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Teleflex Hydraulic Engine Controls Workshop Manual




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and Service
04 SERIES
CAUTION
THIS SYSTEM DOES NOT USE OIL
Use 5050 by volume water
DO NOT USE STOPLEAK TYPE MANUAL SHOULD BE KEPT ON BOARD YOUR VESSEL
182042 Rev5
Page 1 of 36 Pages 105
LIMITED WARRANTY POLICY
TELEFLEX MORSE TRADEMARK Morse warrants that its manufactured products shall be free from defects in materials and workmanship for
a period of twentyfour 24 months from the date of original manufacture Teleflex Morse will rebuild or replace at
its option all products of its manufacture proven to its satisfaction to be defective within such warranty period and
returned to Teleflex Morse Sarasota Florida charges prepaid Teleflex Morses sole obligation and
buyers exclusive remedy hereunder is limited to such rebuilding or products may be returned to any Teleflex Morse factory unless the prior consent
for said return shall have been
obtained from the Teleflex Morse Customer Service Department in Sarasota Florida This Limited Warranty does not
cover shipping costs to the Teleflex factory any costs for labor or otherwise related to or replacement or any other costs of any nature without
consent by Teleflex products and accessories made by others are warranted only to the extent of original manufactures warranty
to Teleflex Morse
This warranty shall not apply to acts of God war or civil insurrection nor shall it apply to products which in the sole
judgment of Teleflex Morse have been subjected to negligence abuse sanctioned racing events tampering alteration nor due to improper installation
operation maintenance or storage nor to other
than normal application use of service including but not limited to operational failures caused by foreign materials
in the system or operation at pressures in excess of recommended shall be solely responsible for determining suitability for use of Teleflex Morse
Products Teleflex Morse
shall not in any event whatsoever have any liability with respect to such FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS
IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF AND
FITNESS FOR A PARTICULAR PURPOSE TELEFLEX MORSE SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONTINGENT DAMAGES TO CONSUMERS THIS LIMITED WARRANTY IS
EXTENDED TO THE COMMERCIAL AND INSTALLERS OF TELEFLEX MORSE PRODUCTS ONLY THE WILL
EXTEND WARRANTY COVERAGE TO YOU WHICH COVERS TELEFLEX MORSE PRODUCTS WARRANTY TO SUCH CUSTOMERS DEALERS AND INSTALLERS IS INTENDED TO SUPPORT THE
WARRANTY EXTENDED TO CONSUMERS
Teleflex Morse Electrical Systems
6980 Professional Parkway East
Sarasota FL 342408414
Phone 9419071000
FAX Page 2 of 36 Pages
Table of MORSE ENGINE CONTROL SYSTEM
WHY IT WORKS 4 PARTS LIST FOR INSTALLATION 4 System Parts List Nylon 14
COMPONENT INSTALLATION 4 System Parts List Copper 17
Sender Installation 4 COMPONENT CROSS SECTIONS 18
NEUTRAL SAFTY Throttle Slave Installation 6
Clutch Slave Installation 8 TEMPLATES 25
Valve Installation 9 CDF04 MOUNTING PLATE 27
TUBING INSTALLATION AND CONNECTION 10 TUBING DIAGRAMS 28
Rules for Routing Tubing 10
Plan ITwin Engine One Station 28
Install Tubing Between Senders and Slaves 11
Plan IITwin Engine Two Station 29
Plan IIITwin Engine Three Station 30
FILLING AND BLEEDING SYSTEM 11
Filling the System 11 Plan IVTwin Engine Four Station 31
Bleeding the System at Slave 11 SUPPLEMENTAL THROTTLE CONTROL
Bleeding the System at Senders 12 CIRCUITS 32
SYSTEM FLUID 12 Plan IS 32
MAKING THE SYSTEM OPERATIONAL 12 Plan IIS 32
Synchronizing the Controls 12 Plan IIIS 33
Connecting Engine Controls 12
Plan IVS 33
OPERATION 34
Throttle Senders 12
Clutch Senders 13
Maintenance 13
Page 3 of 36 Morse Engine Control System with a pilot check valve which locks the throttle slave in the
Why it Works position it has taken in response to the sender The throttle
slave can be driven only by the sender it cannot drive the
The movement of a senders control arm transmits mechani sender
cal energy to an internal piston which in turn pushes hydrau
lic fluid through the other corresponding control senders and Extra hydraulic fluid and a pressure head for the system is
single control slave This movement of hydraulic fluid drives maintained by the systems reservoir The reservoir is charged
a piston in each of the senders and slave The movement of with 80 psi of air over the hydraulic fluid within it This keeps
the individual pistons causes shaft rotation in each unit the entire system under pressure at all times and prevents a
vacuum from existing on the back side of any piston when the
The piston in each of the individual control senders and system is has two small valves which are opened when the
piston reaches the end of its stroke allowing additional fluid Fluidflow to and from the reservoir is regulated by a charging
to pass through the system By allowing this flow of hydraulic valve located on the bottom of the reservoir This valve is
fluid the controls may be synchronized with each other by necessary to keep the system under pressure and to pre
moving the control arm at one control station from stop to vent excessive pressures caused by the expansion of fluid
stop when the fluid becomes warm
The control slave is very similar to the control sender except Nylon tubing is used to pipe the system for two reasons 1
the body is a rectangular block An overtravel bungee is ease of installation 2 nylon tubing expands and in the linkage between the slave
arm and engine control in very much the same manner as the hydraulic fluid a most
arm to assure that the slave can reach the end of its stroke important factor The expansion and contraction of the
in each direction The slave for the transmission has a built tubing reduces drift of the controls as temperature changes
