mounting holes Drill and cut the holes using the template markings Check the hole
139. l 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 Install the Engine Speed Sensor Harness Wiring portion of the Engine Control harnesses as follows See Figure 41 HARNESS WIRING ENGINE SPEED SENSOR SEE ENGINE CONTROL HARNESS INSTALLATION SECTION j Sene 1020706 ff SENSOR SIGNAL 05 11 RED GRN STRIPE V A SENSOR RETURN 05 12 GRN RED STRIPE B A D YA 9156 powan CONNECTOR KIT ENGINE THROTTLE J1 J2 J4 J5 J6 J7 E o o 17g 12 o o o o 22 2 820 556 les Ls J8 J9 noO n20 J130 Sy fA Figure 41 Engine Speed Sensor Harness Wiring EC300 Marine Conirol System Installation Manual 1024168 99 Electrical Installation Twin Disc Incorporated Refer to General Electrical Installation Guidelines for harness routing criteria 1 Remove the locking wedge from the J5 Deutsch connector 2 Insert the red with a green stripe wire into position 11 of the J5 connector 3 Insertthe green with a red stripe wire into position 12 of the J5 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section fo
140. le s receptacle onto the transmission oil temperature sensor s plug Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Note It may be desirable to complete any other terminations for this harness before securing the harness EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Transmission Output Speed Sensor Wiring Installation Install the wiring for a Transmission Output Speed Sensor as follows See Figure 42 Refer to General Electrical Installation Guidelines for harness routing criteria 1 Align the Engine Room Analog Harness connector with the J6 receptacle of the EC300 Control and push it in until it snaps into place 2 Route the Engine Room Analog Harness to the associated transmission Note The Transmission Output Speed Sensor cable is part of the Engine Room Analog harness Cable ties may be removed for routing purposes 3 Install the Transmission Output Speed Sensor cable s plug into the Transmission Output Speed Sensor s receptacle 4 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Tooth Count Note The EC300 Control must be configured with the correct tooth count for the specific transmission installed Obtain the correct tooth count information from the manufacturer s literature or count the teeth EC300 Marine Control System Installation Ma
141. lectrical Installation Transmission Oil Filter Differential Pressure Switch Wiring Installation Install the wiring connections for a Transmission Oil Filter Differential Pressure Switch as follows See Figure 49 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 Refer to General Electrical Installation Guidelines before proceeding with this section 1 Align the harness connector with the J12 receptacle of the EC300 Control and push it in until it snaps into place 2 Route the Engine Room Switch Harness to the Transmission Oil Filter Differential Pressure Switch area 4 Terminate the red with green stripe OIL FILTER J12 pin 1 wire to either screw terminal for the Transmission Cil Filter Differential Pressure Switch 5 Terminate the green with red stripe OIL FILTER J12 pin 2 wire to the other screw terminal for the Transmission Oil Filter Differential Pressure Switch Note Refer to Figure 50 for detailed information about the conductors Refer to the transmission manufacturer s technical manual for any recommendations for terminating the wires Refer to Wire Connections for other requirements 6 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Note It may be desirable to complete any other terminations for this harness before securing the harness EC
142. lugs that are required to fill the connector contact positions Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector The Neutral Start Interlock wiring and Engine Throttle wiring if applicable should be fabricated and routed to the EC300 Control prior to installing the Engine Speed Sensor Harness See Figure 39 and Figure 40 The following criteria must be met when installing engine control harness wiring The Neutral Start Interlock wires must be 14 AWG stranded copper wire All other wires must be a minimum of 18 AWG stranded copper wire Q Before installing the Neutral Start Interlock Wiring plan if the Engine Throttle harnesses and or the Engine Speed Sensor Harness are to be installed Consider the harness routing for each component to consolidate wire routing Refer to General Electrical Installation Guidelines for harness routing criteria prior to proceeding with this section This section contains the following sub sections Q Neutral Start Interlock Wiring Installation Q Engine Throttle Wiring Installation Q Engine Speed Sensor Wiring Installation EC300 Marine Control System Installation Manual 1024168 89 Electrical Installation Twin Disc Incorporated THROTTLE SIGNAL TO ENGINE CONTROL MODULE SEE APPENDIX J5 2 THROTTLE COMMON FROM ENGINE CONTROL MODULE y TO ENGINE pure FOR SPECIFIC J5 3 ENGINE CONNECTIONS START SWITCH 1 NEU
143. n 118 The Twin Disc Display Harness Assembly consists of a communication harness two adapter harnesses two J1939 T Connectors and two J1939 terminating resistors The J1939 CAN Harness adapts the Communications Harness to the display s 3 pin receptacle via a J1939 T Connector The Multiple Display Adapter Harness adapts the Communications Harness to the control s 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 This section contains the following sub sections Q Twin Disc Display Harness Wiring Note The purchase and installation of the Twin Disc Display is an option 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated TO CONTROL HEAD Electrical Installation
144. n resistant 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 Mount the Station Doubler using four 4 sets of fasteners and lock washers Note Place lock washers under the mounting screw heads Tighten the fasteners to 1 13 Nm 10 Ib in maximum Reference Multiple Station Dual Lever Control Head Wiring Installation for harness installation EC300 Marine Control System Installation Manual 1024168 45 Component Installation Twin Disc Incorporated Servo Actuator Installation The EC300 Control System supports one servo actuated device per control The EC300 Control Systems can control either a mechanically shifted transmission a mechanically controlled throttle or a mechanically controlled troll valve The Servo Actuator can be mounted in any orientation on a flat surface See Figure 16 for preferred mounting orientation The Servo Actuator should be located within the reach of the supplied harness and as close to the engine transmission as practical Note The Servo Actuator and Push Pull Cable Installation 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 the complete installation This section contains the following sub sections Serv
