Page 1
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
Page 1 of 36 Pages
182042 Rev.5
1/05
Page 2
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 CONSEQUENTIAL, 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
Page 3
Table of Contents
TELEFLEX MORSE ENGINE CONTROL SYSTEM--
WHY IT WORKS......................................................... 4
PREPARATION FOR INSTALLATION........................ 4
COMPONENT INSTALLATION................................... 4
Sender Installation.................................................4
Throttle Slave Installation ...................................... 6
Clutch Slave Installation ........................................ 8
Reservoir/Charging Valve Installation .................... 9
TUBING INSTALLATION AND CONNECTION.......... 10
Rules for Routing Tubing ..................................... 10
Install Tubing Between Senders and Slaves ........ 11
FILLING AND BLEEDING SYSTEM ......................... 11
Filling the System................................................ 11
Bleeding the System, at Slave ............................ 11
Bleeding the System, at Senders ........................ 12
PARTS LIST............................................................. 16
System Parts List (Nylon) ..................................... 14
System Parts List (Copper) ................................. 17
COMPONENT CROSS SECTIONS .......................... 18
NEUTRAL SAFTY SWITCH.....................................22
TEMPLATES ............................................................ 25
CDF-04 MOUNTING PLATE ..................................... 27
TUBING DIAGRAMS ................................................ 28
Plan I—Twin Engine, One Station........................ 28
Plan II—Twin Engine, Two Station ...................... 29
Plan III—Twin Engine, Three Station ................... 30
Plan IV—Twin Engine, Four Station..................... 31
SUPPLEMENTAL THROTTLE CONTROL
CIRCUITS ................................................................. 32
SYSTEM FLUID ....................................................... 12
MAKING THE SYSTEM OPERATIONAL ................. 12
Synchronizing the Controls .................................. 12
Connecting Engine Controls................................. 12
OPERATION ..........................................................12
Throttle Senders ................................................... 12
Clutch Senders .................................................... 13
Maintenance ........................................................ 13
Plan I-S ............................................................... 32
Plan II-S .............................................................. 32
Plan III-S ............................................................. 33
Plan IV-S............................................................. 33
TROUBLESHOOTING .............................................. 34
Page 3 of 36 Pages
Page 4
Teleflex Morse Engine Control System—
Why it Works
The movement of a sender’s control arm transmits mechanical energy to an internal piston which in turn pushes hydraulic fluid through the other corresponding control senders and
single control slave. This movement of hydraulic fluid drives
a piston in each of the senders and slave. The movement of
the individual pistons causes shaft rotation in each unit.
The piston in each of the individual control senders and
slaves has two small valves which are opened when the
piston reaches the end of its stroke, allowing additional fluid
to pass through the system. By allowing this flow of hydraulic
fluid, the controls may be synchronized with each other by
moving the control arm at one control station from stop to
stop.
The control slave is very similar to the control sender, except
the body is a rectangular block. An over-travel bungee is
used in the linkage between the slave arm and engine control
arm to assure that the slave can reach the end of its stroke
in each direction. The slave for the transmission has a builtin detent mechanism to indicate neutral position.
On most engines the throttle exerts considerable force to
return to the idle position. Each throttle slave is equipped
with a pilot check valve which locks the throttle slave in the
position it has taken in response to the sender. The throttle
slave can be driven only by the sender, it cannot drive the
sender.
Extra hydraulic fluid and a pressure head for the system is
maintained by the system’s reservoir. The reservoir is charged
with 80 psi of air over the hydraulic fluid within it. This keeps
the entire system under pressure at all times and prevents a
vacuum from existing on the back side of any piston when the
system is operated.
Fluid-flow to and from the reservoir is regulated by a charging
valve located on the bottom of the reservoir. This valve is
necessary to keep the system under pressure, and to prevent excessive pressures caused by the expansion of fluid
when the fluid becomes warm.
Nylon tubing is used to pipe the system for two reasons: (1)
ease of installation, (2) nylon tubing expands and contracts
in very much the same manner as the hydraulic fluid (a most
important factor). The expansion and contraction of the
tubing reduces drift of the controls as temperature changes,
thereby helping to keep all the components of the system
synchronized. The tubing is virgin nylon, which has been
heat and light stabilized and contains no plasticizers. The
burst pressure of the tubing is in excess of 1200 psi.
