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Teleflex Hydraulic Engine Controls Workshop Manual



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  Hydraulic
Engine Controls
Installation and Service
                       -04 SERIES




                      CAUTION!
        THIS SYSTEM DOES NOT USE OIL.
    Use 50/50 (by volume) ethylene-glycol/distilled water

  DO NOT USE STOP-LEAK TYPE ANTI-FREEZE


THIS MANUAL SHOULD BE KEPT ON BOARD YOUR VESSEL
                                                            182042   Rev.5
                        Page 1 of 36 Pages                            1/05
                               LIMITED WARRANTY POLICY
                         TELEFLEX MORSE TRADEMARK PRODUCTS

Teleflex Morse warrants that its manufactured products shall be free from defects in materials and workmanship for
a period of twenty-four (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, transportation charges prepaid. Teleflex Morse's sole obligation, and
buyer's exclusive remedy hereunder, is limited to such rebuilding or replacement.

No 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 Morse-Sarasota factory, any costs for labor or otherwise related to produce
removal or replacement, or any other costs of any nature without consent by Teleflex Morse-Sarasota.

Parts, 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, accident,
misapplication, 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 maximums.

Purchaser 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 determination.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. TELEFLEX MORSE SHALL NOT BE LIABLE FOR ANY CONSEQUEN-
TIAL, INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER.

NOTE TO CONSUMERS: THIS LIMITED WARRANTY IS EXTENDED TO THE COMMERCIAL CUSTOMERS,
DEALERS, AND INSTALLERS OF TELEFLEX MORSE PRODUCTS ONLY. THE SUPPLIER/INSTALLER WILL
EXTEND WARRANTY COVERAGE TO YOU WHICH COVERS TELEFLEX MORSE PRODUCTS. TELEFLEX
MORSE 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 34240-8414
                                                 Phone 941.907.1000
                                                  FAX 941.907.1010




                                                   Page 2 of 36 Pages
                                                             Table of Contents

TELEFLEX MORSE ENGINE CONTROL SYSTEM--
WHY IT WORKS ......................................................... 4      PARTS LIST ............................................................. 16

PREPARATION 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 SWITCH.....................................22
    Throttle Slave Installation ...................................... 6
    Clutch Slave Installation ........................................ 8      TEMPLATES ............................................................ 25

   Reservoir/Charging Valve Installation .................... 9               CDF-04 MOUNTING PLATE ..................................... 27
TUBING INSTALLATION AND CONNECTION .......... 10                              TUBING DIAGRAMS ................................................ 28
   Rules for Routing Tubing ..................................... 10
                                                                                  Plan I--Twin Engine, One Station ........................ 28
   Install Tubing Between Senders and Slaves ........ 11
                                                                                  Plan II--Twin Engine, Two Station ...................... 29

                                                                                  Plan III--Twin Engine, Three Station ................... 30
FILLING AND BLEEDING SYSTEM ......................... 11
    Filling the System ................................................ 11        Plan IV--Twin 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 I-S ............................................................... 32

MAKING THE SYSTEM OPERATIONAL ................. 12                                Plan II-S .............................................................. 32
   Synchronizing the Controls .................................. 12               Plan III-S ............................................................. 33
   Connecting Engine Controls ................................. 12
                                                                                  Plan IV-S ............................................................. 33
OPERATION ..........................................................12
                                                                              TROUBLESHOOTING .............................................. 34
  Throttle Senders ................................................... 12
   Clutch Senders .................................................... 13
   Maintenance ........................................................ 13




                                                                  Page 3 of 36 Pages
Teleflex 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 sender's 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 system's 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 operated.
slaves has two small valves which are opened when the
piston reaches the end of its stroke, allowing additional fluid      Fluid-flow 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 over-travel bungee is            ease of installation, (2) nylon tubing expands and contracts
used 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 psi.