145. n 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 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Install the control power wiring as follows See Figure 51 and Figure 52 Electrical 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 Note Note Figure 51 and Figure 52 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 controller s 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 Figure 51 and Figure 52 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 6 VDC batteries can also be connected in series to achieve either 12 VDC or 24 VDC Batteries can also be connected in parallel in order to increase the available battery current Using a multimeter test the voltage of each battery and across all
146. n the hole 36 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation 6 Install gasket on display See Twin Disc Display Harness J9 installation for wiring instructions y Insert the display in the dash or control panel 8 Attach the mounting bracket and tighten the nuts until the display is firmly secured in the dash 9 If applicable repeat steps 1 through 8 for each additional display Refer to Twin Disc Display Harness J9 Installation for display harness wiring installation EC300 Marine Control System Installation Manual 1024168 37 Component Installation Twin Disc Incorporated Speed Sensor Installation 38 Applications with options such as Sync Mode engine synchronization Express Mode and Troll Mode require the installation of an engine speed sensor and or transmission output speed sensor Engine speed sensors transmission input are most often installed on the marine transmission however in some cases the engine speed sensor is installed on the engine flywheel The output speed sensor may be installed directly into the transmission or on a bracket near the output shaft with a speed pick up wheel connected to the output flange Only Twin Disc speed sensors are acceptable for the output shaft speed There are many types of engine speed sensors available and many will work with the EC300 Control System This section outlines the installation of the sensors a
147. ncorporated Control Head Harness J1 J2 or J3 Installation 66 The Control Head Harness J1 J2 and J3 provides the main interface between the Control Head and the EC300 Controller The vessel will have one or more Control Heads located at the vessel control stations with either single lever or dual lever heads The Control Head Harnesses J1 J2 and J3 are fully pre fabricated and plug into the J1 J2 and J3 connector at the EC300 or the station doubler if used The J1 J2 or J3 connectors contain all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector Refer to General Electrical Installation Guidelines for harness routing criteria prior to proceeding with this section This section contains the following sub sections Q Multi Station Single Lever Control Head Wiring Installation Multi Station Dual Lever Control Head Wiring Installation m Q Split Single Lever Control Heads in Twin Engine Installations Multi Station Dual Lever Control Head Wiring Installation Using Station Doublers EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Multi Station Single Lever Control Head Wiring Installation This section is applicable to single engine applications with up to three Single Lever Control Heads See Figure 30
148. nd Grounding Harness J13 provides operating power for the EC300 Controller This harness is field fabricated and plugs into the J13 connector at the EC300 Controller via the 6 pin Deutsch connector The EC300 J13 connector is supplied by Twin Disc Incorporated and the wiring harness and equipment end connectors are supplied by the customer The J13 connector kit 6 pin Deutsch connector contains all contacts and sealing plugs that are required to fill the connector contact positions Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector This section contains the following sub sections EC300 Control Power Wiring EC300 Control Bonding Installation EC300 Marine Control System Installation Manual 1024168 137 Electrical Installation Twin Disc Incorporated 138 EC300 Control Power Wiring 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 Controller power or grounding connections can not be made at any conductor through which motor starting current flows Do not use a connection directly on the engine or starter Locate the connection as close to the battery as practical Use the same source of power for the EC300 Control as used for the electronically controlled engine if a
149. nd for a mechanically controlled troll valve See Figures 21 25 Note Use either a Conductive or Nonconductive Push Pull Cable Installation Kit as required by the vessel PULL POSITION ADJUSTING CLAMP CENTERS TRAVEL TO MATCH CABLE WITH ACTUATOR PUSH POSITION PUSH PULL CABLE ADJUSTING BALL JOINT POSITION UP INCREASES CABLE TRAVEL ADJUSTING BALL JOINT POSITION DOWN DECREASES CABLE TRAVEL CABLE CLAMP TERMINAL EYE PIN OR BALL JOINT CONNECTOR MOUNTING PAD Figure 21 Servo Actuator Push Pull Cable Installation 1 Fabricate a 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 the clamp mounting holes to centerline of the engine transmission lever See Figure 22 Secure the bracket to engine transmission CUSTOMER SUPPLIED STATIONARY MOUNTING BRACKET SERVO ACTUATOR ENGINE or TRANSMISSION Figure 22 Push Pull Cable Mounting Bracket 52 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Brackets 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 inch Loosely attach the cable
150. neral Electrical Installation Guidelines for harness routing criteria 1 Connect the circular connector end of the dual lever harness to the Control Station 1 main most used Dual Lever Control Head Note For each Control Head connector align the large connector key with the large keyway and push the connector into place Then turn the connector s collar until the engagement snap is felt 2 Ensure that the Dual Lever Control Head is firmly mounted 3 Route the harness marked PORT to the EC300 Port Control 4 Connect the Dual Lever Control Head Harness plug to the J1 receptacle of the PORT EC300 Control 5 Route the harness marked STARBOARD to the EC300 Starboard Control 6 Connect the Dual Lever Control Head Harness plug to the J1 receptacle of the STARBOARD EC300 Control 7 If applicable repeat steps 1 through 6 for connecting additional Control Stations using J2 for the second Control Head and J3 for the third Control Head 8 If J2 and or J3 are not used install a connector kit into these receptacles to seal the connector See System Drawing for Connector Plug Kit p n 9 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Note It is desirable especially on single station vessels to route the port and starboard harnesses as far apart as possible This minimizes the odds of both harnesses being accidently damaged at the same time allowing