Preparation for Installation
CAUTION
Dirt and foreign matter in the hydraulic system
cause damage and malfunction. It is extremely
important to keep tubing and fittings clean
when installing and connecting components.
Cut tube cleanly and tape the open end while
running tubing.
Before installation is started, the parts list should be checked
to verify that a complete system has been received. Parts
lists are located on pages 16 and 17.
It is advised that all system components be installed, (senders, shift, throttle slaves, and reservoir) prior to running the
system tubing. This allows the tubing to be run between two
definite points with less chance of an error.
Should it become necessary for the tubing to be strung first,
a system of marking the different tubing runs should be used.
Component Installation
Components have red plastic plugs installed in their ports to
keep out foreign matter. As you remove these red plastic
plugs, replace them immediately with the proper adapter;
then install the red plugs into the adapters until you are ready
to connect tubing.
Use Loctite ® hydraulic sealant on all NPT fittings prior to
installation. DO NOT use teflon tape or pipe dope.
Sender Installation
1. Locate sender on panel so that the control arm’s arc will not
interfere with the ship’s wheel or panel. Be certain that
access is available to the small bleeder screw at the top of
each sender head.
The design of the new Engine Control "T" handle requires a
minimum distance between control heads to provide adequate handle clearance when two sets of controls are
mounted side by side. See Figure 1.
NOTE: This minimum distance does not apply to installa-
tions using the optional "knob" style control handles.
2. Using the template provided in the appendix, mark and cut
a hole for the sender. Figure 29 is the proper template for the
single head and Figure 30 for the side by side sender
mounting. Refer to Figure 1 for minimum distance required
when mounting two sets of controls side by side.
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.
5. The sender’s ports are tapped 1/4" NPTF. Suitable adapters must be installed to accept the tubing used. It is more
convenient to install these adapters prior to mounting the
senders. (Instructions for copper tubing installations are on
page 12.)
Page 4 of 36 Pages
Page 5
NOTE
If the area under the control panel is too confined to
allow the tubing to be connected with moderate
ease, do not secure the sender at this time. Proceed
with the installation of the remaining senders per
Steps 1 thru 5 above. The sender may be secured
after the tubing has been connected to it.
6. Secure senders per Figure 2 for single head, or Figure 3
for side by side mounting.
7. The sender’s handle position may be set within limits by
loosening the tightening screw (using a 1/4" allen wrench) in
the lower end of the arm and then rotating the arm as desired
and resetting the screw. After the arm is set, it will have a 115°
maximum arc.
8. Secure the remaining senders per Steps 1 thru 7.
NOTE
The minimum distance does not apply 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
Page 6
Throttle Slave Installation
Steps 1 thru 8 apply to both ST-04 and ST-06 Systems
NOTE
The standard Teleflex Morse System,
MC-04, uses the ST-06 Integrated Throttle
Slave. You may have chosen to order a
non-standard system which includes the
ST-04 Throttle Slave and STV-10 Lock-out
Valve. Depending on which system you
have, follow the corresponding installation instructions in this section.
Teleflex Morse throttle slaves must be mounted so that at the
mid-stroke of both the engine’s throttle arm and the slave’s
control arm, they are: 1) In the same plane; 2) parallel to each
other; and 3) right angles will be formed between the connecting linkage and each arm. See Figure 4.
If these criteria are met, an ideal installation will result.
A spring bungee-ball joint assembly is furnished with each
throttle slave. It is installed in the slave arm-to- throttle
linkage according to Figure 4. It allows up to 3/16" slave
arm over-travel in each direction. This over-travel lets the
slave cylinder travel its full stroke and still provide full travel
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
stroke in each direction in order to synchronize the system.
The throttle slave’s arm may be set to any desired position by
loosening the tightening screw (using a 3/16" allen wrench)
in the lower end of the arm and then rotating the arm as
desired and resetting the screw. After the arm is set, it will
have a 78° maximum arc.
CAUTION
The Throttle Slave must not be mounted to
any surface exceeding 220° F (103° C). If
mounting in a "hot spot" is unavoidable, the
slave must be insulated from the heat.