Preparation 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 arm's arc will not
   cause damage and malfunction. It is extremely                     interfere with the ship's 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 installa-
lists 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 sender
definite points with less chance of an error.                        mounting. Refer to Figure 1 for minimum distance required
Should 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 7/16" 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 sender's ports are tapped 1/4" NPTF. Suitable adapt-
Components 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 sender's handle position may be set within limits by
allow the tubing to be connected with moderate
                                                              loosening the tightening screw (using a 1/4" 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. Side-By-Side Senders
                                                   Page 5 of 36 Pages
Throttle Slave Installation                                             Steps 1 thru 8 apply to both ST-04 and ST-06 Systems

                             NOTE                                       1. Secure the mounting bracket to the engine. A suitable
     The standard Teleflex Morse System,                                bracket must be fabricated.
     MC-04, uses the ST-06 Integrated Throttle
                                                                        2. Secure the throttle slave to the mounting bracket using
     Slave. You may have chosen to order a
                                                                        3/8-16 mounting bolts.
     non-standard system which includes the
     ST-04 Throttle Slave and STV-10 Lock-out                           3. Install a lock nut and bungee-ball joint on the end of a
     Valve. Depending on which system you                               1/4-20 stainless or brass threaded rod.
     have, follow the corresponding installa-
                                                                        4. Position the throttle slave to its mid-stroke and connect the
     tion instructions in this section.
                                                                        bungee end of the 1/4-20 threaded rod to it (not provided).
                                                                        5. Position the engine's throttle arm to its mid-stroke. Deter-
Teleflex Morse throttle slaves must be mounted so that at the           mine the length of threaded rod required and cut off the
mid-stroke of both the engine's throttle arm and the slave's            excess.
control 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 ball-joint to the engine's throttle
necting 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 bungee-ball 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 arm-to- throttle           direction. By adjusting the ball-joint and bungee, a fine
linkage according to Figure 4. It allows up to       3/16" slave        adjustment in both directions can be achieved. Be sure the
arm over-travel in each direction. This over-travel lets the            slave arm can over-travel 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.            ball-joint and bungee assembly to the threaded rod with lock
                                                                        nuts provided. Disconnect the linkage from the throttle slave's
The throttle slave's arm may be set to any desired position by          arm.
loosening the tightening screw (using a 3/16" allen wrench)
in the lower end of the arm and then rotating the arm as                                ST-06 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 ST-06 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 built-in 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 Installation"
                                                                             and "Connection" on page 8.

                                                                        11. Verify all fittings installed have been tightened. Repeat
                                                                        these throttle slave installation procedures for the second
                                                                        engine.



                                                                                       ST-04 Installation Only
                                                                        9. To prevent engine retard due to governor spring or
                                                                        vibration, a separate STV-10 lock-out valve is used with the
                                                                        ST-04 Throttle Slave.
Figure 4. Throttle Slave to Throttle Arm Installation

                                                            Page 6 of 36 Pages
               Figure 5. ST-06 Integrated Throttle Slave with Tee and Bleeder Valve Installation


                            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 Installation"
    out valve installation. The STV-10 Lock Out                           and "Connection."
    Valve must be plumbed as shown in Figure 6.
    The lock-out 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 lock-out 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 they're 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 lock-out valve on the throttle slave and              engine.
secure 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. ST-04 Throttle Slave with STV-10 Lock-Out Valve

                                                          Page 7 of 36 Pages
Clutch Slave Installation
The Morse clutch slave must be mounted so that when the
engine's transmission is in neutral and the Morse clutch
slave's arm is at its mid-stroke, 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 1/4-20
                                                                       stainless steel or brass threaded rod (not provided).