151. ness to the EC300 Control 10 Install a 1939 T Connector into the 3 pin plug of the Multiple Display Adapter harness 11 Install the 3 pin plug of the Communications harness into the J1939 T Connector 120 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated 20 21 Electrical Installation Remove the 8 pin receptacle from the Multiple Display Adapter harness located near the J9 connector at the EC300 Control Remove the locking wedge from the Multiple Display Adapter harness s 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 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 Twin Disc Display Communications Harness Assembly Note Terminating resistors must be installed at each end of the Twin Disc Display Communication Harness Assembly for the communications to work properly Repeat steps 1 through 16 for each additional Twin Disc Display When all pins have been inserted in the connector body install the locking wedge into the Multiple Display Adapter harness 8 pin plug Install the 8 pin receptacle onto the Multiple Display Adapter harness s 8 pin plug Align the Multiple Display Adapter harness 6 pin conne
152. ng Drawings Section for pin numbering information Note The J5 connector is provided in the Engine throttle connector kit Note Ensure that the pin to wire crimp is uniform and complete Ensure that the pin is locked into in the connector EC300 Marine Control System Installation Manual 1024168 97 Electrical Installation 98 10 11 12 Twin Disc Incorporated When all pins have been inserted in the connector body then insert the Deutsch locking wedge 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 EC300 Marine Control System Installation Manual 1024168 Electrical Installation Twin Disc Incorporated Engine Speed Sensor Harness Installation HARNESS WIRING ENGINE THROTTLE The Engine Speed Sensor Harness is a prefabricated wiring harnesses with connectors installed on the equipment end and terminals installed on the EC300 end of the harness The terminals on these harnesses will be installed into the EC300 connector J5 provided by Twin Disc Incorporated The Neutral Start Interlock wiring and Engine Throttle wiring if applicable should be fabricated and routed to the EC300 prior to installing the Engine Speed Sensor Harness The engine speed sensor signa
153. ng Resistor into the J1939 T Connector receptacle located at each end of the Communication Harness Assembly Note Terminating resistors must be installed at each end of the communication harness assembly for the communications to work properly Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 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 The T connector allows daisy chaining to the J10 connector at each EC300 Controller Each communications harness is connected to the EC300 Controller through a short controller communications harness 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 PORT CONTROL PORT INBOARD CONTROL STARBOARD CONTROL mise o J2 Ja E o o o o o o o o 9 MEE B E MEE 22 22 2 HH 22 2 3 3 3 3 3 3 3 3 3 23 2 22 2 2 22 22 22 2 22 22 22 22 2 o o o o o o o o o o o o o o m
154. nition 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 EC300 Marine Control System Installation Manual 1024168 139 Electrical Installation 140 Twin Disc Incorporated Do not connect the EC300 Control s battery or power input directly to the engine or any of its electrical components Connect the EC300 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 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 i
155. nual 1024168 103 Electrical Installation Twin Disc Incorporated PWM Driver Harness J7 Installation The PWM Driver Harness J7 provides solenoid driver outputs for transmission gear selection and other functions Not all of these outputs are used in any specific application The following sections provide instructions for the installation of the PWM Driver Harness The PWM Driver harness is fully pre fabricated and plugs into the J7 connector at the EC300 Control and directly into the solenoid connectors at the other end The J7 connector contains all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector This section contains the following sub sections Two Solenoid Transmission Clutch Control Wiring Installation Three Solenoid Transmission Clutch Control Wiring Installation Shaft Brake Wiring Installation Stabilizer Disable Wiring Installation B EB O Troll Enable Wiring Installation EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 07 6 BROWN LIGHT BLUE STRIPE E J7 3 X LIGHT BLUE BROWN STRIPE X NEUT
156. o Actuator Mounting Push Pull Cable Installation Guidelines Push Pull Cable Installation Kits for Conductive Vessels Push Pull Cable Installation Kits for Nonconductive Vessels D D D Push Pull Cable Installation e Mechanically Shifted Transmission Mechanically Controlled Throttle Mechanically Controlled Troll Valve Push Pull Cable Final Adjustment 46 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Servo Actuator Mounting 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 Ib of force at the innermost point on the lever and a maximum of 11 3 kg 25 Ib of force at the outermost point on the lever Figure 16 Preferred Mounting Arrangement for Servo Actuator 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 for your specific actuator Note All mounting hardware must be corrosion resistant Note Neither the engine nor the transmission push pull cable clamp and bracket are supplied Note Fabricate brackets shims or spacers as required to provide a flat surface 2 Mark and drill the four mounting holes for the 6 35 mm 0 25 in mounting hardware 3 Mount the Servo Actuator using four sets of fasteners
157. on Oil Temperature Sensor Wiring Installation 103 PWM Driver Harness J7 Installation 104 Two Solenoid Transmission Clutch Control Wiring Installation 106 Three Solenoid Transmission Clutch Control Wiring Installation 107 Shaft Brake Wiring 108 Stabilizer Disable Wiring Installation 109 Troll Enable Wiring Installation s 110 Bridge Signals Harness J8 Installation 111 lgnition Switch Wiring bna nananana 112 Manual Override Switch Wiring 114 Tachometer Output Wiring Installation 116 Twin Disc Display Harness J9 Installation 118 Twin Disc Display Harness Wiring 1 120 Communication Harness J10 Installation 122 Dual Engine Communication Harness Installation 123 Multiple Engine Communication Harness Installation 125 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Table of Contents Servo Actuator Harness J11 Installation 127 Servo Actu