1. Secure the mounting bracket to the engine. A suitable
bracket must be fabricated.
2. Secure the throttle slave to the mounting bracket using
3/8-16 mounting bolts.
3. Install a lock nut and bungee-ball joint on the end of a
1/4-20 stainless or brass threaded rod.
4. Position the throttle slave to its mid-stroke and connect the
bungee end of the 1/4-20 threaded rod to it (not provided).
5. Position the engine’s throttle arm to its mid-stroke. Determine the length of threaded rod required and cut off the
excess.
6. Connect a lock nut and a ball-joint to the engine’s throttle
arm and the free end of the threaded rod.
7. Find the proper hole in the slave arm to provide a linkage
length combination that will allow idle to full throttle on the
engine, using all but a few degrees of slave arm travel in each
direction. By adjusting the ball-joint and bungee, a fine
adjustment in both directions can be achieved. Be sure the
slave arm can over-travel through the bungee to the end of
its stroke in each direction.
8. After determining the correct rod length, securely lock the
ball-joint and bungee assembly to the threaded rod with lock
nuts provided. Disconnect the linkage from the throttle slave’s
arm.
ST-06 Installation Only
9. To prevent engine retard due to governor spring or
vibration, a pilot check valve is built into the ST-06 Throttle
Slave.
NOTE
This built-in valve will lock the slave arm in place
allowing it to be moved only by the sender
Figure 4. Throttle SlavetoThrottleArmInstallation
Page 6 of 36 Pages
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.
Page 7
Figure 5. ST-06 Integrated Throttle Slave with Tee and Bleeder Valve Installation
NOTE
If the throttle slave is in a limited space, it may
be removed from the bracket during the lockout valve installation. The STV-10 Lock Out
Valve must be plumbed as shown in Figure 6.
The lock-out valve will lock the slaves arm
and allow it to be moved by only the sender.
The check valve and slave must be mounted in
close proximity to one another. If they're not,
abnormal locking action and poor performance
will result.
10. Install the lock-out valve on the throttle slave and
secure it using clean lubricant or Loctite hydraulic sealant on
the threads. Install appropriate adapters to accept tubing.
Refer to Figure 6.
NOTE
Tube connectors are installed on the tubing
per instructions under “Tubing Installation”
and “Connection.”
11. Using a short piece of tubing provided, connect the open
port on the tee to the S2 port on the lock-out valve. See
Figure 6. (See Figure 16 for Copper Tubing connection.)
Plug open fittings at the V1 and V2 ports.
12. Verify all fittings installed have been tightened. Repeat
these throttle slave installation procedures for the second
engine.
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
Page 8
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
Installation
NOTE
The clutch slave’s arm may be set to any
desired position by loosening the tightening
screw (using a 3/16" allen wrench) in the lower
end of the arm. Rotate arm as desired and
reset the screw. After the arm is set it will have
a 78° maximum arc.
1. Secure mounting bracket to the engine. A suitable bracket
must be fabricated.
2. Secure the transmission slave to the mounting bracket
using the 3/8-16 mounting bolts.
3. Set the transmission in the neutral position, and the clutch
slave’s arm at its mid-stroke.
4. Loosen the set screw in the detent ring on the clutch slave
and rotate the detent ring to the full detent position. To locate
the detent ring, see Figure 8.
7. Position the clutch slave to its mid-stroke and connect the
ball joint end of the 1/4-20 threaded rod to it.
8. Position the engine’s clutch arm to neutral, determine the
proper length of the threaded rod required and cut off the
excess.
9. Install a lock nut and ball joint on the other end of the
threaded rod.
10. By locating the slave arm ball-joint in its proper hole and
adjusting both ball joint on the threaded rod, find the correct
length of linkage that will allow both "full- forward" and "fullreverse" on the transmission for full throw on the clutch slave
arm.
11. After determining the correct linkage length, securely
lock the ball-joints to the threaded rod with lock-nuts provided. Disconnect the linkage from the clutch slave’s arm.
12. Locate and secure in place two tees, two bleeder valves,
and two tubing adapters, per Figure 9.
13. Repeat this clutch slave installation procedure for the
second engine.