   Figure 7. Proper Clutch Slave to Throttle Arm                       7. Position the clutch slave to its mid-stroke and connect the
                    Installation                                       ball joint end of the 1/4-20 threaded rod to it.
                                                                       8. Position the engine's clutch arm to neutral, determine the
                             NOTE                                      proper length of the threaded rod required and cut off the
    The clutch slave's 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 3/16" 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 ball-joint 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
                                                                       arm.
must be fabricated.
                                                                       11. After determining the correct linkage length, securely
2. Secure the transmission slave to the mounting bracket
                                                                       lock the ball-joints to the threaded rod with lock-nuts pro-
using the 3/8-16 mounting bolts.
                                                                       vided. Disconnect the linkage from the clutch slave's arm.
3. Set the transmission in the neutral position, and the clutch
                                                                       12. Locate and secure in place two tees, two bleeder valves,
slave's arm at its mid-stroke.
                                                                       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. SS-04 Shifter Slave - Bleeder Valve and Tubing Adapters Installation
                                                          Page 8 of 36 Pages
Reservoir Installation
                                                                                     R-04 Reservoir Installation
                            NOTE                                     The reservoir should be located in the ship's engine room in
    The standard Morse System, MC-04, uses                           an accessible location. In locating the reservoir the following
    the R-13 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
    R-04 Reservoir and an MCV-04 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 single-engine                     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
                R-13 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 ship's engine room in
an accessible location. In locating the reservoir the following
conditions should be met:
1. Reservoir must be in a vertical position with pressure
gauge 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.

7. Reservoir must be mounted to the bulkhead, wall, or post,            Figure 11. Ports on Bottom of R-04 Reservoir
using either bolts or screws.
                                                                                MCV-04 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
    reservoir's fluid. See Figure 10.                                2. Mount the charging valve using two screws or bolts.




   Figure 10. Charging Valve on R-13 Reservoir                                 Figure 12. MCV-04 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 non-metallic
Four tubing installation plans are provided in the Tubing       ties and clamps.
Diagrams 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 correspondingly, 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 avoid
recorded on the chosen plan diagram for future reference.          kinking and tangling.




  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 theO-ring
                                                                (211010).




  2. Slip the nut (530015) over
  the tubing end. The nut
  should slide freely.


                                                              6. Install the 0-ring (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 Pages
Install Tubing Between Senders and Slaves                            5. The system will now begin to fill with fluid. As the system
(See Pages 22-27 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 sender,
repeating 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.                                                            sender's 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 bottomed.
tubing 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 two-inch
    over- tighten clamps or ties, as overtightening                  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 on"System 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
MCO-03 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 Pages
Bleeding the System at Senders                                           The ethylene glycol chosen for use should be as pure (no
                                                                         additives) as possible, proportionately mixed with distilled
After 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 ANTI-FREEZE.
trapped 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.
1/2 and 2/3 full), and leave about 100 psi on the pressure
gauge.                                                                   Field service pre-filtering can be accomplished by using a
                                                                         "Mr. Coffee"or 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 1/2 gallon ` of
     sender, to prevent fluid from spilling on the
                                                                         ethylene glycol solution.
     console.
                                                                         The MCO-03 fluid provided by Morse is proportionately
2. Very slowly open the bleeder plug using a 3/16" 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 sender's arm
                                                                         from stop to stop, 3 to 5 complete cycles. Each sender should
                                                                         be synchronized at this time.

                                                                                                    NOTE
                                                                             This synchronization can be performed at any
                                                                             of the control stations.

                                                                         2. If the position of the sender's handle requires an awkward
                                                                         motion by the user, adjust the handle by loosening the set
                                                                         screw (using a 1/4" allen wrench) and rotating the handle so
                Figure 14. Bleeder Screw                                 that the user has more of a direct push-pull 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 stroke.
bubbles.                                                                 3. Should one of the controls not come into synchronization,
4. Tighten the bleeder screw after bleeding.                             go to that station which is out of synchronization and perform
                                                                         Step 1.
5. Repeat Steps 1 to 4 above, for each sender.
                                                                         Connecting Engine Controls
6. The reservoir level should be between 1/2 and 2/3 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 engines.
System Fluid                                                                                        NOTE
The fluid recommended for use in the system is a 50/50                       For any operational problems at this point,
mixture by volume of distilled water and ethylene glycol. The                consult the trouble shooting section.
type of ethylene glycol used is very important for proper
operation of your system and especially the synchronization
(charging) valve. Some additives, especially silicone addi-              Operation
tives, are very thick in consistency and will clog the elements          Throttle Senders
in the synchronization valve. If this occurs your system will
be unable to maintain synchronization between sender and                 Forward Motion -- Increases Throttle.
slave.                                                                   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 sender's 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 throttle.