158. one customer supplied wire to the signal input connection on the tachometer 2 Connect the other customer supplied wire to the return connection on the tachometer 6 Route the two wires to the EC300 Control 4 Remove the locking wedge from the Deutsch connector 5 Insert the wire connected to the tachometer signal input into position 5 of the J8 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J8 connector is part of the Bridge Signals Harness 6 Insert the wire connected to the tachometer signal return into position 6 of the J8 connector 116 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 7 When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body 8 Ensure that sealing plugs are installed in all empty connector positions 9 Align the harness connector with the J8 receptacle of the EC300 Control and push it in until it snaps into place 10 Secureallharnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals Note It may be desirable to complete any other terminations for this harness before securing the harness EC300 Marine Control System Installation Manual 1024168 117 Electrical Installation Twin Disc Incorporated Twin Disc Display Harness J9 Installatio
159. or circuit breaker Note If no auxiliary battery is present do not install a wire to J13 Pin 2 Pin 2 should be plugged 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 The two batteries and the EC300 Controller s negative power connection must be made at the same point 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 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 Using the Deutsch crimping tool P N HDT 48 00 crimp the wires to the Deutsch contacts 14 AWG P N 0462 209 16141 EC300 Marine Control System Installation Manual 1024168 145 Electrical Installation 146 Twin Disc Incorporated Assemble the J13 Deutsch Mating Connector P N DT06 6S P012 See Figure 51 and Figure 52 Ensure that sealing plugs are installed in all empty connector positions Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 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
160. orporated 14 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals J8 J9 J319 20 J130 A T 14 AWG B 5 AMP 3 BATTERY FUSE HOLDER SUPPLIED WITH ACTUATOR HARNESS INSTALL NEAR BATTERY 14 AWG TO STBD 5 p HARNESS WIRING ACTUATOR PIN 4 PRIMARY BATT PIN 5 AUXILIARY BATT PIN 6 GROUND CUSTOMER SUPPLIED HARNESS S ACTUATOR POWER CE i e Ges RED gt POWER SIGNAL J11 1 alu OWER SIG lll y BLACK POSITION SIGNAL To EM ACTUATOR am ORANGE POSITION REFERENCE t ae Figure 48 Wiring the Servo Actuator 130 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Station Transfer Signal Wiring Installation Note The Station Transfer Signal feature will not be available for EC300 Control Installations with Servo Actuators The station transfer signal output circuit is used to alert ships personnel that control of the ship s propulsion system is being transferred from one control station to another via an
161. ot used install a connector kit into these receptacles to seal the connector See System Drawing for Connector Plug Kit p n 11 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 72 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 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 Each EC300 Control can directly accept up to three Control Head inputs Using Station Doublers a total of five Control Head inputs can be supported Each Station Doubler combines the signals from two separate Control Heads and routes the combined signals to each of the EC300 Controls at J2 or J3 See Figures 33 and 34 Figure 33 shows five Control Heads and two Station Doublers The control head not connected to a station doubler must be connected to J1 PORT STBD PORT STBD PORT STBD PORT STBD CONTROL STATION 2 CONTROL STATION 3 CONTROL STATION 4 CONTROL STATION 5 5 6 mm PORT STBD CONTROL STATION 1 T z CIRCULAR YW CONNECTOR Yy 7 PLACES
162. oublers 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 to doubler harness is used with a Port Control Head A starboard station to doubler harness is used with a Starboard Control Head PORT STBD CONTROL STATION 1 PORT STBD CONTROL STATION 2 TO STBD TO PORT V CONTROL CONTROL ND WIRE rH pm WITH RING LUG m 8 8 BOX JUNCTION STATION DOUBLER R 0 0 0 0 5 STARBOARD STARBOARD Mt HARNESS WIRING DUAL LEVER NS PORT PORT 3 PLACES Figure 34 Station Doubler Connection Using Dual Lever Control Heads Install the Control Head harnesses as follows Note Note 74 The Doubler to Station Harness routes between th
163. ounting hardware must be corrosion resistant 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 Mark and drill three 3 mounting holes for the 6 35 mm 0 25 in mounting hardware Mount the control using three 3 sets of fasteners and lock washers Note Place lock washers under the mounting screw heads Tighten fasteners up to 1 13 Nm 10 Ib in maximum EC300 Marine Control System Installation Manual 1024168 27 Component Installation Twin Disc Incorporated 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 a side mount Control Head Assembly There are separate instructions for the single dual lever Control Head and the side mount Control Head Assemblies Note Only EC300 Control Heads will work with the EC300 Control The EC200 250 251 Control Heads are not compatible Note Locate the Control Head s where they will not be in direct spray splash or submerged Note Chrome plated Control Heads should be polished periodically using a chrome polish to help retard corrosion The following s
164. ove and reinstall or equivalent credit In this context labor is defined as the flat rate labor hours established by Twin Disc Incorporated in the published Twin Disc Flat Rate Schedule required to remove disassemble inspect repair reassemble reinstall and test the Twin Disc Incorporated product only Authorized reasonable travel and living expenses will be considered for payment in all model except MG340 MG360 and Electronic Control Systems Under no circumstances including a failure of the exclusive remedy shall Twin Disc Incorporated be liable for economic loss consequential incidental or punitive damages The above warranty and remedy are subject to the following terms and conditions 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
165. plit Lever harness with the two circular connectors to the port Single Lever Control Head Note For each Control Head connector align the large connector key with the large keyway and push the connector into place Then turn the connector s collar until the engagement snap is felt 2 Route the Split Lever harness to the Starboard Control Head 3 Connect the circular connector end of the Split Lever harness to the starboard Single Lever Control Head 4 Connect the circular connector end of the Dual Lever harness to the male circular connector of the Split Lever harness at the Port Single Lever Control Head 5 Ensure that the port and starboard single lever Control Heads are firmly mounted 6 Route the Dual Lever harness to the EC300 Port Control and Starboard Control Note Itis desirable especially on single station vessels to route the port and starboard harnesses as far apart as possible This minimizes the odds of both harnesses being accidently damaged at the same time allowing continued but reduced control of the vessel 7 Connect the Dual Lever Harness plug labeled Port to the J1 receptacle of the Port EC300 Control 8 Connect the Dual Lever Harness plug labeled Starboard to the J1 receptacle of the Starboard EC300 Control 9 If applicable repeat steps 1 through 6 for connecting additional Control Stations using J2 for the second Control Head and J3 for the third Control Head 10 IfJ2and or J3 are n