in detent mechanism to indicate neutral position thereby helping to keep all the components of the system
synchronized The tubing is virgin nylon which has been
On most engines the throttle exerts considerable force to heat and light stabilized and contains no plasticizers The
return to the idle position Each throttle slave is equipped burst pressure of the tubing is in excess of 1200 for Installation
Use Loctite hydraulic sealant on all NPT fittings prior to
installation DO NOT use teflon tape or pipe dope
CAUTION Sender Installation
Dirt and foreign matter in the hydraulic system 1 Locate sender on panel so that the control arms arc will not
cause damage and malfunction It is extremely interfere with the ships wheel or panel Be certain that
important to keep tubing and fittings clean access is available to the small bleeder screw at the top of
when installing and connecting components each sender head
Cut tube cleanly and tape the open end while The design of the new Engine Control T handle requires a
running tubing minimum distance between control heads to provide ad
equate handle clearance when two sets of controls are
Before installation is started the parts list should be checked mounted side by side See Figure 1
to verify that a complete system has been received Parts NOTE This minimum distance does not apply to are located on pages 16 and 17
tions using the optional knob style control handles
It is advised that all system components be installed send 2 Using the template provided in the appendix mark and cut
ers shift throttle slaves and reservoir prior to running the a hole for the sender Figure 29 is the proper template for the
system tubing This allows the tubing to be run between two single head and Figure 30 for the side by side points with less chance of an
error mounting Refer to Figure 1 for minimum distance it become necessary for the tubing to be strung first when
mounting two sets of controls side by side
a system of marking the different tubing runs should be used 3 Drill 716 holes in the panel for the mounting bolts
4 Set sender in place and check to see if all mounting holes
match up
Component Installation
5 The senders ports are tapped 14 NPTF Suitable have red plastic plugs installed in their ports to ers must be installed to accept the tubing
used It is more
keep out foreign matter As you remove these red plastic convenient to install these adapters prior to mounting the
plugs replace them immediately with the proper adapter senders Instructions for copper tubing installations are on
then install the red plugs into the adapters until you are ready page 12
to connect tubing
Page 4 of 36 Pages
6 Secure senders per Figure 2 for single head or Figure 3
NOTE for side by side mounting
If the area under the control panel is too confined to
7 The senders handle position may be set within limits by
allow the tubing to be connected with moderate
loosening the tightening screw using a 14 allen wrench in
ease do not secure the sender at this time Proceed
the lower end of the arm and then rotating the arm as desired
with the installation of the remaining senders per
and resetting the screw After the arm is set it will have a 115
Steps 1 thru 5 above The sender may be secured
maximum arc
after the tubing has been connected to it
8 Secure the remaining senders per Steps 1 thru 7
NOTE
The minimum distance does not ap
ply to installations using the knob
style control handles
Figure 1 Mounting T Handle Controls Side by Side
Figure 2 Single Head Sender Figure 3 SideBySide Senders
Page 5 of 36 Slave Installation Steps 1 thru 8 apply to both ST04 and ST06 Systems
NOTE 1 Secure the mounting bracket to the engine A suitable
The standard Teleflex Morse System bracket must be fabricated
MC04 uses the ST06 Integrated Throttle
2 Secure the throttle slave to the mounting bracket using
Slave You may have chosen to order a
3816 mounting bolts
nonstandard system which includes the
ST04 Throttle Slave and STV10 Lockout 3 Install a lock nut and bungeeball joint on the end of a
Valve Depending on which system you 1420 stainless or brass threaded rod
have follow the corresponding installa
4 Position the throttle slave to its midstroke and connect the
tion instructions in this section
bungee end of the 1420 threaded rod to it not provided
5 Position the engines throttle arm to its midstroke Morse throttle slaves must be mounted so that at the mine the length of threaded rod
required and cut off of both the engines throttle arm and the slaves arm they are 1 In the same plane 2 parallel to each
other and 3 right angles will be formed between the con 6 Connect a lock nut and a balljoint to the engines linkage and each arm See
Figure 4 arm and the free end of the threaded rod
If these criteria are met an ideal installation will result 7 Find the proper hole in the slave arm to provide a linkage
length combination that will allow idle to full throttle on the
A spring bungeeball joint assembly is furnished with each engine using all but a few degrees of slave arm travel in each
throttle slave It is installed in the slave armto throttle direction By adjusting the balljoint and bungee a fine
linkage according to Figure 4 It allows up to 316 slave adjustment in both directions can be achieved Be sure the
arm overtravel in each direction This overtravel lets the slave arm can overtravel through the bungee to the end of
slave cylinder travel its full stroke and still provide full travel its stroke in each direction
to the throttle arm You must use almost all of the slave travel
or about 75 to operate the throttle The slave must go full 8 After determining the correct rod length securely lock the
stroke in each direction in order to synchronize the system balljoint and bungee assembly to the threaded rod with lock
nuts provided Disconnect the linkage from the throttle slaves