Figure 9. SS-04 Shifter Slave - Bleeder Valve and Tubing Adapters Installation
Page 8 of 36 Pages
Page 9
Reservoir Installation
NOTE
The standard Morse System, MC-04, uses
the R-13 Integrated Reservoir. You may
have a different system which includes the
R-04 Reservoir and an MCV-04 Charging
Valve. Depending on which system you
have, follow the corresponding installation instructions in this section.
NOTE
If your installation includes two reservoirs
(one for each engine), or is a single-engine
installation, special plumbing will required
which is not covered in this manual. Contact Teleflex Morse for this information.
R-13 Reservoir Installation
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.
R-04 Reservoir Installation
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 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. Reservoir must be mounted to the bulkhead, wall or post
using either bolts or screws.
NOTE
There are two ports located on the bottom of the
reservoir. One is plugged and can be used as a
drain port. The other has a filter assembly and is
used for connecting to the system. See Figure 11.
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,
using either bolts or screws.
NOTE
The charging valve is located on the bottom of
the reservoir. The plug located on the charging valve holds the fluid filter in place. This
plug and filter can be removed to drain the
reservoir’s fluid. See Figure 10.
Figure 11. Ports on Bottom of R-04 Reservoir
MCV-04 Charging Valve Installation
The charging valve should be located in the general vicinity
of the reservoir.
1. Install appropriate adapters for the tubing used. For port
locations see Figure 12.
2. Mount the charging valve using two screws or bolts.
Figure 10. Charging Valve on R-13 Reservoir
Page 9 of 36 Pages
Figure 12. MCV-04 Charging Valve
Page 10
Tubing Installation and Connection
CAUTION
Dirt and foreign matter in the hydraulic
system cause damage and malfunction. It
is extremely important to keep tubing and
fittings clean when installing and connecting components. Cut tube cleanly and
tape the open end while running tubing.
Four tubing installation plans are provided in the Tubing
Diagrams Section later in this manual:
1. Twin Engine, One Station, (Plan I)
2. Twin Engine, Two Station, (Plan II)
3. Twin Engine, Three Station, (Plan III)
4. Twin Engine, Four Station, (Plan IV)
Before beginning to run the tubing, it is recommended that
each tube be assigned a number which is marked on both
ends, and correspondingly, marked at the origin and destination of that tube. These designations should also be
recorded on the chosen plan diagram for future reference.
Rules for Routing Tubing
NOTE
The instructions and illustrations in this section
apply to nylon tubing ONLY. Information on
use of Copper Tubing may be found on page 12.
1. Keep tubing free of dirt and foreign matter.
2. Keep tubing away from batteries, since battery acid is
corrosive to the tubing.
3. Tie the tubing down at regular intervals using non-metallic
ties and clamps.
4. Do not allow tubing to become kinked. If it does, replace
that particular run of tubing.
5. String tubing so that it will not interfere with hatchways or
machinery removal.
6. Use only nylon tubing supplied with system from Morse.
Assemble tubing connectors on every tube end as described
and illustrated in Figure 13.
NOTE
The roll of tubing should be laid in a horizontal position and moved as little as possible to avoid
kinking and tangling.
1. Cut the tubing with a razor or very sharp knife, leaving the cutoff end as square
as possible.
2. Slip the nut (530015) over
the tubing end. The nut
should slide freely.
3. Push the lock ring
(530025) over the end of the
tubing and move it back at
least one sleeve length from
the end. The lock ring may
slide on freely or require
slight pressure and "screwon" action. (The lock ring
has a left hand thread.)
5. Force the sleeve (530045)
into the end of the tubing by
pushing it against a clean,
flat surface. Thread the lock
ring (530025) toward the end
of the tube as far as possible by hand. Leave sufficient room between the lock
ring and the end of the
tube to install theO-ring
(211010).
6. Install the 0-ring (211010)
over the end of the tubing
and against the lock ring
(530025).
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
Page 11
Install Tubing Between Senders and Slaves
(See Pages 22-27 for Plumbing Circuits)
1. Locate the tubing roll in a convenient location.
2. Starting at the highest control station, begin running tubing
from the upper tubing port of the right most sender to its
connecting point as shown on the diagram.