166. pplicable Ensure that the circuit current rating is adequate for combined load of the EC300 Control and the engine controller 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 Power Wiring Requirements The following criteria must be met when installing power distribution wiring for US installations 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 60 C 140 F EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Battery positive and negative power wires must be 14 American Wire Gauge AWG minimum 15 amps max Approved fuses or manual re
167. r out two full turns 4 Tighten the lock nut to 4 52 Nm 40 Ib in maximum while holding the Speed Sensor body in place The Hall Effect Pick Up output speed sensor used for the EC300 Marine Control System cannot be used to provide signals to other devices on the vessel The output signal must be connected directly to the EC300 Control 42 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Installation Tachometer Signal Generator Tachometer signal generators will also work with the EC300 Control System See Figure 14 The tachometer 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 tachometer signal generator available The output amplitude of the tachometer signal generator must be a minimum of 1 5 volts RMS AC Note The number of pulses per revolution must be known in order for the EC300 control software to be properly configured TACHOMETER GENERATOR DRIVE TANG 75 CUSTOMER SUPPLIED DRIVE FLANGE Figure 14 View of Tachometer Signal Generator Note Mechanical drive components that are necessary to convert an existing tachometer sender drive to a dual tachometer sender drive must be ordered from the accessory supplier
168. r pin numbering information 4 When both pins have been inserted in the connector body then insert the Deutsch locking wedge 5 Ensure that sealing plugs are installed in all empty connector positions 6 Align the harness connector with the J5 receptacle of the EC300 Control and push it in until it snaps into place 7 Route the Engine Speed Sensor Harness to the Engine Speed Sensor 8 Plug the 2 pin connector of the Engine Speed Sensor Harness into the Engine Speed Sensor receptacle 9 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 100 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Engine Room Analog Harness J6 Installation The Engine Room Analog Harness Connector J6 provides analog inputs from a transmission oil temperature sensor and a transmission output speed sensor The oil temperature sensor is not applicable in all installations The Engine Room Analog harness is fully pre fabricated and plugs into the J6 connector at the EC300 Control and directly into the temperature sensor and output speed sensor at the other end The J6 connector contains all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector This section contains the following sub sections Q Transmiss
169. r with the J11 receptacle of the EC300 Control 10 Secure all harnesses to a supporting structure with clamps or cable ties per applicable codes and standards Note It may be desirable to complete any other terminations of this harness before securing the harness 0 9 CONNECTOR KIT W STATION TRANSFER 2 CUSTOMER SUPPLIED HARNESS STATION TRANSFER ALERT DRIVER JM 1 SIGNAL 7 Ss eu TO CUSTOMER SUPPLIED AUDIBLE DEVICE 4 SOURCING SUPPLY BATTERY VOLTAGE DRAWING 1A Jl1 4 RETURN J Figure 49 Wiring the Station Transfer Signal 132 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation 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 manufacturer s literature if itis necessary to install these components The Engine Room Switch Harness J12 is pre fabricated and plugs into the J12 connector at the EC300 Control The equipment end of the harness is fabricated by the installer at the time of installation with componen
170. re 23 Transmission Gear Select Actuator 1 Position Control Head lever at the Forward Detent The Servo Actuator lever will move to the Forward position 2 Position the transmission lever to Forward Detent The attached push pull cable will move accordingly 3 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 4 Repeat with the Control Head lever at 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 Proceed to Push Pull Cable Final Adjustment 54 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Push Pull Cable Adjustment for Mechanically Controlled Throttle The engine s 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 24 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 t
171. re into position 9 of the J7 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J7 connector is part of the PWM Driver Harness 6 Insert the black wire into position 12 of the J7 connector T When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body 8 Ensure that sealing plugs are installed in all empty connector positions 9 Align the harness connector with the J7 receptacle of the EC300 Control and push itin until it snaps into place 10 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 108 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Stabilizer Disable Wiring Installation Install the wiring for a stabilizer disable solenoid as follows See Figure 43 Note The connector kit supplied for the PWM Driver Harness has enough contacts and plugs necessary to fill the connector Use only the contacts needed Unused connector positions must have a sealing plug inserted to maintain the environmental integrity of the connector Refer to General Electrical Installation Guidelines before proceeding with this section 1 2 10 Connect the red wire to the signal lead for the Stabilizer Disable input Connect the black wire to the return lead for
172. ring drawings are for reference only Please refer to your bill of materials for part numbers specific to your application Q Morse 33 Series Cable Mounting Dimensions Servo Actuator Mounting Dimensions 1018791 Twin Disc Display Mounting Dimensions Control Head Mounting Template Side Mount Lever Mounting Template D D O D O Side Mount Selector Assembly Mounting Template EC300 Marine Control System Installation Manual 1024168 151 Engineering Drawings 152 1020676 1020676 1024103 page 1 of 2 1024103 page 2 of 2 Twin Disc Incorporated EC300 Control Mounting Dimensions Sheet 1 EC300 Control Mounting Dimensions Sheet 2 System 1 SingleEngine 1 Station System 2 Twin Engine 2 Stations Sheet 1 Port Control System 2 Twin Engine 2 Stations Sheet 2 Starboard Control System 3 Twin Engine 1 Station with Mechanical Actuators Sheet 1 Port Control System 3 Twin Engine 1 Station with Mechanical Actuators Sheet 2 Starboard Control System Control EC300 with MAN Engine Sheet 1 System Control EC300 with MAN Engine Sheet 2 Wiring Diagram Sheet 1 Port Control Wiring Diagram Sheet 2 Starboard Control EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Engineering Drawings Morse 33 Series Cable Mounting Dimensions FABRICATE BRACKET LEVER TO PROVIDE DIMENSIONS SHOWN 25 4 1 00 f N CABLE CL
