PERFECTPASS MasterCraft 2007 Istruzioni operative

MasterCraft 2007

Troubleshooting

(Electronic Throttle Engines)

System Not Controlling/Surging in both RPM & Speed Mode

You can quickly perform a “Control Test” to confirm whether PerfectPass has proper control of

the ECM. This test is on Page 3 and can be done on a “fake lake” or in the water.

The PerfectPass “Drive by Wire” (DBW) system for new electronic throttle engines

results in a simplified and enhanced version of PerfectPass. From the drivers seat,

PerfectPass operation is virtually identical to the present mechanical systems.

PerfectPass is now comprised of just four main parts:

1. DBW Master Control Module

2. DBW Plug & Play Engine Wiring Harness

3. Plug & Play Display Harness

4. In-Dash Display

5. ALDL Plug

On 2007 MCX and RPT, an “ALDL” ground plug is

required. On the 2006 6.0L and 8.lL, a re-flash of the

ECM is required.

Engine Display

Harness Harness

How it Operates:

The ECM of an electronic throttle engine allows an external device such as PerfectPass

to control the engine rpm using the throttle servo motor when all control signals are valid

and manual throttle lever position exceeds the rpm level request of PerfectPass.

Just three individual wires in the PerfectPass DBW wiring harness connect the speed

control to the engine ECM.

1. The Request Line from PerfectPass requests the ECM to allow PerfectPass to take

control.

2. The Status Line from the ECM indicates PerfectPass now has control of the engine.

The Status Line is the signal that confirms engagement (beeper) and system control

and must be operational for system to engage & control properly.

3. The VGOV Line establishes the engine RPM level as set by PerfectPass.

Problems with PerfectPass should be rare given the few components that now make up

the system. Most troubleshooting will simply involve voltage/continuity testing on the

PerfectPass engine harness.

PerfectPass Control Systems (902) 468-2150 Page 1

Wiring Identification

Signal Color

9-Pin

MATE-

N-LOK

14-Pin

AMP

Seal

16-Pin

Connector

at Engine ECM

MEFI 5

STAT Orange 1 1 D J1-55

VGOV Blue 2 10 E J3-57

RQST Brown 3 12 C J1-30

J1-45

Ground Black 4 14 H

RPM White 5 9 B J1-24

J1-25

Speed Green 6 8

12 Volts Red 7 4

10 14

10 11 12 13 14

12 3 4 5

14-Pin AMPSEAL

(Black)

Back View

Connected to

PerfectPass Module

9-Pin MATE-N-LOK

(White)

Front View

Connected to

MasterCraft Harness

3 1

2007 MasterCraft

DBW En

ine Harness

Problems with PerfectPass Controlling / Not Controlling

Open circuit (bad connection/broken wire) symptoms of a DBW System

Problem #1 RQST Line Open – PerfectPass never takes control in any mode, the engine is

controlled only by the manual throttle handle.

PerfectPass Control Systems (902) 468-2150 Page 2

Problem #2 VGOV Line Open (RQST Line OK) – With the PerfectPass system

control ON, the engine will not go above idle no matter how far the manual

throttle is pushed. With PerfectPass control OFF, the engine is controlled as

normal by manual throttle handle.

Problem #3 STAT Line Open (RQST Line and VGOV Lines OK) – Engine

operates normally with PerfectPass control ON, the engine RPM’s become

limited at speed slightly above system set point, but there is no proper control

and speed remains one or two mph above setpoint. The PerfectPass does not

beep to acknowledge engagement and the underline characters never appear.

Problem #4 PerfectPass Does Not Engage The “S” (Status Line) never

appears during control test. Check “ALDL” ground plug. If not connected

properly, ECM will never give PerfectPass control. (Connects where “Diacom”

plugs into harness).

Problem #5 System Surges During Operation and During Control Test as

Described Below Reason – Poor ground. MasterCraft has had ground issues

on the ground wire for PerfectPass. Check all wires at ground bar and tighten as

required.