The throttle slaves arm may be set to any desired position by the tightening screw using a 316 allen wrench
in the lower end of the arm and then rotating the arm as ST06 Installation Only
desired and resetting the screw After the arm is set it will
have a 78 maximum arc 9 To prevent engine retard due to governor spring or
vibration a pilot check valve is built into the ST06 Throttle
CAUTION Slave
The Throttle Slave must not be mounted to
any surface exceeding 220 F 103 C If NOTE
mounting in a hot spot is unavoidable the This builtin valve will lock the slave arm in place
slave must be insulated from the heat allowing it to be moved only by the sender
10 Locate a tee and bleeder valve on the throttle slave and
install suitable adapters to accept tubing per Figure 5
NOTE
Tube connectors are installed on the tubing
per instructions under Tubing and Connection on page 8
11 Verify all fittings installed have been tightened Repeat
these throttle slave installation procedures for the second
engine
ST04 Installation Only
9 To prevent engine retard due to governor spring or
vibration a separate STV10 lockout valve is used with the
ST04 Throttle Slave
Figure 4 Throttle Slave to Throttle Arm Page 6 of 36 Pages
Figure 5 ST06 Integrated Throttle Slave with Tee and Bleeder Valve NOTE
NOTE
If the throttle slave is in a limited space it may Tube connectors are installed on the tubing
be removed from the bracket during the lock per instructions under Tubing out valve installation The STV10 Lock Out
and Valve must be plumbed as shown in Figure 6
The lockout valve will lock the slaves arm 11 Using a short piece of tubing provided connect the open
and allow it to be moved by only the sender port on the tee to the S2 port on the lockout valve See
Figure 6 See Figure 16 for Copper Tubing connection
The check valve and slave must be mounted in
Plug open fittings at the V1 and V2 ports
close proximity to one another If theyre not
abnormal locking action and poor performance 12 Verify all fittings installed have been tightened Repeat
will result these throttle slave installation procedures for the second
10 Install the lockout valve on the throttle slave and it using clean lubricant or Loctite hydraulic sealant on
the threads Install appropriate adapters to accept tubing
Refer to Figure 6
CONTROL ARM MAY BE ROTATED
TO ANY POSITION ON SHAFT
Figure 6 ST04 Throttle Slave with STV10 LockOut Valve
Page 7 of 36 Pages
Clutch Slave Morse clutch slave must be mounted so that when the
engines transmission is in neutral and the Morse arm is at its midstroke both arms will be 1 in the
same plane 2 parallel to each other and 3 right angles will
be formed between connecting linkage and each arm see
Figure 7
Figure 8 Detent Ring Location
5 Secure detent ring in this position by tightening the set
screw
6 Install a lock nut and ball joint on the end of the 1420
stainless steel or brass threaded rod not provided
Figure 7 Proper Clutch Slave to Throttle Arm 7 Position the clutch slave to its midstroke and connect the
Installation ball joint end of the 1420 threaded rod to it
8 Position the engines clutch arm to neutral determine the
NOTE proper length of the threaded rod required and cut off the
The clutch slaves arm may be set to any excess
desired position by loosening the tightening 9 Install a lock nut and ball joint on the other end of the
screw using a 316 allen wrench in the lower threaded rod
end of the arm Rotate arm as desired and
reset the screw After the arm is set it will have 10 By locating the slave arm balljoint in its proper hole and
a 78 maximum arc adjusting both ball joint on the threaded rod find the correct
length of linkage that will allow both full forward and full
reverse on the transmission for full throw on the clutch slave
1 Secure mounting bracket to the engine A suitable bracket
must be fabricated
11 After determining the correct linkage length securely
2 Secure the transmission slave to the mounting bracket
lock the balljoints to the threaded rod with locknuts pro
using the 3816 mounting bolts
vided Disconnect the linkage from the clutch slaves arm
3 Set the transmission in the neutral position and the clutch
12 Locate and secure in place two tees two bleeder arm at its midstroke
and two tubing adapters per Figure 9
4 Loosen the set screw in the detent ring on the clutch slave
13 Repeat this clutch slave installation procedure for the
and rotate the detent ring to the full detent position To locate
second engine
the detent ring see Figure 8
Figure 9 SS04 Shifter Slave Bleeder Valve and Tubing Adapters Installation
Page 8 of 36 Installation
R04 Reservoir Installation
NOTE The reservoir should be located in the ships engine room in
The standard Morse System MC04 uses an accessible location In locating the reservoir the following
the R13 Integrated Reservoir You may conditions should be met
have a different system which includes the
1 Reservoir must be in a vertical position with pressure
R04 Reservoir and an MCV04 Charging gauge on top
Valve Depending on which system you
have follow the corresponding installa 2 Sight glass must be visible and easy to read
tion instructions in this section 3 Pressure gauge be visible and easily read
4 The operator must have easy access to the air filler valve
NOTE on the top of the tank
If your installation includes two reservoirs 5 The operator must have easy access to the fill port on top
one for each engine or is a singleengine of the tank
installation special plumbing will required 6 Reservoir must be mounted to the bulkhead wall or post
which is not covered in this manual Con using either bolts or screws
tact Teleflex Morse for this information NOTE
There are two ports located on the bottom of the
reservoir One is plugged and can be used as a
R13 Reservoir Installation drain port The other has a filter assembly and is
used for connecting to the system See Figure 11