173. roller and push it in until it snaps into place Connect the Communication Harness between the EC300 Controllers by installing the 3 pin plugs into the J1939 T Connector receptacles located on the Controller Comms Harness at each EC300 Controller Install a J1939 Terminating Resistor into the J1939 T Connector receptacle located at the far ends 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 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Servo Actuator Harness J11 Installation Note The Station Transfer Signal feature will not be available for EC300 Control Installations with Servo Actuators The Servo Actuator Harness J11 provides the interface between the EC300 Controller and the Servo Actuator The Servo Actuator Harness is pre fabricated and plugs into the J11 Connector at the EC300 and into the 12 pin connector atthe servo actuator The Servo Actuator Power Harness is fabricated by the installer at the time of installation with components provided by the customer The J11 Connector contains all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector con
174. s Q Dual Engine Communication Harness Installation Multiple Engine Communication Harness Installation EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Dual Engine Communication Harness Installation A Communication Harness Assembly is required to connect the two EC300 Controllers on a dual engine installation This prefabricated harness assembly comes with connectors at both ends Connect the communication harness to the EC300 Controller 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 PORT CONTROL STARBOARD CONTROL AR 015 rowan gof 9 2 J3 J4 J5 J6 ri 5 A E E i B i o o o E o 9 o o 29 m E E EA t Xu J8 J9 09 119 J120 9 9 D E ID HARNESS WIRING tonal Sg COMMUNICATION 6 0 i 0 0 E 0 0 HARNESS WIRING Sg 0 cc CONTROLLER COMMS CONNECTOR
175. s 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 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 contacts are provided in the Engine throttle connector kit J5 for the neutral start interlock wiring Connector J5 pin 9 and connector J5 pin 10 are for use with commonly available DC engine system voltages 12 24 VDC Nominal Install the Neutral Start Interlock portion of the Engine Control harnesses as follows See Figure 40 EC300 Marine Control System Installation Manual 1024168 91 Electrical Installation Twin Disc Incorporated ENGINE CONTROL MODULE SEE ENGINE CONTROL HARNESS INSTALLATION SECTION START SWITCH NEUTRAL START RELAY CONTACT N O 14 AWG 5 9 HARNESS WIRING t ENGINE THROTTLE CUSTOMER SUPPLIED MANUAL OVERRIDE NEUTRAL START RELAY CONTACT COM 14 AWG SWIFGH BATT CUSTOMER SUPPLIED WIRE v f 1 ECM POWER SUPPLY CONNECT FROM 8 2 J5 1 HARNESS WIRING 7
176. set trip free circuit breakers must be used for the EC300 Control System power distribution wiring as per the applicable codes or standards The fuse or circuit breaker rating must be 15 amps Note A fuse or circuit breaker is required at the battery or power distribution point for cable protection The EC300 Control is internally protected 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 Note 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 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 Ig
177. ssion and control system options 4 Harness Assembly eliminating the need for individual harnesses Various harness options are available to accommodate diffferent transmission and control system options 5 Quantity indicated is based on the requirement for an input and output speed sensor 20 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Introduction Table 2 Optional Components c 5 Single Engine with Optional Components Display J9 Display Harness Twin Disc One Station Two Stations e o Single Engine with Station Doubler Servo Actuator J1 1 Servo Harness CUSTUNER HARNESS F ACTUATOR FOWER DT P J12 Engine Room Switch Harness 1 Optional Display The use of a display will require the installation of a J9 Display Harness 2 One Per station 7 Optional Station Doublers are required in applications requiring more then 3 control stations per EC300 Control maximum of 5 J1 connection will not support a Station Doubler Optional Servo Actuator is required for the operation of mechanical control Installation of a Servo Actuator will require the installation of a J11 Servo Harness Option
178. st also comply with that standard Specifically harness support systems meeting the requirements of IEEE 1580 2001 may be used where IEEE 1580 2001 harnesses are installed Some applicable codes and standards notably RMRS require different spacing for harness supports The following table shows RMRS spacing requirements Table 7 RMRS Wire Fastening Points External diam eter of Distance between fastening cable mm points for cables mm W ith W ithout W ith m ineral O ver Up to arm our arm our insulation 8 8 13 370 13 20 300 350 450 30 350 400 450 sas 400 450 450 Metallic wire harness 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 and sufficient width as to not cause damage to the insulation Non metallic clamps and supports must be resistant to oil gasoline and water and shall have a temperature range of 34 to 121 C 30 to 250 F They shall be flame retardant in accordance with IEC Publication 60092 101 Where used for wire harnesses that are not routed on top of horizontal cable trays suitable metal clips or straps are to be added at regular interv
179. stem Installation Manual 1024168 111 Electrical Installation Twin Disc Incorporated Ignition Switch Wiring Ignition switch wiring is accomplished through the 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 Note The following instructions refer to a combination ignition switch which has an ON position and a START position For this type of ignition switch installation power to the EC300 Control must not be interrupted when starting the engine If common master power switch is used to enable separate START push buttons then use this master ON switch as this signal source Install the Ignition Switch Wiring portion of the Bridge Signals harnesses as follows See Figure 44 The DC voltage from the ignition switch to J8 Pin 1 must be from the same source as the voltage used by the EC300 Control It must not be interrupted when the engine is started Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the wire to be used for the ignition wiring to the load side of the ignition switch 2 Route the wire to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness 3 Remove the locking wedg