NOTE
Tubing may be run from the sender to connecting point or from connecting point to sender,
whichever is easier.
5. The system will now begin to fill with fluid. As the system
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
sight glass release the pressure and refill the tank, as in Step
4.
6. Repressurize the system and repeat this procedure of
filling the reservoir as required until no fluid drop is noted. At
this point, the system is filled and must now be bled.
7. Check entire system for leaks and correct as required.
Bleeding the System at Slave
3. Secure each end of the newly run tube by Inserting the
tube end assembly into the proper adapter (#530175), previously installed in components. Tighten down only until
there is firm resistance felt on the wrench.
4. Run the tubing from the lower port of the same sender,
repeating the previous steps.
5. Progress leftward across the control panel until all lines
have been run and secured. Then go to the next lower station
and run tubing from it in the same manner as it was from the
upper station.
6. If the boat has more than two stations, continue running
tubing from them in the same manner, still following the
tubing diagram.
7. At this point all tubing should be run and connected. Now,
secure tubing using ties and clamps. This should be done
prior to filling the system.
NOTE
When securing tubing with clamps, do not
over- tighten clamps or ties, as overtightening
will crimp the tubing causing poor
system operation.
Filling and Bleeding System
Filling the System
NOTE
The bleeding procedure is much easier for two
people to perform than one. (One to keep the
reservoir filled and under pressure, while the
other one bleeds the system.)
1. Fill the reservoir as required.
NOTE
Verify that linkage is disconnected, and
sender’s handles are free to move.
While bleeding, move the slave arm and verify
that the piston has bottomed.
2. Using the bleeder tube provided and a clean, empty
container, insert the bleeder tube in the bleeder valve at one
side of a slave. Open the bleeder valve about one turn and
bleed system until no air bubbles are evident in the flowing
fluid. When the fluid is clear, close the bleeder valve. During
the bleed operation maintain the system pressure above 60
psi, and the fluid level in the sight gauge above the two-inch
mark. Should the fluid level drop below two inches close the
bleeder valve and release the pressure from the system.
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
system. Draw at least a full reservoir of fluid thru each side
of each circuit.
1. Verify that all sender arms are free to traverse their
complete arc.
2. Verify that all bleeder valves on the throttle and clutch
slaves are closed, and linkages disconnected.
IMPORTANT NOTE
See section on“System Fluid” for fluid specifications on Page 10.
3. Remove fill port plug from the reservoir and fill the
reservoir within one inch of the top of the sight tube with
MCO-03 water glycol fluid. Replace fill port plug.
4. Pressurize reservoir to 100 +/-10 psi through the air filler
valve in the top of the reservoir.
Page 11 of 36 Pages
NOTE
Since there are two positions at each slave to
be bled and four slaves, the reservoir must be
filled at least 8 times during the bleed operation. The fluid which has been bled off should
be used to refill the reservoir.
3. Tighten bleeder valve after the bleed operation.
4. Bleed the second port of the slave as described in Steps
1, 2, and 3.
5. Repeat steps 1 thru 4 with a second person at the sender
moving the handles back and forth slowly five to ten times
6. Continue performing the preceding five steps for each
remaining slave.
Page 12
Bleeding the System at Senders
After bleeding system at each slave bleeder valve, each
sender must now be bled. A small amount of air will be
trapped at the high point in each sender head.
1. Refill reservoir if required (fill tank at this time to between
1/2 and 2/3 full), and leave about 100 psi on the pressure
gauge.
NOTE
Place a rag over the bleeder hole on the
sender, to prevent fluid from spilling on the
console.
2. Very slowly open the bleeder plug using a 3/16" allen
wrench. See Figure 10 for location of bleeder screw.
The ethylene glycol chosen for use should be as pure (no
additives) as possible, proportionately mixed with distilled
water then filtered to assure its purity. NEVER USE STOP-
LEAK TYPE ANTI-FREEZE.
Filtration is accomplished by passing the fluid through a 5
micron filter before using in the system.
Field service pre-filtering can be accomplished by using a
“Mr. Coffee”or equivalent paper filter placed in a funnel and
then pouring the ethylene glycol solution through it.
