ch7800 mechanical control user manual
Contents
1. 0 22 in 0 5 59 mm 4 holes 6 35 mm Radius 0 81 in 20 57 mm 2007 Teleflex Inc 2 YEAR LIMITED WARRANTY The Teleflex Marine division of Teleflex Incorporated Teleflex Marine warrants its products to be free from defects in materials and workmanship for a period of two years from the date of original retail purchase provided however the warranty period for Teleflex Marine products used commercially or in any rental or other income producing activity shall be as follows Ninety days from the date of original purchase for mechanical and electrical products and One year from the date of original purchase for hydraulic products We will provide replacement product without charge for any Teleflex Marine product covered by this warranty which is returned freight prepaid within the warranty period to the dealer from whom such products were purchased or to us at the appropriate address In any such case Teleflex Marine products found to be defective and covered by this warranty will be replaced or repaired at Teleflex Marine s option and returned to the customer Teleflex Marine s sole responsibility under this warranty is limited to the repair or replacement of product which is in Teleflex Marine s opinion defective Teleflex Marine is not responsible for charges connected with the removal of such product or reinstallation of replacement or repaired parts We will have no obligations under this w2. A CAUTION Do not tighten cable hangers or clamps to the extent that they crush or stress the cables in any way Doing so may impair the function of the cable The information contained in this manual is believed to be accurate at the time of going to print but no responsibility direct or consequential can be accepted for damage resulting from the use of this information The manufacturer reserves the right to make changes without notice to any of its products User Manual ISCH7800 Mechanical Controls Rev 0 0 INTRODUCTION This Teleflex Marine Control provides both shift and throttle operation for outboards inboards or I Os stern drives We recommended the use of Teleflex TFXTREME control cables Standard Control Features Single lever shift and throttle operation Neutral Throttle Warm up Neutral Safety Switch to prevent starting in gear Friction Damper to prevent throttle creep Control Options Trim Switches Trim amp Tilt Switches Adaptability Control Cable This control will connect to many current 3300 33C or OEM type control cables A cable nest kit also known as a quick connect adaptor part 212151 003 which mates to the engine s shift and throttle cables is included with this control NOTICE Note Unique Cable Nests required for Merc Gen II control cables only are also included with the control 2007 Teleflex Inc CONTROL FEATURES AND OPERATION 1 NEUTRAL THROTTL
3. UP User Manual ISCH7800 Mechanical Controls Rev 0 0 CH7800 OPERATION Push Button Used for starting or engine warm up When the hand lever is in the neutral detent position depress the button in the center of the handle to enable operation of the throttle without engaging forward or reverse gear When warm ups is completed return the lever to the neutral position the button will pop back out making the control ready for normal operation RE T Throttle Friction Adjustment Adjustment of this screw enables the friction in the throttle operating mechanism to be increase and prevent unwanted handle movement To adjust place the hand lever in the forward or reverse throttle position just beyond the shift position Remove the cover and adjust the throttle friction screw turning the screw clockwise increases the friction Care should be taken not to over tighten PUSH BUTTON FOR NEUTRAL THROTTLE OPERATION ADJUSTABLE THROTTLE FRICTION 2007 Teleflex Inc CH7800 GENERAL DIMENSIONS Front View 8 1 2 RE CIO 5 1 8 e E 3 3 8 User Manual ISCH7800 Mechanical Controls Rev 0 0 Side View 2007 Teleflex Inc MAINTENANCE Maintenance and Corrosion Protection For maximum protection especially in a salt water environment the Control Head and Hand Lever should be washed
