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Manufacturer's Operating and Installation Instructions for Hydraulic Engine Control System

PREPARATION FOR INSTALLATION

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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 complete system has been received.

It is advised that all systems 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

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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 seats of controls are mounted side by side. See Figure 1.

NOTE: This minimum distance does not apply to installations using the optional "knob" style control handles.

2. Using the template provided in the appendix, mark and cut a hole for the sender. Figure 29is 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. (Also see instructions for copper tubing installations)

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.

Figure 1: Mounting
Figure 2. Single Head Sender
Figure 3. Side-By-Side Senders

Throttle Slave Installation

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NOTE
The standard 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.

Morse throttle slaves must be mounted so that at the mid-stroke of both the engine's throttle arm and the Morse 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.

Figure 4. Throttle Slave to Throttle Arm Installation
Steps 1 thru 8 apply to both ST-04 and ST-06 Systems

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 steel 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.

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 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. 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

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".

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


Figure 5. ST-06 Integrated Throttle Slave with Tee and Bleeder Valve Installation

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.

NOTE
If the throttle slave is in a limited space, it may be removed from the bracket during the lock-out valve installation. The STV-10 Lock Out Valve must be plumbed as shown in Figure 6. The lock-out valve will lock the slave's 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 install the 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, 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.

Figure 6. ST-04 Throttle Slave with STV-10 Lock-Out Valve

Clutch Slave Installation

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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 7. Proper Clutch Slave to Clutch 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.

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 a 1/4-20 stainless steel or brass threaded rod.

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 hold and adjusting both ball joints 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 arm.

11. After determining the correct linkage length, securely lock the ball-joints to the threaded rod with lock-nuts. 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
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 be required which is not covered in this manual. Contact Morse for this information.

R-13 Reservoir Installation

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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 easy to read.

4. The operator must have easy access to the air filter 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 mountable 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 10. Charging Valve on R-13 Reservoir

R-04 Reservoir Installation

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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 easy to 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 mountable 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.

Figure 11. Ports on Bottom of R-04 Reservoir

MCV-04 Charging Valve Installation

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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 to a bulkhead using two screws.

Figure 12. MCV-04 Charging Valve

Tubing Installation and Connection

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CAUTION
Dirt and foreign matter in the hydraulic system will 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.

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 (Nylon)

NOTE
The instructions and illustrations in this section apply to Nylon Tubing ONLY. Also see information on use of Copper Tubing.

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. Keep tubing away from any high heat source, such as an engine turbo charger.

5. Do not allow tubing to become kinked. If it does, replace that particular run of tubing.

6. String tubing so that it will not interfere with hatchways or machinery removal.

7. Use only nylon tubing supplied with system from Hynautic.

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.

Figure 13. Assembling Tubing Connectors

Installing Tubing Between Senders and Slaves

(Also see Plumbing Circuit Diagrams)

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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 circuit.

NOTE
Tubing may be run from the sender to connecting point or from connecting point to sender, whichever is easier.

3. Secure each end of the newly run tube by inserting the tube and 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 appropriate tubing circuit.

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 over tightening will crimp the tubing causing poor system operation.

Copper Tubing Installation and Connection

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

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 fittings. 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 malfunction of the system may occur.

The following figures illustrate the proper connections for copper tubing installation between components of the Engine Control System.

Figure 15. Charging Valve on Bottom of R-13 Integrated Reservoir

Figure 16. ST-06 Integrated Throttle Slave
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
Figure 20. SS-04 Shifter Slave

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