One paper filter will filter approximately 1/2 gallon ` of
ethylene glycol solution.
The MCO-03 fluid provided by Morse is proportionately
mixed and filtered to assure its purity and is ready for use.
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.
Figure 14. Bleeder Screw
3. Allow the fluid to bleed out until the fluid is clear without air
bubbles.
4. Tighten the bleeder screw after bleeding.
5. Repeat Steps 1 to 4 above, for each sender.
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 thi s
level. Verify that pressurize in the reservoir is between
80 and 85 psi.
System Fluid
The fluid recommended for use in the system is a 50/50
mixture by volume of distilled water and ethylene glycol. The
type of ethylene glycol used is very important for proper
operation of your system and especially the synchronization
(charging) valve. Some additives, especially silicone additives, are very thick in consistency and will clog the elements
in the synchronization valve. If this occurs your system will
be unable to maintain synchronization between sender and
slave.
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
that the user has more of a direct push-pull motion. Do not
position handle so that it binds against the sender body at
either end of its stroke.
3. Should one of the controls not come into synchronization,
go to that station which is out of synchronization and perform
Step 1.
Connecting Engine Controls
1. Connect throttle linkages to the throttle slave. Repeat for
both engines.
2. Connect clutch linkages to the clutch slave. Repeat for
both engines.
NOTE
For any operational problems at this point,
consult the trouble shooting section.
Operation
Throttle Senders
Forward Motion — Increases Throttle.
Aft Motion — Decreases Throttle.
Page 12 of 36 Pages
Page 13
NOTE
When working on engine and operating the
engine throttle arm by hand, disconnect
throttle linkage from the control slave. If
linkage is not disconnected the pilot check
valve will not allow a throttle retardation
Prior to starting engines, both throttles and
clutches should be synchronized. This is
done by moving the sender’s control arm in
a complete cycle fore and aft, stop to stop.
This needs to be done at only one station.
unless a sender arm is actuated to decrease 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
Page 14
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.
The following figures illustrate the proper connections for
copper tubing installation between components of the Engine Contol System.
Figure 15. Charging Valve on Bottom of
R-13 Integrated Reservoir
Figure 16. ST-06 Integrated Throttle Slave
Page 14 of 36 Pages
Page 15
Figure 17. ST-04 Throttle Slave with STV-10 Lock-Out Valve
Figure 18. Ports on Bottom of R-04 Reservoir
Figure 20. SS-04 Shifter Slave
Page 15 of 36 Pages
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
connection.
Page 16
System Parts List
Nylon Tubing
SINGLE ENGINE TWIN ENGINE
MC-B4-S1D (Ball Handle) or MC-T4-S1D ("T" Handle)
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
MC-B4-S1 (Ball Handle) or MC-T4-S1 ("T" Handle)
MC-B4-T1 (Ball Handle) or MC-T4-S1 ("T" Handle)
MC-B4-T2 (Ball Handle) or MC-T4-T2 ("T" Handle)
MC-B4-T1D (Ball Handle) or MC-T4-T1D ("T" Handle)
MC-B4-S2D (Ball Handle) or MC-T4-S2D ("T" Handle)
MC-B4-S2 (Ball Handle) or MC-T4-S2 ("T" Handle)
MC-B4-T3 (Ball Handle) or MC-T4-T3 ("T" Handle)
MC-B4-T2D (Ball Handle) or MC-T4-T2D ("T" Handle)
MC-B4-S3D (Ball Handle) or MC-T4-S3D ("T" Handle)
MC-B4-S3 (Ball Handle) or MC-T4-S3 ("T" Handle)