180. t 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 J8 pin 2 A three pin GM Packard Weather Pack connector 12010717 mates with the Cummins OEM throttle connector Table 16 Engine Connections at Cummins 50 pin Connector Engine Signal Description Harness J5 Decsription Connector J5 Pin 1 EC300 Engine EC300 Signal Customer OEM J5 Pin 2 B2 ee Signal PhB ete Position Throttle J5 Pin 3 ECM Power Supply A V Throttle Return GND Common EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B 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 Table17 and Table 18 Refer to the engine manufacturer s literature to resolve any discrepancies Table 17 Engine Connections at the Cummins Throttle Harness Stub EC300 Engine EC300 Signal
181. t 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 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 D D D O 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 Use the correct fasteners and mounting hardware as follows 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 26 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation EC300 Control Installation Note The EC300 Control can be mounted in any orientation on aflat surface E 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 m
182. t be used to isolate the Servo Actuator from push pull cables See Figure 19 and Figure 20 One kit is required to attach the cable to each Servo Actuator Consult Twin Disc Incorporated or a local distributor for substitutions or alterations Refer to Morse 33 Series Cable Mounting Dimensions in Engineering Drawings for additional information 48 32 X 0 75 2 8 SHOULDER WASHER 2 TEFLON NYLON CE CLAMP MORSE P N 31509 SHIM MORSE P N 31538 c 3 0 218 ID NYLON FLAT WASHER 2 ACTUATOR PLATE c 3 0 218 ID NYLON FLAT WASHER 2 38 32 STOP NUT 2 TD eee W NYLON INSERT Figure 19 Installing Cable Clamp on Servo Actuator for Nonconductive Vessels EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation RETAINING RING NYLON TERMINAL EYE _ 300646 MODIFIED TERMINAL MORSE P N 301456 0 250 ID FLAT WASHER ACTUATOR ARM M 0 250 ID FLAT WASHER 7 MORSE LOCK WASHER NUT Figure 20 Installing Terminal Eye Pin for Nonconductive Vessels EC300 Marine Control System Installation Manual 1024168 51 Component Installation Twin Disc Incorporated Push Pull Cable Mounting Bracket and Cable Installation This section describes how to install the push pull cable for a mechanically shifted transmission for a mechanically controlled throttle a
183. tact positions in order to maintain the integrity of the connector This section contains the following sub sections Servo Actuator Harness Wiring The following criteria must be met when installing Servo Actuator harness wiring Battery positive and negative power wires must be 14 American Wire Gauge AWG minimum 15 amps max Note A fuse or circuit breaker is required at the battery or power distribution point for cable protection The Servo Actuator is internally protected Refer to General Electrical Installation Guidelines for harness routing guidelines Power distribution wiring must be insulated Caps or boots are required at all terminals in order to prevent accidental shorts 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 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 EC300 Marine Control System
184. tem Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J8 connector is part of the Bridge Signals Harness Insert the other wire into position 4 of the J8 connector When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body Ensure that sealing plugs are installed in all empty connector positions Align the harness connector with the J8 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 Note It may be desirable to complete any other terminations for this harness before securing the harness EC300 Marine Control System Installation Manual 1024168 115 Electrical Installation Twin Disc Incorporated Tachometer Output Wiring Installation The tachometer output circuit is used to drive a tachometer indicator This signal can be used to drive a tachometer at the helm indicating either engine or propeller speed Install the tachometer output wiring portion of the Bridge Signals harnesses as follows See Figure 44 Refer to General Electrical Installation Guidelines before proceeding with this section Note EC300 Bridge Signals Harness J8 also may contain wiring for other features Route the harness to the most convenient location serving all the applicable connections 1 Connect
185. the Stabilizer Disable input Route the red and black wires to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness Remove the locking wedge from the Deutsch connector Insert the red wire into position 8 of the J7 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J7 connector is part of the PWM Driver Harness Insert the black wire into position 11 of the J7 connector When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body Ensure that sealing plugs are installed in all empty connector positions Align the harness connector with the J7 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 EC300 Marine Control System Installation Manual 1024168 109 Electrical Installation Twin Disc Incorporated Troll Enable Wiring Installation Install the wiring for a troll enable solenoid as follows See Figure 43 Note The connector kit supplied for the PWM Driver Harness 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 integri
186. the actuator See Figure 27 ADJUST BALL JOINT POSITION UP RESULT Figure 27 Adjustment of Cable Attachment C When the travel of the Servo Actuator lever and push pull cable matches closely but 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 28 Eca E ADJUST CABLE BRACKET INWARD RESULT Figure 28 Adjustment of Cable Clamp Short D When the travel of the Servo Actuator lever and push pull cable matches closely but the cable overshoots the Servo Actuator lever at both ends of travel moving the cable clamp outwards away from the actuator lever See Figure 29 ADJUST CABLE BRACKET OUTWARD RESULT Figure 29 Adjustment of Cable Clamp Overshoot Note Electrical harness installation for the Servo Actuator is completed in Electrical Installation 58 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Electrical Installation General Electrical Harness Information The EC300 Control System is provided with 13 wiring harness connections example J1 J2 or J3 All 18 connections are not used in all applications Each of these connections is described separately within this manual Most harnesses provided by Twin Disc Incorporated are supplied in 609 mm 2 ft increments Note If a harness needs to be shortened refer to the installation