The reservoir should be located in the ships engine room in
an accessible location In locating the reservoir the should be met
1 Reservoir must be in a vertical position with on top
2 Sight glass must be visible and easy to read
3 Pressure gauge must be visible and easily read
4 The operator must have easy access to the air filler valve
on the top of the tank
5 The operator must have easy access to the fill port on top
of the tank
6 The operator must have easy access to charging valve on
bottom of Reservoir must be mounted to the bulkhead wall or post Figure 11 Ports on Bottom of R04 either bolts or screws
MCV04 Charging Valve Installation
NOTE
The charging valve should be located in the general vicinity
The charging valve is located on the bottom of of the reservoir
the reservoir The plug located on the charg
1 Install appropriate adapters for the tubing used For port
ing valve holds the fluid filter in place This
locations see Figure 12
plug and filter can be removed to drain the
reservoirs fluid See Figure 10 2 Mount the charging valve using two screws or bolts
Figure 10 Charging Valve on R13 Reservoir Figure 12 MCV04 Charging Valve
Page 9 of 36 Pages
Tubing Installation and Connection Rules for Routing Tubing
CAUTION NOTE
Dirt and foreign matter in the hydraulic The instructions and illustrations in this section
system cause damage and malfunction It apply to nylon tubing ONLY Information on
is extremely important to keep tubing and use of Copper Tubing may be found on page 12
fittings clean when installing and connect 1 Keep tubing free of dirt and foreign matter
ing components Cut tube cleanly and
2 Keep tubing away from batteries since battery acid is
tape the open end while running tubing
corrosive to the tubing
3 Tie the tubing down at regular intervals using tubing installation plans are provided in the Tubing ties and Section later in this manual
4 Do not allow tubing to become kinked If it does replace
that particular run of tubing
1 Twin Engine One Station Plan I
5 String tubing so that it will not interfere with hatchways or
2 Twin Engine Two Station Plan II machinery removal
3 Twin Engine Three Station Plan III 6 Use only nylon tubing supplied with system from Morse
Assemble tubing connectors on every tube end as described
4 Twin Engine Four Station Plan IV
and illustrated in Figure 13
Before beginning to run the tubing it is recommended that
each tube be assigned a number which is marked on both
NOTE
ends and marked at the origin and desti The roll of tubing should be laid in a horizontal po
nation of that tube These designations should also be sition and moved as little as possible to on the chosen plan diagram for future
reference kinking and 1 Cut the tubing with a ra 5 Force the sleeve 530045
zor or very sharp knife leav into the end of the tubing by
ing the cutoff end as square pushing it against a clean
as possible flat surface Thread the lock
ring 530025 toward the end
of the tube as far as pos
sible by hand Leave suffi
cient room between the lock
ring and the end of the
tube to install theOring
2 Slip the nut 530015 over
the tubing end The nut
should slide freely
6 Install the 0ring 211010
3 Push the lock ring over the end of the tubing
530025 over the end of the and against the lock ring
tubing and move it back at 530025
least one sleeve length from
the end The lock ring may
slide on freely or require
slight pressure and screw
on action The lock ring
has a left hand thread
4 Insert the sleeve 530045
in the tube until it just makes
contact all around
Figure 13 Assembling Tubing Connectors
Page 10 of 36 Tubing Between Senders and Slaves 5 The system will now begin to fill with fluid As the system
See Pages 2227 for Plumbing Circuits fills the fluid level in the reservoir will become lower When
the fluid level is between 1 to 2 inches from the bottom of the
1 Locate the tubing roll in a convenient location
sight glass release the pressure and refill the tank as in Step
2 Starting at the highest control station begin running tubing 4
from the upper tubing port of the right most sender to its
6 Repressurize the system and repeat this procedure of
connecting point as shown on the diagram
filling the reservoir as required until no fluid drop is noted At
this point the system is filled and must now be bled
NOTE
Tubing may be run from the sender to connect 7 Check entire system for leaks and correct as required
ing point or from connecting point to sender
whichever is easier Bleeding the System at Slave
3 Secure each end of the newly run tube by Inserting the NOTE
tube end assembly into the proper adapter 530175 pre The bleeding procedure is much easier for two
viously installed in components Tighten down only until people to perform than one One to keep the
there is firm resistance felt on the wrench reservoir filled and under pressure while the
other one bleeds the system
4 Run the tubing from the lower port of the same the previous steps 1 Fill the reservoir as required
5 Progress leftward across the control panel until all lines
have been run and secured Then go to the next lower station NOTE
and run tubing from it in the same manner as it was from the Verify that linkage is disconnected and
upper station senders handles are free to move
6 If the boat has more than two stations continue running While bleeding move the slave arm and verify
tubing from them in the same manner still following the that the piston has diagram
2 Using the bleeder tube provided and a clean empty
7 At this point all tubing should be run and connected Now container insert the bleeder tube in the bleeder valve at one
secure tubing using ties and clamps This should be done side of a slave Open the bleeder valve about one turn and
prior to filling the system bleed system until no air bubbles are evident in the flowing
fluid When the fluid is clear close the bleeder valve During