4. 3 3 4 4 MERCURY18 amp 25 HP 5 6 6 7 8 7 EVINRUDE JOHNSON 5 6 5 7 8 8 INBOARDS 3 3 4 4 PULL for FORWARD SHIFT PORT STARBOARD MANUFACTURER CABLE SHIFT CABLE SHIFT NEST KIT LEVER NEST KIT LEVER 3300 CABLES 4 4 3 3 MERCURY 7 8 7 5 6 6 EVINRUDE JOHNSON 7 8 8 5 6 5 HONDA NISSAN SUZUKI 4 4 3 3 TOHATSU US MARINE 4 4 3 3 4 4 3 3 INBOARDS 4 4 3 3 CABLE NEST BRACKET 2007 Teleflex Inc NENNEN Throttle Cable Connection e PUSH PULL refer to the direction of cable motion to shift into Control End forward or to open the throttle e Refer to the appropriate manufacturer s manual for shift and throttle direction and adjustments Numbered holes on mechanism chassis correspond to holes shift and throttle levers for example connect cable mount to hole 4 on chassis and cable end fitting to hole 4 on lever e Cables and wiring should be pre installed on control before final mounting is made Cable Mounting Diagram PUSH to OPEN THROTTLE PORT STARBOARD THROTTLE MANUFACTURER CABLE THROTTLE CABLE THROTTLE NEST KIT LEVER NEST KIT LEVER MERCURY18 amp 25 HP 1 1 1 1 JOHNSON EVINRUDE 1 1 1 1 BRP OMC 1 0 YAMAHA 90HP amp UP US MARINE SUZUKI PULL to OPEN THROTTLE PORT STARBOARD MANUFACTURER CABLE THROTTLE CABLE THROTTLE NEST KIT LEVER NEST KIT LEVER MER
5. CH7800 MECHANICAL CONTROL USER MANUAL Instructions for your Teleflex Marine product Please read these instructions through carefully and entirely before using All specifications and features are subject to change without warning ISCH7800 Teleflex Revision 0 0 MARINE Notice to Boat Manufacturer Installer and Boat Operator Throughout this manual Warnings and Cautions accompanied by the International Hazard Symbol N are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Warnings alone do not eliminate dangers nor are they a substitute for safe boat handling and proper accident prevention measures Observe these alerts carefully These safety alerts alone cannot eliminate the hazards that they signal Strict compliance to these special instructions when installing operating or performing maintenance and using common sense are the most effective accident prevention measures DANGER WARNING Immediate hazards which Hazards or unsafe will result in severe practices which COULD personal injury or death result in severe personal injury or death CAUTION NOTICE Hazards or unsafe Information that is important practices which COULD to proper installation result in injury product operation or maintenance and or property damage but is not hazard related For example
6. CURY 1 0 amp 0 B 2 2 2 2 VOLVO 1 0 2 2 2 2 YAMAHA 70HP amp UNDER 2 2 2 2 HONDA 2 2 2 2 NISSAN TOHATSU 2 2 2 2 CABLE NEST BRACKET 8 User Manual ISCH7800 Mechanical Controls Rev 0 0 Shift amp Throttle Cable Connection Control End Shift Arm Cable Terminal Connection Shift Arm Cable Terminal Connection for Mercury for 3300 33C Type Cables Mariner Force OEM and OMC BRP OEM Type Cables gt Throttle arm or shift arm ref Locknut head screw Marinet Throttle arm or OEM type shift arm ref cables 0 125in 4 OMC BRP 3 175mm Bushing OEM type Pivot cables 33C cable OMC BRP Mercury OEM type or Mariner cables e CABLE ROD END SHOULD EXTEND APPROX cables 0 125in 3 175mm THROUGH PIVOT Note For GEN lt gt nest is neutral in to retain cables color Cable options L eaan aaa Clip f eX 990 cable ib alle DJA hie p cables lt gt 7 Ds Flat head screw Lage Swivel bearing o Mercury Gen II Nest Kit gt Cable End Options e Mercury Gen Il note neutral next color 3300 33C type cables Universal note black nest color Mercury Mariner Force OEM type cables note black nest color BRP OMC OEM type cables note black nest color Each cable type connects differently 2007 Teleflex In
7. E WARM UP BUTTON This feature provides a throttle only option to warm up the engine before driving the boat When the Control Hand Lever is in Neutral push and hold the button at the base of the handle While holding the button 1 move the lever forward to throttle up the engine When you return the handle to the Neutral position the button will reset automatically Once the button resets the hand lever will work both shift and throttle functions 2 ENGINE TRIM SWITCH Used to move the engine IN or OUT to level the boat while underway 3 TRAILER TILT SWITCH Used to raise the engine for trailering the boat User Manual ISCH7800 Mechanical Controls Rev 0 0 TOOLS NEEDED FOR INSTALLATION amp OEM EQUIPMENT APPLICATIONS ELECTRICAL TRE PHILLIPS amp STANDARD T M SCREWDRIVERS SABRE SAW BOX END WRENCH SET DRILL BIT SET OPTIONAL 3 4 1 amp 3 50 hole saws See cutout patterns n er Other Equipment Needed 1 Four each Teleflex 3300 33C type cables or four each OMC BRP OEM type cables or four each Mercury Mariner Force OEM type cables 2 for shift 2 for throttle 2 Throttle and Shift engine connection kits See Teleflex Catalog contact your nearest Teleflex dealer Ec pu LL nl OEM Equipment Applications OMC BRP applications would include Outboards Evinrude and Johnson I Os Stern Drives OMC some Volvo Mercury appli
