MPC 4000 GEN II Series Additional Instructions For Installation And Operation Download

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90-891909001 AUGUST 2005

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MPC 4000 GEN II SERIES LOCK BAR

MECHANICAL PANEL CONTROL

INSTALLATION AND OPERATION

NOTICE

After completing installation, these instructions should be placed with the product for the owner's future use.

NOTICE

This document is written to aid our dealers, boatbuilders, and company service personnel in the proper

installation or service of our products. Persons who are not familiar with these or similar products produced

by Mercury Marine, and who have not been trained in the recommended servicing or installation procedures

should have the work performed by an authorized Mercury Marine dealer technician. Improper installation

or servicing of the Mercury product could result in damage to the product or personal injury to the installer

or persons operating the product.

Lock Bar Remote Control

17428

Notice to Installer/Owner

Safety Alerts and Notices

Throughout this publication, "Warnings" and "Cautions," accompanied by the

international HAZARD symbol

, are used to alert the technician to special

instructions concerning a particular service or operation that may be hazardous if

performed incorrectly or carelessly. Observe these safety alerts carefully.
These safety alerts alone cannot eliminate the hazards they signal. Strict compliance to

these special instructions when performing the service, and common sense operation are

major accident prevention measures.

Summary of Contents for 4000 GEN II Series

Page 1: ...ed by an authorized Mercury Marine dealer technician Improper installation or servicing of the Mercury product could result in damage to the product or personal injury to the installer or persons operating the product Lock Bar Remote Control 17428 Notice to Installer Owner Safety Alerts and Notices Throughout this publication Warnings and Cautions accompanied by the international HAZARD symbol are...

Page 2: ...cision Parts Accessories Guide for the available shift and throttle cables for your application This control requires the use of Mercury Quicksilver GEN II shift and throttle cables IMPORTANT Remote control cables must be the correct length sharp bends on too short cables result in kinks too long cables require unnecessary bends and or loops Both conditions place extra stress on the cables IMPORTA...

Page 3: ...erious injury or death from sudden unexpected loss of throttle shift control The control handle retaining bolt must be properly torqued and retained with Loctite Threadlocker to prevent the control handle retaining bolt from loosening thus resulting in disengagement of the control handle 1 If the control handle is removed and reinstalled for any reason apply Loctite 271 Threadlocker on the threads...

Page 4: ...l wiring harness are routed correctly CAUTION To shift the remote control into reverse gear when the engine is not running the propeller or propshaft must be rotated in the proper direction Forcing the shift mechanism into reverse may damage the control system 5 Operate the control handle several times see Caution preceding Any binding or stiffness in the operation of the control handle is usually...

Page 5: ...5 75 in 147 mm 7 78 in 197 6 mm 8 62 in R 218 9 mm 2 00 in 50 8 mm 69 9 mm 2 75 in 353 1 mm 13 9 in 303 3 mm 11 94 in 17434 32 8 mm 1 29 in 125 5 mm 4 94 in 76 5 mm 3 00 in 25 4 mm 1 00 in 218 9 mm 8 62 in 40 6 mm 1 60 in 142 2 mm 5 60 in a b b c d a Maximum mounting panel thickness b If shift and throttle cables are not mounted in the same housing slot position do not use clamping straps an incre...

Page 6: ...ke sure handle clears dash seats steering wheel and any other obstructions when rotating NOTE When mounting the panel control on the port side decal 37 891905002 must be ordered and attached to the bezel Bezel Location and Drilling Mounting Area IMPORTANT Mounting panel thickness must not exceed 25 4 mm 1 in NOTE The remote control template supplied with this instruction sheet will allow the insta...

Page 7: ...Maximum mounting panel thickness 25 4 mm 1 in c Template Installing Bezel 1 Install bezel to mounting surface as shown Tighten bezel mounting screws to specified torque 17438 a b c d a Screw 0 250 20 x 1 750 in 3 b Washers 3 c Nuts 0 250 20 3 d Mounting surface Description Nm lb in lb ft Bezel mounting screw 5 6 50 NOTE On some boat installations it may be helpful to first make the cutout for remo...

Page 8: ...Route the trim switch leads from the handle assembly through the bezel cover and bezel opening as shown 2 Allow sufficient slack in leads to permit free movement of trim leads through the full range of shift handle motion 17440 a d c b a Bezel opening b Trim switch c Trim leads d Bezel cover IMPORTANT Verify trim trailer wires are not pinched when mounting remote control module to panel of boat Tr...

Page 9: ...and the remote control in neutral install the control module Secure with three screws Tighten the screws to specified torque 17441 a b a Control module mounting screw 3 b Control module Description Nm lb in lb ft Control module mounting screw 5 6 50 7 Connect the trim switch wires to appropriate wiring harness 17445 b a c a Trim lead connector b Trim pump lead c Trim switch wires ...

Page 10: ...II Module Assembly Apply a small amount of 2 4 C with Teflon to inside of bushing 17446 95 a a Bushing Tube Ref No Description Where Used Part No 95 2 4 C with Teflon Inside of the 4000 GEN II Module Assembly bushing 92 802859A1 9 Align the tabs on the bezel cover with slots on the bezel Snap the bezel cover in place 17540 a b c a Bezel b Tabs 4 c Bezel cover ...

Page 11: ...nt of the control handle 10 If the control handle is removed and reinstalled for any reason apply Loctite 271 Threadlocker on the threads of the control handle retaining bolt Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Control handle retaining bolt 92 809819 11 Place the handle assembly onto the remote control module and secure with the control handle retaining bolt using...