MC-B4-T3D (Ball Handle) or MC-T4-T3D ("T" Handle)
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
Page 17
System Parts List
Copper Tubing
SINGLE ENGINE TWIN ENGINE
MC-B5-S1D (Ball Handle) or MC-T5-S1D ("T" Handle)
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
MC-B5-S1 (Ball Handle) or MC-T5-S1 ("T" Handle)
MC-B5-T1 (Ball Handle) or MC-T5-S1 ("T" Handle)
MC-B5-T2 (Ball Handle) or MC-T5-T2 ("T" Handle)
MC-B5-T1D (Ball Handle) or MC-T5-T1D ("T" Handle)
MC-B5-S2D (Ball Handle) or MC-T5-S2D ("T" Handle)
MC-B5-S2 (Ball Handle) or MC-T5-S2 ("T" Handle)
MC-B5-T3 (Ball Handle) or MC-T5-T3 ("T" Handle)
MC-B5-T2D (Ball Handle) or MC-T5-T2D ("T" Handle)
MC-B5-S3D (Ball Handle) or MC-T5-S3D ("T" Handle)
MC-B5-S3 (Ball Handle) or MC-T5-S3 ("T" Handle)
MC-B5-T3D (Ball Handle) or MC-T5-T3D ("T" Handle)
Copper Tubing, 5/16" O.D.* *As Required
Page 17 of 36 Pages
Page 18
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
21.. * 0-Ring 211020 1
22. Cylinder End (Eccentric) 560034 1
23.. * 0-Ring 211028 2
24. Piston Assembly 600070 1
25. * Teflon Back-up Ring 252125 2
26. . * 0-Ring 211125 1
27. Cylinder Tube 500131 1
28. Cylinder End 560064 1
29. Plate 520014 1
30. Bolt 240717 2
31. * Dill Valve (w/red seal) 160061 2
** Optional Handle (Red) CK-01
Red Knob 610058
Optional Handle (Black) CK-02
Black Knob 610048
* - Part of Seal Kit ECS-05
Consists of:
2 Valves 160011
1 O-Ring 211018
1 O-Ring 211020
2 O-Rings 211024
1 O-Rings 211027
1 O-Ring 211121
1 Seal 224011
2 Rings 252121
1 Gasket 390028
1 Wiper 700088
Figure 21. Sender Assembly
Page 18 of 36 Pages
Page 19
Ball and Tee Handle Installation
CAUTION
When Installing
ball handle do not
torque screw to
more than 10 ft. lbs.
CAUTION
When installing tee handle
do not torque screw to
more than 14 ft. lbs.
TORQUE TO
90-110 IN-LBS
(10-12.5 Nm)
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)
Page 19 of 36 Pages
Page 20
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
14. * O-Ring 211020 1
15. Cylinder End (Eccentric) 560034 1
16. * O-Ring 211028 1
17. Piston Assembly 600070 1
18. * Teflon Back-Up Ring 252125 2
19. * O-Ring 211125 1
20. Cylinder Tube 500131 1
21. Tube 500164 1
22. * O-Ring 211010 2
23. * O-Ring 211030 1
24. Plate 520634 1
25. Bolt 240717 2
26. * Dill Valves (w/red seal) 160061 2
* - Part of Seal Kit, ECS-06
Consists of:
2 Dill Valves 160061
2 O-Rings 211010
1 O-Ring 211018
1 O-Ring 211020
1 O-Ring 211027
2 O-Rings 211028 (1 extra)
1 O-Ring 211030
1 O-Ring 211125
1 Seal 224011
2 Rings 252125
1 Wiper 700088
Figure 22. ST-06 Throttle Slave Assembly
Page 20 of 36 Pages
Page 21
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
21. * 0-Ring 211020 1
22. Cylinder End (Eccentric) 560034 1
23. * 0-Ring 211028 2
24. Piston Assembly 600070 1
25. * Teflon Back-up Ring 252125 2
26. * 0-Ring 211125 1
27. Cylinder Tube 500131 1
28. Cylinder End 560064 1
29. Plate 520014 1
30. Bolt 240717 2
31. * Dill Valve (w/red seal) 160061 2
Figure 23. SS-04 Transmission Slave Assembly
* - Part of Seal Kit, ECS-06
Consists of:
2 Dill Valves 160061
2 O-Rings 211010 (not used)
1 O-Ring 211018
1 O-Ring 211020
1 O-Ring 211027
2 O-Rings 211028
1 O-Ring 211030 (not used)
1 O-Ring 211125
1 Seal 224011
2 Rings 252125
1 Wiper 700088
Page 21 of 36 Pages
Page 22
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
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
520524 SWITCH PLATE
870220 SWITCH
COVER
260147 FLAT
WASHER
270177 HEX
NUT
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 illustration.