NOTE the bleed operation maintain the system pressure above 60
When securing tubing with clamps do not psi and the fluid level in the sight gauge above the twoinch
over tighten clamps or ties as mark Should the fluid level drop below two inches close the
will crimp the tubing causing poor bleeder valve and release the pressure from the system
system operation Refill the reservoir with the fluid that has been bled off
repressurize the system and continue bleeding Bleed long
enough that no air or foam remains in this branch of the
Filling and Bleeding System system Draw at least a full reservoir of fluid thru each side
Filling the System of each circuit
1 Verify that all sender arms are free to traverse their
NOTE
complete arc
Since there are two positions at each slave to
2 Verify that all bleeder valves on the throttle and clutch be bled and four slaves the reservoir must be
slaves are closed and linkages disconnected filled at least 8 times during the bleed opera
tion The fluid which has been bled off should
IMPORTANT NOTE be used to refill the reservoir
See section onSystem Fluid for fluid speci
3 Tighten bleeder valve after the bleed operation
fications on Page 10
4 Bleed the second port of the slave as described in Steps
3 Remove fill port plug from the reservoir and fill the 1 2 and 3
reservoir within one inch of the top of the sight tube with 5 Repeat steps 1 thru 4 with a second person at the sender
MCO03 water glycol fluid Replace fill port plug moving the handles back and forth slowly five to ten times
4 Pressurize reservoir to 100 10 psi through the air filler 6 Continue performing the preceding five steps for each
valve in the top of the reservoir remaining slave
Page 11 of 36 the System at Senders The ethylene glycol chosen for use should be as pure no
additives as possible mixed with bleeding system at each slave bleeder valve each
water then filtered to assure its purity NEVER USE STOP
sender must now be bled A small amount of air will be
LEAK TYPE at the high point in each sender head
Filtration is accomplished by passing the fluid through a 5
1 Refill reservoir if required fill tank at this time to between
micron filter before using in the system
12 and 23 full and leave about 100 psi on the Field service prefiltering can be
accomplished by using a
Mr Coffeeor equivalent paper filter placed in a funnel and
NOTE then pouring the ethylene glycol solution through it
Place a rag over the bleeder hole on the
One paper filter will filter approximately 12 gallon of
sender to prevent fluid from spilling on the
ethylene glycol solution
console
The MCO03 fluid provided by Morse is Very slowly open the bleeder plug using a 316 allen mixed and filtered to assure its purity and
is ready for use
wrench See Figure 10 for location of bleeder screw
Making the System Operational
Synchronizing the Controls
The system is now operational except for synchronizing the
controls
1 Go to one control station and move each senders arm
from stop to stop 3 to 5 complete cycles Each sender should
be synchronized at this time
NOTE
This can be performed at any
of the control stations
2 If the position of the senders handle requires an awkward
motion by the user adjust the handle by loosening the set
screw using a 14 allen wrench and rotating the handle so
Figure 14 Bleeder Screw that the user has more of a direct pushpull motion Do not
position handle so that it binds against the sender body at
3 Allow the fluid to bleed out until the fluid is clear without air either end of its
3 Should one of the controls not come into Tighten the bleeder screw after bleeding go to that station which is out
of and perform
Step 1
5 Repeat Steps 1 to 4 above for each sender
Connecting Engine Controls
6 The reservoir level should be between 12 and 23 full If
the level is below this the reservoir should be filled to this 1 Connect throttle linkages to the throttle slave Repeat for
level Verify that pressurize in the reservoir is between both engines
80 and 85 psi 2 Connect clutch linkages to the clutch slave Repeat for
both Fluid NOTE
The fluid recommended for use in the system is a 5050 For any operational problems at this by volume of distilled water and
ethylene glycol The consult the trouble shooting section
type of ethylene glycol used is very important for of your system and especially the valve Some additives especially silicone addi are
very thick in consistency and will clog the elements Throttle Senders
in the valve If this occurs your system will
be unable to maintain between sender and Forward Motion Increases
Aft Motion Decreases Throttle
Page 12 of 36 Pages
NOTE
When working on engine and operating the Prior to starting engines both throttles and
engine throttle arm by hand disconnect clutches should be synchronized This is
throttle linkage from the control slave If done by moving the senders control arm in
linkage is not disconnected the pilot check a complete cycle fore and aft stop to stop
valve will not allow a throttle retardation This needs to be done at only one station
unless a sender arm is actuated to de
crease the Position Forward Position Neutral
Aft clutch and throttle sender bodies are made of 6061T6 aluminum which has been anodized To clean them a warm should be used Do not attempt to use
an abrasive compound as is done when shining brass
Maintenance Schedule
Every 30 Days
1 Check hydraulic fluid level should be between 12 and 23 full on the sight glass
2 Check system pressure pressure should be between 7090 psi see note below concerning reservoir
pressure
NOTE
The reservoir pressure will vary between 7090 psi due to temperature changes There is no reason to become
alarmed unless the pressure drops below 70 psi then the system should be repressurized to 80 psi If the
pressure loss is over a relatively short period check for air leakage Should the pressure loss from full pressure