Clutch Senders

Forward Position -- Forward Direction
Center Position -- Neutral
Aft Position--Reverse Direction


Maintenance
The clutch and throttle sender bodies are made of 6061-T6 aluminum, which has been anodized. To clean them, a warm soapy
solution 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 1/2 and 2/3 full on the sight glass).

        2. Check system pressure (pressure should be between 70-90 psi), see note below concerning reservoir
           pressure.



                                                             NOTE

        The reservoir pressure will vary between 70-90 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 1/2 to 2/3 of sight glass).

        2. Check system pressure, it should be between 70-90 psi. Consult the note above about system pressure
           change.

        3. The system is self-lubricating, but the ball-joints 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 Connection

Use these instructions in conjunction with this Manual's
Section on Tubing Installation, Page 8.

1. Use 5/16" 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. (Single-bundled)

4. 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
   2651-5 Hose with 401-5B Fittings may be used for the
   transition from hull-mounted to engine-mounted tubing.
   This will prevent work-hardening 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                         R-13 Integrated Reservoir
copper tubing installation between components of the En-
gine Contol System.




                                        Figure 16. ST-06 Integrated Throttle Slave


                                                       Page 14 of 36 Pages
                     Figure 17. ST-04 Throttle Slave with STV-10 Lock-Out Valve




Figure 18. Ports on Bottom of R-04 Reservoir                   Figure 19. MCV-04 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. SS-04 Shifter Slave
                                         Page 15 of 36 Pages
System Parts List
Nylon Tubing                                                                                 SINGLE ENGINE                                                          TWIN ENGINE




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COMPONENT        DESCRIPTION

R-13       Reservoir & Charging Valve       1          1          1         1            1         1          1         1          1          1          1          1

MCVF-04    Charging Valve Fittings           -         -          -          -           -         -          1         1          1          1          1          1

MCVF-05    Charging Valve Fittings          1          1          1         1            1         1          -         -          -          -           -          -

CL-B4 or   Control-Left (Ball Handle) or    1          1          2          2           3         3          2         2          4          4          6          6
CL-T4      Control-Left ("T" Handle)

CR-B4 or   Control-Right (Ball Handle) or   1          1          2          2           3         3          2         2          4          4          6          6
CR-T4      Control-Right ("T" Handle)

CDF-04     Dual Mounting Plate               -         1          -          2           -         3          -         2          -          4           -         6

CF-04      Control Fittings                 2          2          4          4           6         6          4         4          8          8         12          12

SS-04      Shift Slave                      1          1          1          1           1         1          2         2          2          2          2          2

SSF-04     Slave Fittings                   1          1          1          1           1         1          2         2          2          2          2          2

ST-06      Throttle Slave & Double          1          1          1          1           1         1          2         2          2          2          2          2
           Pilot Check Valve

STF-12     Slave Fittings                   1          1          1          1           1         1          2         2          2          2          2          2


           ADDITIONAL REQUIREMENTS - NOT INCLUDED IN SYSTEMS

MCEF-04    Extra Fittings Package           1          1          1          1           1         1          1         1          1          1          1          1

MCT-02     100' Nylon Tube                  2*         2*         2*        2*         3*          3*         3*        3*        4*         4*           -          -

MCT-05     500' Nylon Tube                   -         -          -          -           -         -          -         -          -          -         1*          1*

MCO-03     Hydarulic Fluid                  2*         2*         2*        2*         3*          3*         2*        2*        3*         3*         4*          4*

                                       *As Required




                                                                  Page 16 of 36 Pages
System Parts List
Copper Tubing                                                                            SINGLE ENGINE                                                        TWIN ENGINE




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COMPONENT        DESCRIPTION
R-13       Reservoir & Charging Valve       1         1         1         1          1         1         1          1         1          1         1          1

MCVF-10    Charging Valve Fittings          -         -         -         -          -         -         1          1         1          1          1         1

MCVF-11    Charging Valve Fittings          1         1         1         1          1         1         -          -         -          -          -         -

CL-B4 or   Control-Left (Ball Handle) or    1         1         2         2          3         3         2          2         4          4          6         6
CL-T4      Control-Left ("T" Handle)