TESTING (CONTROL TEST)

To enter the Test Mode, press the Menu & UP Keys together and scroll down

and enter Device Test. Rope Test will first appear, press menu to enter

Servo/Control Test. This test can be performed in the shop or on water.

CONTROL 1.0

R RPM

In this test mode. Perfect

Pass requests control of the

ECM and maintains a

constant 1-volt level.

SERVO TEST

CONTROL 1.0

R RPM

SERVO TEST

CONTROL 1.0

R S

RPM

In this screen, the “S”

appears which indicates the

system is working properly.

TEST

Make sure system is in ON Mode prior to starting test. You must have an RPM

reading on PerfectPass display or it will never work properly.

With engine ON, lock the gearshift in neutral and advance the throttle

handle to 1800 RPM. When all is working correctly an “S” will appear next

to the “R” and the engine will hold at approximately 1730 RPM (it may

surge up and down by about 100 rpm). If the RPM is holding at 1730 but

the “S” is not on the display, there is a problem with the “STAT” line.

PerfectPass Control Systems (902) 468-2150 Page 3

If you lower the 1.0 volt setting by pressing Down Key to .7 volts, the engine rpm

will drop to about 1420 and hold reasonably steady.

(If you perform this test on the water on the fly, it should hold very steady at

about 1730).

If the RPM does not hold at 1730 the “RQST” line may not be connected. Either

the Request Line or the VGOV Line has lost continuity.

If the engine holds RPM at approximately 1730, but the S does not appear on

screen, then check continuity of the Status Line. Voltage Testing in Control Test

Mode. If the test fails, perform voltage checks.

Voltage Test (Control Test Mode)

These measurements are taken in Control Test Mode with system ON and R

must be on screen. This test will confirm whether PerfectPass and the ECM are

properly connected.

Locate the 14-pin engine connector on the PerfectPass Module or ideally the 9-

pin MAT N LOK connector on PerfectPass harness. You will need to apply test

tee connectors or insert small test pins beside the wires as they exit the

connector to be able to measure the voltage present on each wire. These are

taken while in Control Test, with “R” on screen.

-Measure the voltage on the RQST (request line) which should measure

less than 1 volt. (0 to 1 volt) Engine running or not running.

-Measure voltage on VGOV (vgov line) which should measure about 1 volt.

(.8 to 1.2 volts) Engine running or not running.

-Measure voltage on STAT (stat line) which will be 10 + volts when Sis not

on display. (When engaged and working properly this pin at ECM is

grounded and voltage will be less than 1 volt.) Engine must be running for any

measurement on STAT line.

-Press the OFF key and the “R” will disappear. Now measure voltage on

RQST wire again which should now measure more than 4.5 volts, this

confirms proper operation of PerfectPass Request driver and ECM

connection.

Other Measurements:

With control OFF and R not on Screen:

RQST Line – 4.5 V

VGOV Line – 4 V +

STAT Line – 10 V +

PerfectPass Control Systems (902) 468-2150 Page 4

Trouble Shooting DBW

Problem – System surges in all modes, including control test.

Check – Poor ground connection for PerfectPass main ground wire.

- Perform Open circuit voltage tests on vgov, stat & rqst which may lead

you to a incorrect ECM wire location or harness issue.

Problem – Customer indicates system does not engage.

Check – Perform a CONTROL TEST. If it engages & holds properly during

control test, check the adjustable parameters (KDW, NN and Control Settings

CS/CR) If it does not engage, perform Open Circuit Tests.

Make sure there is an rpm reading on screen or PerfectPass will never operate

properly.

Problem – No speed reading on PerfectPass Display

Check – If your boat speedometer is O.K., check paddle wheel signal on green

wire coming into the Master Module on Amp Seal Connector. If paddle is spun

slowly, you should see 0 volts / 12 volts as wheel slowly turns. As wheel is spun

quickly, you will see an average of 5 volts.

(If voltage is good, perform a “System Reset”).

If MasterCraft speedometer is not reading, it must be corrected and PerfectPass

will likely then read properly.