to minimal operation pressure be over an extended time period just repressurize the system This extended
pressure loss is normal and may be compared to the same type pressure loss one experiences with a good
set of automotive tires after an extended time
Every 6 Months
1 Check fluid level in the reservoir level should be approximately 12 to 23 of sight glass
2 Check system pressure it should be between 7090 psi Consult the note above about system pressure
change
3 The system is but the balljoints on control linkages should be oiled
4 Check mounting bolts on the control slaves clutch and throttle to verify that vibration has not loosened
them
5 Check lock nuts on control linkages verify that they are tight
6 Check fitting connections for any leakage
7 Where tubing runs are exposed and are bordering heavy traffic areas check for damage and repair as
required
Page 13 of 36 Pages
Copper Tubing Installation and these instructions in conjunction with this on Tubing Installation Page 8
1 Use 516 OD soft copper refrigeration type tubing
2 Use standard 45 flares for fittings Be careful to make
good flares and do not allow dirt or chips into the system
DO NOT use pipe dope on fitings Refer to cautions in this
manual
3 All tubing runs outside the engine room should be run
together Inside the engine room lengths of tubing on each side of
the same circuit should be essentially the same length
5 If desired short lengths maximum 24 of Aeroquip
26515 Hose with 4015B Fittings may be used for the
transition from hullmounted to tubing
This will prevent of the copper from
flexing and vibration Again make sure no dirt or chips
are introduced into the hose ends or damage and
malfuntion of the system may occur
Figure 15 Charging Valve on Bottom of
The following figures illustrate the proper connections for R13 Integrated tubing installation between components of the En
gine Contol System
Figure 16 ST06 Integrated Throttle Slave
Page 14 of 36 Pages
Figure 17 ST04 Throttle Slave with STV10 LockOut 18 Ports on Bottom of R04 Reservoir Figure 19 MCV04 Charging Valve
NOTE
The Tube Fitting and
Bleeder Valve may be
reversed on the Pipe Tee
to allow for easier tube
connec tion
Figure 20 SS04 Shifter Slave
Page 15 of 36 Pages
System Parts List
Nylon Tubing SINGLE ENGINE
TWIN ENGINE
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
COMPONENT Reservoir Charging Valve 1 1 1 1 1 1 1 1 1
1 1 1
MCVF04 Charging Valve Fittings 1 1 1 1 1
1
MCVF05 Charging Valve Fittings 1 1 1 1 1 1

CLB4 or ControlLeft Ball Handle or 1 1 2 2 3 3 2 2 4 4 6
6
CLT4 ControlLeft T or ControlRight Ball Handle or 1 1 2 2 3 3 2 2 4
4 6 6
CRT4 ControlRight T Dual Mounting Plate 1 2 3 2
4 6
CF04 Control Fittings 2 2 4 4 6 6 4 4 8 8
12 12
SS04 Shift Slave 1 1 1 1 1 1 2 2 2 2
2 2
SSF04 Slave Fittings 1 1 1 1 1 1 2 2 2 2
2 2
ST06 Throttle Slave Double 1 1 1 1 1 1 2 2 2 2
2 2
Pilot Check Valve
STF12 Slave Fittings 1 1 1 1 1 1 2 2 2 2
2 2
ADDITIONAL REQUIREMENTS NOT INCLUDED IN Extra Fittings Package 1 1 1 1 1 1 1
1 1 1 1 1
MCT02 100 Nylon Tube 2 2 2 2 3 3 3 3 4 4
MCT05 500 Nylon Tube 1
MCO03 Hydarulic Fluid 2 2 2 2 3 3 2 2 3 3 4
As Required
Page 16 of 36 Pages
System Parts List
Copper Tubing SINGLE ENGINE
TWIN ENGINE
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
ll H
COMPONENT Reservoir Charging Valve 1 1 1 1 1 1 1 1 1 1
1 1
MCVF10 Charging Valve Fittings 1 1 1 1 1
MCVF11 Charging Valve Fittings 1 1 1 1 1 1
CLB4 or ControlLeft Ball Handle or 1 1 2 2 3 3 2 2 4 4 6
6
CLT4 ControlLeft T or ControlRight Ball Handle or 1 1 2 2 3 3 2 2 4
4 6 6
CRT4 ControlRight T Dual Mounting Plate 1 2 3 2
4 6
CF05 Control Fittings 2 2 4 4 6 6 4 4 8 8 12
12
SS04 Shift Slave 1 1 1 1 1 1 2 2 2 2 2
2
SSF06 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2
2
ST06 Throttle Slave Double 1 1 1 1 1 1 2 2 2 2 2
2
Pilot Check Valve
STF13 Slave Fittings 1 1 1 1 1 1 2 2 2 2 2
2
ADDITIONAL REQUIREMENTS NOT INCLUDED IN Hydraulic Fluid 2 2 2 2 3 3 2
2 3 3 4 4
Copper Tubing 516 OD As Required
Page 17 of 36 Pages
Parts List CRB4 Control Rt Red
Model CRT4 Control Rt Red
Model CLB4 Control Lft Blk
Model CLT4 Control Lft Blk
Item Description Part No Qty
1 Lever Arm Tee Red 610120 1
Lever Arm Tee Black 610130 1
2 Screw 240057 1
3 Cam 730014 1
4 Setscrew 240357 1
5 Spring 430296 1
6 Screw 240337 2
7 Washer 260067 2
8 Detent Assembly 730020 2
9 Bushing 630051 2
10 Washer 740018 1
11 Wiper 700088 1
12 0RIng 211018 1
13 Quad Seal 224011 1
14 Bushing 630044 1
15 0Ring 211027 1
16 Bearing Race 190005 2
17 Bearing 190002 1
18 Pinion Assembly 720150 1
19 Body 900254 1
20 Cylinder Assembly 500120 1 Optional Handle Red CK01 Part of Seal Kit ECS05
Red Knob 610058 Consists of
21 0Ring 211020 1 2 Valves 160011
22 Cylinder End Eccentric 560034 1 Optional Handle Black CK02
1 ORing 211018
23 0Ring 211028 2 Black Knob 610048
1 ORing 211020
24 Piston Assembly 600070 1 2 ORings 211024
25 Teflon Backup Ring 252125 2 1 ORings 211027
26 0Ring 211125 1 1 ORing 211121
27 Cylinder Tube 500131 1 1 Seal 224011
28 Cylinder End 560064 1 2 Rings 252121
1 Gasket 390028
29 Plate 520014 1 1 Wiper 700088
30 Bolt 240717 2
31 Dill Valve wred seal 160061 2
Figure 21 Sender Assembly
Page 18 of 36 Pages
Ball and Tee Handle CAUTION
When Installing
ball handle do not
torque screw to CAUTION
more than 10 ft lbs
When installing tee handle
do not torque screw to
more than 14 ft lbs
NOTE
Standard with 14 short arm hex key
wrench will not
overtorque TO
90110 Nm
TORQUE TO
90110 INLBS
10125 Nm
Page 19 of 36 Pages
Parts List Item Description Part No Qty
1 Lever Arm 610024 1
2 Screw 240057 1
3 Spacer 540018 1
4 Wiper 700088 1
5 ORing 211018 1
6 Quad Seal 224011 1
7 Bushing 630044 1
8 ORing 211027 1
9 Bearing Race 190005 2
10 Bearing 190002 1
11 Pinion Assembly 720150 1
12 Body 901054 1
13 Cylinder Assembly 501120 1 Part of Seal Kit ECS06
14 ORing 211020 1 Consists of