Page 12: ...7670 a b c a Handle assembly b Throttle only button c Control handle retaining bolt Description Nm lb in lb ft Control handle retaining bolt 17 150 12 Install the throttle only button 17541 a b a Handle assembly b Throttle only button IMPORTANT Leave the trim harness loose behind the panel Do not use cable ties near the control module harness must have free movement when rotating handle Throttle O...

Page 13: ... LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION 90 891909001 AUGUST 2005 Page 13 26 3 Use a flat blade screwdriver to gently pry the throttle only button out of the control handle 17548 a a Throttle only button ...

Page 14: ...s 18 HP 20 HP 25 HP U S Origin With Push Throttle Cable 4 1 3 1 Mariner and Mercury Outboards Counter Rotation Gearcase All Models through 225 HP 3 2 4 2 Mariner and Mercury Outboards Standard Rotation Gearcase 250HP 275 HP 3 2 4 2 Mariner and Mercury Outboards Counter Rotation Gearcase 250 HP 275 HP 4 2 3 2 17551 a b 1 2 4 3 a Shift arm b Throttle arm Mercury MerCruiser Models IMPORTANT Shift cab...

Page 15: ...r Stud Number 4 2 3 2 Port Mount Mechanical Control Anchor Attachment Points Anchor Attachment Points Shift Cable Throttle Cable Shift Cable Throttle Cable Direction of Arrow X X Y X Lever Stud Number 3 2 4 2 17551 a b 1 2 4 3 a Shift arm b Throttle arm Typical Shift and Throttle Cable Installation Outboard and Mercury MerCruiser WARNING Avoid serious injury or death from sudden unexpected loss of...

Page 16: ... torque 17555 7 b d a c d c e c d a a Small spacer b Screw c Shift cable d Throttle cable e Large spacer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Control cable fastener screws 92 809819 Description Nm lb in lb ft Control cable fastener screws 2 8 25 4 After control cable installation secure back plate with five washers and screws as shown ...

Page 17: ...e rear of the control 17557 a c b a Back plate b Washer 5 c Screw 5 Description Nm lb in lb ft Back plate screws 5 Drive tight Electrical Connections Neutral Start Safety Switch 1 Connect wires from neutral start safety switch leads as shown in the Instrument Lanyard Stop Switch Wiring Diagrams WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting the engine The...

Page 18: ...PPL or PUR Purple RED Red TAN Tan WHT White YEL Yellow LT or LIT Light DK or DRK Dark Lanyard Stop Switch Wiring Diagrams Mercury Mariner Outboards 40 HP through 225 3 0 Liter Force 1993 and Newer a b b c d e f g YEL RED YEL RED YEL RED YEL RED BLK BLK BLK YEL BLK YEL 17563 a Neutral start safety leads b Bullet or eyelet connectors c Ignition key switch d Engine harness connector e Power trim conn...

Page 19: ...asoline Models 12V YEL RED YEL RED YEL RED YEL RED PUR WHT PUR WHT PUR PUR BLU BLU BLU BLU PUR PUR GRN RED 17565 a b c d f g h e b i a Neutral start safety leads b Bullet or eyelet connectors c Ignition key switch d Engine harness connector e To power trim cowl switch f Power trim connector g Lanyard stop leads h 4 pin plastic connector i To power trim pump ...

Page 20: ...els A B BLK YEL 1 BLK 8 TAN WHT 6 WHT GRN 5 BLU TAN 2 TAN BLK 3 BRN 4 B YEL RED 7 GRY 2 BRN WHT 10 TAN 3 TAN BLU 4 PUR 5 RED PUR 6 A 17583 h a b c d e f g h i j LT BLU 8 BLK 1 BLK 7 a Ignition key switch b Stop switch c Light switch and audio test d Pre heat e Alternator f Oil pressure g Coolant temperature h Neutral start switch leads i Bullet or eyelet connectors j Lanyard stop switch ...

Page 21: ...g h i BLK YEL 1 BLK 8 TAN WHT 6 WHT GRN 5 BLU TAN 2 TAN BLK 3 BRN 4 B YEL RED 7 GRY 2 BRN WHT 10 TAN 3 TAN BLU 4 PUR 5 RED PUR 6 A LT BLU 8 BLK 1 BLK 7 j PUR WHT a Water in fuel indicator b Coolant temperature c Oil pressure d Alternator e Pre heat f Light switch and audio test g Ignition key switch h Neutral start switch leads i Bullet or eyelet connectors j Lanyard stop leads ...

Page 22: ...res 4 Lanyard Stop Switch if equipped The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch Tiller handle outboards and some remote control units are equipped with a lanyard stop switch A lanyard stop switch can be installed as an accessory gen...

Page 23: ...boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the en...

Page 24: ...ral Installation Information for instructions IMPORTANT Control handle friction is necessary for proper mechanical control operation Insufficient friction may cause undesirable throttle arm operation MPC 4000 Gen II Series Bezel Template IMPORTANT Due to printing variables the image may have changed from the actual size Check this template with the bezel before cutting the mounting holes or use th...

Page 25: ...ON 90 891909001 AUGUST 2005 Page 25 26 17592 7 14 mm 7 14 mm 31 8 mm 108 mm 9 32 in 9 32 in 1 1 4 in 4 1 4 in b a a 7 14 mm 9 32 in a c d a Machine screw drill size b Remove sharp edges c Only if equipped with a lanyard stop switch d Outline of starboard mounted panel control module ...

Page 26: ...ellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort M with Waves logo Mercury with Waves logo and SmartCraft logo are all registered trademarks of Brunswick Corporation Mercury Product Protection logo is a registered service mark of Brunswick Corporation W6250 Pioneer Road Fond du Lac WI 54936 1939 Page 26 26 90 89190...

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