Problem – No rpm reading on PerfectPass display

Check – The RPM signal wire at the Amp Seal connector coming into Master

Module. With engine off you should see about 9 volts. (With engine running, you

should see a normal tach pulse signal) If no signal, check the pin at ECM. The

system will never control properly in any mode without an RPM signal.

Problem – PerfectPass in Wakeboard mode is set at 22 mph and digital

speedometer shows 22, but actual speed is 24.

Check – Use Menu Key to highlight Menu Arrow Icon and press Down Key to

reach “SPEEDOMETER ADJUST”, quickly press down key several times and

lower speed by 2 mph. All Wakeboard speeds now calibrated.

Problem – Key is on, but PerfectPass screen does not become active and

show data.

Check – PerfectPass requires 12+ volts for start up. Check voltage on red wire

(12 v) power source to Master Module. If backlight is ON, check screen contrast.

Check screen contrast – Press Menu & UP Keys together, then press UP Key a

couple of times. Does data re-appear?

PerfectPass Control Systems (902) 468-2150 Page 5

Problem – Button on PerfectPass Display does not work.

Check - If system was just installed, unplug Display from harness and inspect all

brass pins on connector to ensure they are inline. If problem occurs after much

use, the Display will require repairs by PerfectPass.

Problem – In Wakeboard/Trick mode, system sluggish or exhibits some

surging.

Check – Inspect paddle wheel. If paddle appears OK, go into adjustable

parameters by highlighting menu arrow icon, press UP and Wakeboard will

appear. Press DOWN for settings.

KDW will appear. This value represents how firm the system will control. Heavily

loaded boats may need higher settings. (Typical values 80 – 200)Press Menu to

proceed.

NNW will appear. This is the filter factor of paddle. The higher the value, the

more filtering is done prior to making a speed change.(Typical values 80 – 180)

Problem – The boat accelerates past set speed too far in Wakeboard Mode

before settling in.

Check – Go to “Control Settings” and lower the “CS” value.

Control Settings CR / CS)

These are engagement values which are adjustable to allow a customer to fine

tune engagement performance if necessary. This may be required due to a prop

change, unusual ballast loads or operating at extreme elevations.

These are found under “CTRL SETTNGS” in sub menu by pressing Menu & Up

Keys together.

CS – Control the engagement in paddle wheel speed based modes including

wakeboard.

If it is set too low, the system may not go fast enough to engage, or it will engage

& then disengage. If it is set too high, it may overshoot the set speed by several

mph before beeping and taking over. Factory setting is 750. (Range is 735 – 900)

CR – Is the same as CS except it controls engagement of the RPM Based

Modes such as slalom. Factory setting is 1940. (Range is 1900 – 2100) It would

be rare to see this value require adjustment.

Software Adjustments

System Reset – To reset the entire system back to original factory values, press

& hold ON/OFF & MENU Keys together as you turn key on to power

PerfectPass. Continue holding for a few seconds until [ System Reset ^ = Yes ]

appears. Then simply answer questions as they appear.

PerfectPass Control Systems (902) 468-2150 Page 6

Switching WakeboardPro <> DigitalPro – If you system was selected

incorrectly, perform a system reset. As you proceed through this process, you

will be asked [Wakeboard Only ^ = YES]. Answer YES for WakeboardPro, and

NO for DigitalPro

Engine Selection – On initial start up or during a system reset, PerfectPass will

ask if you have a standard 5.7 litre engine. This will appear as [ 5.7 / MPI ^ =

Yes ] This means press UP for 5.7 and DOWN for Big Block 6L or 8.1L.

To confirm if correct engine was selected, press Menu & Up Keys together to get

into back ground screen and go to “System Settings”. Following battery

voltage, etc you will see which engine was selected. If incorrect, perform a

system reset.

(An incorrectly selected engine can cause unsettled control in rpm mode only)

WakeboardPro to/ DigitalPro – The Master Module for both systems are

identical. The only difference is in the way they were initialized, i.e. as a

DigitalPro or WakeboardPro. You can change the way it was set by performing a

system reset.

PerfectPass Control Systems (902) 468-2150 Page 7

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