CR-B4 or   Control-Right (Ball Handle) or   1         1         2         2          3         3         2          2         4          4          6         6
CR-T4      Control-Right ("T" Handle)

CDF-04     Dual Mounting Plate              -         1         -         2          -         3         -          2         -          4          -         6

CF-05      Control Fittings                 2         2         4         4          6         6         4          4         8          8         12         12

SS-04      Shift Slave                      1         1         1         1          1         1         2          2         2          2          2         2

SSF-06     Slave Fittings                   1         1         1         1          1         1         2          2         2          2          2         2

ST-06      Throttle Slave & Double          1         1         1         1          1         1         2          2         2          2          2         2
           Pilot Check Valve

STF-13     Slave Fittings                   1         1         1         1          1         1         2          2         2          2          2         2

                                     ADDITIONAL REQUIREMENTS - NOT INCLUDED IN SYSTEMS


MCO-03     Hydraulic Fluid*                 2         2         2         2          3         3         2          2         3          3          4         4

           Copper Tubing, 5/16" O.D.*                                                *As Required




                                                                Page 17 of 36 Pages
Parts List (Continued)

Sender Assembly
Model CR-B4 Control, Rt. Red
Model CR-T4 Control, Rt. Red
Model CL-B4 Control, Lft. Blk
Model CL-T4 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.     *   0-RIng                     211018        1
13.     *   Quad Seal                  224011        1
14.         Bushing                    630044        1
15.     *   0-Ring                     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) CK-01     * - Part of Seal Kit ECS-05
                                                          Red Knob             610058         Consists of:
21..    *   0-Ring                     211020        1                                    2 Valves         160011
22.         Cylinder End (Eccentric)   560034        1    Optional Handle (Black) CK-02
                                                                                          1 O-Ring         211018
23..    *   0-Ring                     211028        2    Black Knob           610048
                                                                                          1 O-Ring         211020
24.         Piston Assembly            600070        1                                    2 O-Rings        211024
25.     *   Teflon Back-up Ring        252125        2                                    1 O-Rings        211027
26. .   *   0-Ring                     211125        1                                    1 O-Ring         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 (w/red seal)    160061        2

                                        Figure 21. Sender Assembly
                                                  Page 18 of 36 Pages
                      Ball and Tee Handle Installation

        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 hand-tightening
                            with 1/4" short arm hex key
                                  wrench will not
                                over-torque screw.




TORQUE TO
90-110 IN-LBS
(10-12.5 Nm)


                                            TORQUE TO
                                            90-110 IN-LBS
                                            (10-12.5 Nm)




                                   Page 19 of 36 Pages
Parts List (Continued)




 Item                Description       Part No.    Qty.
  1.        Lever Arm                   610024      1
  2.        Screw                       240057      1
  3.        Spacer                      540018      1
  4.    *   Wiper                       700088      1
  5.    *   O-Ring                      211018      1
  6.    *   Quad Seal                   224011      1
  7.        Bushing                     630044      1
  8.    *   O-Ring                      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, ECS-06
 14.    *   O-Ring                      211020      1                   Consists of:
 15.        Cylinder End (Eccentric)    560034      1
 16.    *   O-Ring                      211028      1                   2     Dill Valves   160061
 17.        Piston Assembly             600070      1                   2     O-Rings       211010
 18.    *   Teflon Back-Up Ring         252125      2                   1     O-Ring        211018
 19.    *   O-Ring                      211125      1                   1     O-Ring        211020
 20.        Cylinder Tube               500131      1                   1     O-Ring        211027
 21.        Tube                        500164      1                   2     O-Rings       211028 (1 extra)
 22.    *   O-Ring                      211010      2                   1     O-Ring        211030
 23.    *   O-Ring                      211030      1                   1     O-Ring        211125
 24.        Plate                       520634      1                   1     Seal          224011
 25.        Bolt                        240717      2                   2     Rings         252125
 26.    *   Dill Valves (w/red seal)    160061      2                   1     Wiper         700088