187. ts provided by the customer The J12 connector contains all contacts and sealing plugs that are required to fill the connector Sealing plugs must be installed into all unused connector contact positions in order to maintain the integrity of the connector This section contains the following sub sections Q Transmission Oil Filter Differential Pressure Switch Wiring Q Transmission Oil Pressure Switch Wiring EC300 Marine Control System Installation Manual 1024168 133 Electrical Installation Twin Disc Incorporated TWIN DISC INCORPORATED Jt J2 J3 J4 J5 6 7 o o o o o o o o o o Hou o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o Sur o o o o o o 2 EJ 2 E 5 5 1w 6 J8 J9 J10 J11 J120 J130 Q Oo HARNESS WIRING ENGINE ROOM SWITCH 1020695 Q0 0 J12 1 SN EER g J12 2 ER 412 3 012 4 5 Q RED GRN STRIPE 9 9 7 GRN RED STRIPE YEL PUR STRIPE 0 97 PUR YEL STRIPE Figure 50 Transmission Switch Harness Wiring Diagram 134 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated E
188. ty of the connector Refer to General Electrical Installation Guidelines before proceeding with this section 1 Connect the red wire to the signal lead for the Troll Enable Solenoid 2 Connect the black wire to the return lead for the Troll Enable Solenoid 3 Route the red and black wires to the EC300 Control Note It may be desirable to complete any other terminations for this harness before securing the harness 4 Remove the locking wedge from the Deutsch connector 5 Insert the red wire into position 8 of the J7 connector Note Refer to the EC300 System Installation Drawings in the Engineering Drawings Section for pin numbering information Note The J7 connector is part of the PWM Driver Harness 6 Insert the black wire into position 11 of the J7 connector T When all pins have been inserted in the connector body reinsert the Deutsch locking wedge into the front of the connector body 8 Ensure that sealing plugs are installed in all empty connector positions 9 Align the harness connector with the J7 receptacle of the EC300 Control and push itin until it snaps into place 10 Secure all harnesses to a supporting structure with clamps or cable ties at 406 mm 16 in intervals 110 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Bridge Signals Harness J8 Installation CUSTOMER SUPPLIED WIRE ECM POWER SUPPLY IGNITION SWITCH 8 1 m
189. ubsections make up this section Single Dual Lever Control Head Assembly Side Mount Control Head Assembly Q Drag Adjustment Procedures 28 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Single Dual Lever Control Head Assembly The Control Head may be either a single or dual lever version This installation procedure applies to both versions 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 operator s 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 1 Select a mounting location that is flat readily accessible permanent and solid 154 9 6 10 STBD LEVER INDICATOR LED 2 PLACES STATION SWITCH STATION SELECT INDICATOR LED 2 PLACES 127 5 0 MINIMUM RECOMMENDED TT MAINTENANCE CLEARANCE Figure 2 Front View of Dua
190. vailable from Twin Disc Incorporated Contact Twin Disc or the nearest distributor for the possible use of other sensors The Speed Sensor is a cylindrical threaded component that screws into either the engine flywheel housing the transmission housing or into a bracket on the output side to sense transmission output speed It is triggered by the crown of the gear teeth when they pass in close proximity to the end of the speed sensor The Speed Sensor produces an output signal 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 This information is either supplied by the engine supplier if flywheel mounted or Twin Disc Incorporated if connected to transmission EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Single output speed sensors are preferred over dual output See Figure 10 however dual output speed sensors are acceptable if the outputs are electrically isolated from each other and have the required electrical characteristics 2 SINGLE OUTPUT DUAL OUTPUT Figure 10 View of Typical Single and Dual Output Speed Sensors The following sub sections make up this section Installation Magnetic Pick up Engine Speed Sensor Installation Hall Effect Pick up Output Speed Sensor Install
191. veco Engine EC300 Engine EC300 Signal F i Engine Connector Engine Signal Description HERR d Power Supply pee es Positive ECM Power Ee Signal E Primary Throttle Position Signal J5 Pin 3 ECM Power Supply B note 1 Negative Battery ECM Power Common The battery positive connection to J5 1 should be switched and from ECM wiring 5 The battery negative connection to J5 3 should be from ECM wiring notbattery bus Voltage Engine Connection Requirements for Voltage Control Table 24 Engine Connections at the Iveco Engine EC300 Engine EC300 Signal Engine Connector Engine Signal Description ERR d Power Supply p Pin 2 e Signal MN Pin B ee Pot Wiper J5 Pin 3 ECM Power Supply S1 Pin A Sensor Return Common Note Connections should be made as close to the Engine Control Unit ECU as possible 6 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Appendix B 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 25 Engine Connections at the John Deere Engine EC300 Engine EC300 Signal Engine Connector Endine Sianal Descrintion Harn
192. witch or engine control panel through the EC300 Control s 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 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 contacts are provided in the Transmission harness connector kit for the neutral start interlock wiring The Neutral start connector pins A and B are for use with commonly available DC engine system voltages 12 24 VDC nominal Pin C is blank and will have a sealing plug installed to maintain the integrity of the connector EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Electrical Installation Install the Neutral Start Interlock portion of the Transmission harnesses as follows See Figure 37 BRACKET TO TRANSMISSION HARNESS MANUAL OVERRIDE 2 START SWITCH 9 NEUTRAL START RELAY CONTACT 14 AWG YELLOW RED OQ pat WIRE PNA p NEUTRAL START a PINB NEUTRAL START RELAY CONTACT COM 14 AWG YELLOW
193. y Positive J13 pin 1 Auxilliary Battery Positive J13 pin 2 Green w Yellow Stripe preferred DC Grounding Conductors or Bonding Only or Green Starter Solenoid Circuits Greater Than 5 Amps Relay Normally Open Single Pole Single Throw SPST voltage rating equal to the starter solenoid voltage contact current rating greater than the starter solenoid current one 1 required per control customer supplied EC300 Marine Control System Installation Manual 1024168 23 Introduction Twin Disc Incorporated 24 EC300 Marine Control System Installation Manual 1024168 Twin Disc Incorporated Component Installation Component Installation General Component Installation Guidelines Ensure a suitable location is chosen for mounting the EC300 Control s Control Head s Twin Disc Display s and any other components EC300 Controls should be mounted near the engines in a location reasonably free from direct splash and spray and protected from mechanical abuse See Appendix A for Environmental Specifications 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

Installation Manual

Contents

Download Pdf Manuals

Related Search

Related Contents