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
870240 MICRO
SWITCH
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.
the Arms are
240201 SCREW
260052 LOCKWASHER
CAM FOLLOWER WHEEL
DETENT
ARM (shown in "up" position)
Page 22 of 36 Pages
Page 23
Figure 24. Clutch Slave Figure 25. Throttle Slave
*Part of Fitting Kit MCVF-08
Consists of:
*Part of Fitting Kit RS-01 Seal Kit
Consists of:
2 O-ring 211010
1 O-ring 211011
1 O-ring 211117
2 O-ring 211206
2 O-ring 211910
2 Seal 224014
1 Inst. Sheet 181033
4 O-ring 211016
4 Plug 380514
4 Spring 430546
4 Poppet Assy 450040
1 Reservoir Plug 380030
1 Inst. Sheet 180054
Figure 27. Charging Valve on
R-13 Integrated Reservoir
Figure 26. R-13 Integrated Reservoir
Page 23 of 36 Pages
Page 24
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
Page 25
Templates
LINE INDICATES OUTER
EDGE OFCONTROL SENDER
DRILL 7/16" DIA. HOLES,
2 PLACES
REMOVE THIS AREA
FROM
THE PANEL
DRILL 7/16" DIA. HOLES, 4 PLACES
REMOVE THIS AREA FROM
THE PANEL
Figure 29. Single Head Figure 30. Side-by-Side Mounting
Page 25 of 36 Pages
Page 26
This page intentionally blank to allow removal/use of Template
Page 26 of 36 Pages
Page 27
CDF-04 Mounting Plate
This plate simplifies mounting of 1-CL and 1-CR control as a dual
unit.
1. Select mounting location, checking for adequate handle
clearance throughout full arc. Also check for access to the allen
screw bleeders in the control heads and clearance below the
mounting surface.
2. When location is determined, use the plate as a templete and
mark position of the 4 mounting bolt holes and outline of
material to be removed.
3. Remove plate from dash. Drill 4-7/16" diameter holes. Remove
material from shaded area as shown.
4. Proceed with sender mounting per installation manual.
1/8" THICK PLATE
Page 27 of 36 Pages
Page 28
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
Page 29
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
Page 30
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
Page 31
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
Page 32
Supplemental Throttle Control Circuits
Plan I-S
Single Station Counterclockwise Throttle Advance
Plan II-S
Two Station Counterclockwise Throttle Advance
Page 32 of 36 Pages
Page 33
Supplemental Throttle Control Circuits
(Continued)
Plan III-S
Three Station, Counterclockwise Throttle Advance
Plan IV-S
Four Station, Counterclockwise Throttle Advance
Page 33 of 36 Pages
Page 34
Troubleshooting
Problem Cause Solution
Spongy Controls (Entire System) Air in System 1.Check reservoir and verify that there is fluid
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.
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.
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.
2.Inspect for fluid leaks at all connections of the s
ystem in question.
3.Bleed system in question.
4.Synchronize controls.
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.
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.
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
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.
4.Re-purge the system of air.
3.Pressurize system.
4.Synchronize throttle control.
engine, and slave and bracket.
3.Shielding around the throttle slave.
4.Re-mounting of the throttle slave in a
less hot area.
Page 34 of 36 Pages
Page 35
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
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.
leak is found remove pressure and repair,
re-pressurize system to 80 psi.
Loss of pressure and fluid on system. System leak. 1. With pressure on system check for fluid leaks
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.
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).
Crimp or kink in tubing. Numerous. 1. Cut out kinked or crimped portion of line.
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.
3. Reconnect tubing as required.
4. Re-pressurize and bleed system.
5. Synchronize controls.
2. Remove pressure from system.
3. Reconnect tubing as required.
4. Pressurize system, bleed system.
5. Synchronize controls.
2. Splice line together using tube connectors
and union.
Leak at a fitting. Bad 0-Ring Remove fitting, replace 0-Ring, replace fitting,
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.
Page 35 of 36 Pages
Pressurize system, and check for leakage. If
Leakage continues replace entire tubing
connector and adapter as required.
3. Pressurize and bleed system.
4. Synchronize clutch controls.
Page 36
Page 36 of 36 Pages
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