                                   Figure 22. ST-06 Throttle Slave Assembly
                                                  Page 20 of 36 Pages
Parts List (Continued)




Item       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.    *   0-RIng                       211018        1
13.    *   Quad Seal                    224011        1
14.        Bushing                      630044        1
15.    *   0-Ring                       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, ECS-06
21.    *   0-Ring                       211020        1                        Consists of:
22.        Cylinder End (Eccentric)     560034        1                    2    Dill Valves   160061
23.    *   0-Ring                       211028        2                    2    O-Rings       211010 (not used)
24.        Piston Assembly              600070        1                    1    O-Ring        211018
25.    *   Teflon Back-up Ring          252125        2                    1    O-Ring        211020
26.    *   0-Ring                       211125        1                    1    O-Ring        211027
27.        Cylinder Tube                500131        1                    2    O-Rings       211028
28.        Cylinder End                 560064        1                    1    O-Ring        211030 (not used)
29.        Plate                        520014        1                    1    O-Ring        211125
30.        Bolt                         240717        2                    1    Seal          224011
31.    *   Dill Valve (w/red seal)      160061        2                    2    Rings         252125
                                                                           1    Wiper         700088
                                 Figure 23. SS-04 Transmission Slave Assembly
                                                   Page 21 of 36 Pages
                 Optional Neutral Safety Switch Kit SSH-01
                          Installation Instructions
1.   Before wiring the Switch, determine the best routing for the wires as they lead away from the switch.
2.   Break out an appropriate knock-out 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 recommendations.
3.   Using #6-32 screws (p/n 240857), #6 flatwashers (p/n 260147), #6 lock washers (p/n 260107), and #6-32 hex nuts (p/n
     270177), mount Switch to Plate as shown in drawing. (Do not tighten screws at this time.)
4.   Using #8-32 round head screws (p/n 240201) and #8 lock washers (p/n 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 knock-out 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 recommendations.
3.   Using #6-32 screws (p/n 240857), #6 flatwashers (p/n 260147), #6 lock washers (p/n 260107), and #6-32 hex nuts (p/n
     270177), mount Switch to Plate as shown in illustration. (Do not tighten screws at this time.)
                                                                            4. Using #8-32 round head screws (p/n 240201)
                        240857 SCREW
                                                                            and #8 lock washers (p/n 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 illustration.
                                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 MCVF-08
                                                         Consists of:
                                                          4 O-ring            211016
            *Part of Fitting Kit RS-01 Seal Kit           4 Plug              380514
            Consists of:                                  4 Spring            430546
             2 O-ring             211010                  4 Poppet Assy       450040
             1 O-ring             211011                  1 Reservoir Plug    380030
             1 O-ring             211117                  1 Inst. Sheet       180054
             2 O-ring             211206
             2 O-ring             211910                      Figure 27. Charging Valve on
             2 Seal               224014                       R-13 Integrated Reservoir
             1 Inst. Sheet        181033

Figure 26. R-13 Integrated Reservoir




                                   Page 23 of 36 Pages
     MCV-04 CHARGING VALVE




*Part of Fitting Kit MCVF-08
Consists of:
 4 O-ring            211016
 4 Plug              380514
 4 Spring            430546
 4 Poppet Assy       450040
 1 Reservoir Plug    380030
 1 Inst. Sheet       180054




                                                      For Reservoir Seal Kit RS-01, See Figure 26

                        Figure 28. R-04 Reservoir with MCV-04 Charging Valve




                                          Page 24 of 36 Pages
Templates




        LINE INDICATES OUTER
        EDGE OFCONTROL SENDER

            DRILL 7/16" DIA. HOLES,                 DRILL 7/16" DIA. HOLES, 4 PLACES
            2 PLACES




   REMOVE THIS AREA
                                                    REMOVE THIS AREA FROM
        FROM
                                                         THE PANEL
      THE PANEL




Figure 29. Single Head                         Figure 30. Side-by-Side Mounting


                                      Page 25 of 36 Pages
This page intentionally blank to allow removal/use of Template




                        Page 26 of 36 Pages
CDF-04 Mounting Plate

This plate simplifies mounting of 1-CL and 1-CR 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 4-7/16" diameter holes. Remove
clearance 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

                                                                                                 1/8" THICK PLATE




                                                            Page 27 of 36 Pages
Tubing Circuits

Plan I - Twin Engine, One Station

Throttle plumbing shown in diagram advances throttle in a
clockwise direction. For a counter-clockwise throttle
advance see supplemental diagram Plan I-S and replumb
throttle citcuits accordingly.