15 Cylinder End Eccentric 560034 1
16 ORing 211028 1 2 Dill Valves 160061
17 Piston Assembly 600070 1 2 ORings 211010
18 Teflon BackUp Ring 252125 2 1 ORing 211018
19 ORing 211125 1 1 ORing 211020
20 Cylinder Tube 500131 1 1 ORing 211027
21 Tube 500164 1 2 ORings 211028 1 extra
22 ORing 211010 2 1 ORing 211030
23 ORing 211030 1 1 ORing 211125
24 Plate 520634 1 1 Seal 224011
25 Bolt 240717 2 2 Rings 252125
26 Dill Valves wred seal 160061 2 1 Wiper 700088
Figure 22 ST06 Throttle Slave Assembly
Page 20 of 36 Pages
Parts List Description Part No Qty
1 Lever Arm 610024 1
2 Screw 240057 1
3 Cam 730014 1
4 Setscrew 240357 1
5 Spring 430296 1
6 Screw 240337 2
7 Washer 260067 2
8 Detent Assembly 730020 2
9 Bushing 630051 2
10 Washer 740018 1
11 Wiper 700088 1
12 0RIng 211018 1
13 Quad Seal 224011 1
14 Bushing 630044 1
15 0Ring 211027 1
16 Bearing Race 190005 2
17 Bearing 190002 1
18 Pinion Assembly 720150 1
19 Body 900254 1
20 Cylinder Assembly 500120 1 Part of Seal Kit ECS06
21 0Ring 211020 1 Consists of
22 Cylinder End Eccentric 560034 1 2 Dill Valves 160061
23 0Ring 211028 2 2 ORings 211010 not used
24 Piston Assembly 600070 1 1 ORing 211018
25 Teflon Backup Ring 252125 2 1 ORing 211020
26 0Ring 211125 1 1 ORing 211027
27 Cylinder Tube 500131 1 2 ORings 211028
28 Cylinder End 560064 1 1 ORing 211030 not used
29 Plate 520014 1 1 ORing 211125
30 Bolt 240717 2 1 Seal 224011
31 Dill Valve wred seal 160061 2 2 Rings 252125
1 Wiper 700088
Figure 23 SS04 Transmission Slave Assembly
Page 21 of 36 Pages
Optional Neutral Safety Switch Kit SSH01
Installation Before wiring the Switch determine the best routing for the wires as they lead away from the switch
2 Break out an appropriate knockout in the Switch Cover and feed the wires through before placing cover on Switch When
positioning the wiring be sure that it will not interfere with the mechanical function of the switch or slave
2 Using the common and normally closed Switch Terminal Screws wire the switch into the circuit between the Starter
Solenoid and the Starter Key Switch in accordance with the engine manufacturers Using 632 screws pn 240857 6 flatwashers pn 260147 6 lock washers
pn 260107 and 632 hex nuts pn
270177 mount Switch to Plate as shown in drawing Do not tighten screws at this time
4 Using 832 round head screws pn 240201 and 8 lock washers pn 260052 mount the Plate to the slave body as shown
in drawing Do not tighten screws at this time
5 Shift the transmission to Forward or Reverse so that the Cam Follower Wheels are out of the Detents and the Arms are
in the UP position as shown in the drawing
6 Make adjustments to the Switch and Plate so that the Switch makes contact when the slave arm is in the UP position
7 After making necessary adjustments tighten all four mounting screws Be sure the slave arm does not cause too much
overtravel on the Switch causing possible damage to the switch arm
1 Before wiring the Switch determine the best routing for the wires as they lead away from the switch
2 Break out an appropriate knockout in the Switch Cover and feed the wires through before placing cover on Switch When
positioning the wiring be sure that it will not interfere with the mechanical function of the switch or slave
2 Using the common and normally closed Switch Terminal Screws wire the switch into the circuit between the Starter
Solenoid and the Starter Key Switch in accordance with the engine manufacturers Using 632 screws pn 240857 6 flatwashers pn 260147 6 lock washers
pn 260107 and 632 hex nuts pn
270177 mount Switch to Plate as shown in illustration Do not tighten screws at this time
4 Using 832 round head screws pn 240201
240857 SCREW
and 8 lock washers pn 260052 mount the Plate
to the slave body as shown in drawing Do not
tighten screws at this time
520524 SWITCH PLATE
5 Shift the transmission to Forward or Reverse
870220 SWITCH
COVER so that the Cam Follower Wheels are out of the
260147 FLAT Detents and the Arms are in the UP position
WASHER
as shown in 270177 HEX
NUT 6 Make adjustments to the Switch and Plate so
that the Switch makes contact when the slave arm
is in the UP position
260107 LOCK
WASHER 7 After making necessary adjustments tighten all
870240 MICRO four mounting screws Be sure the slave arm does
SWITCH not cause too much overtravel on the Switch
causing possible damage to the switch arm
DETENT ARM shown in up position
240201 SCREW
260052 LOCKWASHER
CAM FOLLOWER WHEEL
Page 22 of 36 Pages
Figure 24 Clutch Slave Figure 25 Throttle Slave
Part of Fitting Kit MCVF08
Consists of
4 Oring 211016
Part of Fitting Kit RS01 Seal Kit 4 Plug 380514
Consists of 4 Spring 430546
2 Oring 211010 4 Poppet Assy 450040
1 Oring 211011 1 Reservoir Plug 380030
1 Oring 211117 1 Inst Sheet 180054
2 Oring 211206
2 Oring 211910 Figure 27 Charging Valve on
2 Seal 224014 R13 Integrated Reservoir
1 Inst Sheet 26 R13 Integrated Page 23 of 36 Pages
MCV04 CHARGING of Fitting Kit of
4 Oring 211016
4 Plug 380514
4 Spring 430546
4 Poppet Assy 450040
1 Reservoir Plug 380030
1 Inst Sheet 180054
For Reservoir Seal Kit RS01 See Figure 26
Figure 28 R04 Reservoir with MCV04 Charging Valve
Page 24 of 36 LINE INDICATES OUTER
EDGE OFCONTROL SENDER
DRILL 716 DIA HOLES DRILL 716 DIA HOLES 4 PLACES
2 PLACES
REMOVE THIS AREA
REMOVE THIS AREA FROM
FROM
THE PANEL
THE 29 Single Head Figure 30 SidebySide Mounting
Page 25 of 36 Pages
This page intentionally blank to allow removaluse of Template
Page 26 of 36 Pages
CDF04 Mounting Plate
This plate simplifies mounting of 1CL and 1CR control as a dual mark position of the 4 mounting bolt holes and outline of
unit material to be removed
1 Select mounting location checking for adequate handle 3 Remove plate from dash Drill 4716 diameter holes throughout full arc Also
check for access to the allen material from shaded area as shown
screw bleeders in the control heads and clearance below the