                                                   Page 28 of 36 Pages
Tubing Circuits

Plan II - Twin Engine, Two Station

Throttle plumbing shown in diagram advances throttle in a
clockwise direction. For a counter-clockwise throttle
advance see supplemental diagram Plan II-S, and
replumb throttle citcuits accordingly.




                                                   Page 29 of 36 Pages
Tubing Circuits

Plan III - Twin Engine, Three Station

Throttle plumbing shown in diagram advances throttle in a
clockwise direction. For a counter-clockwise throttle
advance see supplemental diagram Plan II-S, and
replumb throttle citcuits accordingly.




                                                   Page 30 of 36 Pages
Tubing Circuits

Plan IV - Twin Engine, Four Station

Throttle plumbing shown in diagram advances throttle in a
clockwise direction. For a counter-clockwise throttle
advance see supplemental diagram Plan IV-S, and
replumb throttle citcuits accordingly.




                                                    Page 31 of 36 Pages
Supplemental Throttle Control Circuits
Plan I-S                                                        Plan II-S
Single Station Counterclockwise Throttle Advance                Two Station Counterclockwise Throttle Advance




                                                   Page 32 of 36 Pages
Supplemental Throttle Control Circuits
(Continued)
Plan III-S                                                     Plan IV-S
Three Station, Counterclockwise Throttle Advance               Four Station, Counterclockwise Throttle Advance




                                                   Page 33 of 36 Pages
Troubleshooting

 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 synchronization.        Synchronize controls.
 mid-stroke.

 FuII throttle on the sender will not        1. Throttle linkage length out of       1. Re-adjust 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. Re-adjust 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 malfunctioning.       1. Remove pressure from system.
 idle                                                                                2. Re-pressurize the system.
                                                                                     3. Re-purge the system of air.

                                             Slave's 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. Re-pressurize the system.
                                                                                     4. Re-purge 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 synchronization.         spot which has caused excessive         1. The use of heat resistant gasket material
                                             heating of the throttle slave, which       (approximately 1/8' 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. Re-mounting 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. Re-pressurize the system.
                                             erly.                                   3. Re-purge system of air.

                                             If twin engines are equipped with       1. Re-adjust springs proper tension.
                                             synchronizer, governor or               NOTE: excessive tension in either throttle
                                             synchronizer's tension springs are       extremes will cause synchronization
                                             out of adjustment.                      problems.




                                                         Page 34 of 36 Pages
Troubleshooting (Continued)
Problem                                   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,
                                                                              re-pressurize system to 80 psi.

NOTE
System 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 0-ring (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 controls.

Sender arm moved at one station re-     Improper reversed tubing connec-      1. Recheck tubing connections made against

suIts 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. Re-pressurize and bleed system.
                                                                              5. Synchronize controls.

Sender 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 controls.


Crimp 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 0-Ring                            Remove fitting, replace 0-Ring, replace fitting,
                                                                              Pressurize system, and check for leakage. If
                                                                              Leakage continues replace entire tubing
                                                                              connector and adapter as required.

Throttle System seems locked up         Slipped sender handle                 1. Re-establish sender's handle position, if
after initial installation                                                      required, to allow full 115 degree travel.


Forward or reverse on clutch sender     Clutch save to transmission linkage   Re-adjust linkage length.
will not obtain a full forward          out of adjustment
or reverse on transmission

Forward on clutch sender gives          Tubing incorrectly connected          1. Remove pressure from system.
reverse on engine                                                             2. Reverse tubing at the clutch slave.
                                                                              3. Pressurize and bleed system.
                                                                              4. Synchronize clutch controls.




                                                       Page 35 of 36 Pages
Page 36 of 36 Pages


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