mounting surface 4 Proceed with sender mounting per installation manual
2 When location is determined use the plate as a templete and
18 THICK PLATE
Page 27 of 36 Pages
Tubing I Twin Engine One plumbing shown in diagram advances throttle in a
clockwise direction For a see supplemental diagram Plan IS and citcuits Page 28 of 36 Pages
Tubing II Twin Engine Two plumbing shown in diagram advances throttle in a
clockwise direction For a see supplemental diagram Plan IIS and
replumb throttle citcuits Page 29 of 36 Pages
Tubing III Twin Engine Three plumbing shown in diagram advances throttle in a
clockwise direction For a see supplemental diagram Plan IIS and
replumb throttle citcuits Page 30 of 36 Pages
Tubing IV Twin Engine Four plumbing shown in diagram advances throttle in a
clockwise direction For a see supplemental diagram Plan IVS and
replumb throttle citcuits Page 31 of 36 Throttle Control Circuits
Plan IS Plan IIS
Single Station Throttle Advance Two Station Throttle Advance
Page 32 of 36 Throttle Control IIIS Plan IVS
Three Station Throttle Advance Four Station Throttle Advance
Page 33 of 36 Problem Cause Solution
Spongy Controls Entire System Air in System 1 Check reservoir and verify that there is fluid
and pressure is 80 psi
2 Inspect for fluid leaks at all connections
3 Check for air leaks in the reservoir use soapy
water solution
4 Bleed entire system
5 Synchronize controls on one clutch or throttle
system
Spongy Controls on one clutch or Air in that singular system 1 Check reservoir verify that there is fluid and
throttle system pressure is 80 psi
2 Inspect for fluid leaks at all connections of the s
ystem in question
3 Bleed system in question
4 Synchronize controls
Sender arm wants to stop at its Controls out of Synchronize controls
midstroke
FuII throttle on the sender will not 1 Throttle linkage length out of 1 Readjust length of the throttle linkage
achieve maximum throttle RPM on adjustment 2 Service Engine
Engine 2 Engine out of tune
Full idIe on sender will not achieve idle 1 Throttle linkage length out of 1 Readjust length of the throttle linkage
RPM on engine adjustment 2 Service Engine
2 Engine governor out of adjustment
3 Engine out of tune
Engine Throttle tends to creep toward Pilot check valve 1 Remove pressure from system
idle 2 Repressurize the system
3 Repurge the system of air
Slaves internal piston seals or syn 1 Remove pressure from system
chronizing valves leaking due to 2 Rebuild or replace throttle slave
wear or debris 3 Repressurize the system
4 Repurge the system of air
Full Throttle on sender gives idle on System tubing connected back 1 Remove pressure from the system
engine ward 2 Reverse tubing at the throttle slave
3 Pressurize system
4 Synchronize throttle control
After a long running period the Throttle Slave is located at an engine hot Several Suggested Remedies
tends to go out of spot which has caused excessive 1 The use of heat resistant gasket material
heating of the throttle slave which 18 Thick between the
in turn has caused the slave to de mounting bracket and engine
velop a vapor lock 2 Spaces between the bracket and
engine and slave and bracket
3 Shielding around the throttle slave
4 Remounting of the throttle slave in a
less hot area
Contamination in pilot check valve 1 Remove pressure from system
keeping it from functioning prop 2 Repressurize the system
erly 3 Repurge system of air
If twin engines are equipped with 1 Readjust springs proper tension
synchronizer governor or NOTE excessive tension in either throttle
tension springs are extremes will cause out of adjustment
Page 34 of 36 Cause Solution
Loss of system pressure but not loss Air leak in reservoir While pressure is on system use a soapy water
of fluid solution to find an air leak on the tank When
leak is found remove pressure and repair
repressurize system to 80 pressure will vary as much as
10 psi due to temperature changes
When system pressure drops below
70 psi a leak should be checked for
Loss of pressure and fluid on system System leak 1 With pressure on system check for fluid leaks
at all connections
2 When found repair leak If a tubing connection is
leaking remove and replace 0ring if leak
persists see section of trouble shooting which
concerns leaks at fittings for further repair
procedures
3 Pressurize system bleed system filling as
required
4 Synchronize arm moved at one station re Improper reversed tubing connec 1 Recheck tubing connections made in the wrong arm movement at
tions tubing diagram used
the other station s 2 Remove pressure from the system
3 Reconnect tubing as required
4 Repressurize and bleed system
5 Synchronize arm moved at one station re Tubing runs improperly connected 1 Compare tubing connections made with
suits in another arm moving at the Prime area for improper connection tubing diagram used check area of charging
same station would be at the charging valve valve
2 Remove pressure from system
3 Reconnect tubing as required
4 Pressurize system bleed system
5 Synchronize or kink in tubing Numerous 1 Cut out kinked or crimped portion of line
2 Splice line together using tube connectors
and union
Leak at a fitting Bad 0Ring Remove fitting replace 0Ring replace fitting
Pressurize system and check for leakage If
Leakage continues replace entire tubing
connector and adapter as System seems locked up Slipped sender handle 1 Reestablish senders handle position if
after initial installation required to allow full 115 degree or reverse on clutch sender
Clutch save to transmission linkage Readjust linkage length
will not obtain a full forward out of adjustment
or reverse on on clutch sender gives Tubing incorrectly connected 1 Remove pressure from on engine
2 Reverse tubing at the clutch slave
3 Pressurize and bleed system
4 Synchronize clutch Page 35 of 36 Pages
Page 36 of 36 Pages

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