8. arranty for any product which has been improperly installed has been used in an installation other than as recommended in our installation or operation instructions or specifications has failed or has been damaged due to an accident or abnormal operation including racing misuse or alterations outside our factory has been repaired or modified by entities other than Teleflex Marine has been used on an engine boat combination where the engine horsepower exceeds the rating established by the boat manufacturer has been used with other product s which in Teleflex Marine s opinion are incompatible with the Teleflex Marine product THE EXPRESS WARRANTY SET FORTH ABOVE IS 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 MARINE EMPLOYEES OR REPRESENTATIVES ORAL OR OTHER WRITTEN STATEMENTS DO NOT CONSTITUTE WARRANTIES SHALL NOT BE RELIED UPON BY CUSTOMER AND ARE NOT A PART OF THE WARRANTY STATED HEREIN THIS WARRANTY WILL BE THE CUSTOMER S EXCLUSIVE REMEDY IN NO EVENT WILL TELEFLEX MARINE BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY RELATING TO THE PRODUCTS Some states do not allow limitations on an implied warranty or the exclusion of incidental or consequential damages so the above exclusions may not apply to you You may also have other rights which va
9. c Shift amp Throttle Cable Connection Engine End CAUTION The throttle cable must be disconnected from the motor before making motor idle adjustments Adjustment of the motor idle while the throttle cable is connected to the motor may cause jamming action against the idle stop As a result the control may not function properly and damage to the control the cable and or the motor may occur 1 Make sure the Control is in NEUTRAL DETENT 2 The Engine Throttle Lever should rest lightly against the Idle Stop on the carburetor 3 Connect the Throttle Cable to the Engine Throttle Lever 4 To assure smooth control operation and avoid preloading of system Put hand lever into full forward throttle before connecting cable to shift lever and transmission linkage Refer to engine manufacturers recommendations for attaching cable to transmission shift lever Engine throttle lever Throttle cable terminal Throttle cable 33C shown MINIMUM PRESSURE HERE Idle stop NOTE THIS FIGURE DOES NOT REPRESENT ANY PARTICULAR ENGINE NOTICE Throttle Cable must be free of load NO LOAD when throttle lever is in the idle position to prevent hard shifting User Manual ISCH7800 Mechanical Controls Rev 0 0 ee Electrical Connections Neutral Safety Switch This control is provided with a Neutral Safety Switch This switch is used to prevent the engine from starting in gear NOTICE Use a batter
10. cations would include Outboards Mercury Mariner most Force Os Stern Drives MerCruiser Inboards Mercury and MerCruiser Where a particular engine brand is noted in the illustrations on page 9 those cable mounting locations are for OEM type cables not the universal 3300 33C type 2007 Teleflex Inc s INSTALLATION Location of Control 1 3 4 Allow adequate clearance for hand lever swing forward and reverse positions Allow adequate clearance under the console or in the gunwale for the cables AND allow a minimum of 36 from the cable nest connection with no restraint When supporting the cables beyond 36 do not tie or clamp tightly After a suitable location for the control is determined use the separate mounting template Closely follow the instructions provided on the template Cut amp drill the mounting holes required On all models the cover will have to be removed to expose the mounting holes BEEE H Measuring the Cables Measure the cable routing path from the control head connection to the engine connection Outboards 1 Measure from the control connection along an unobstructed cable routing to the center of the outboard engine 2 Add four 4 feet to the measurement to allow for a loop which TYPICAL OUTBOARD CABLE ROUTING provides unrestricted engine movement Round UP
11. ry from state to state If any part of this Limited Warranty is determined to be void or illegal the remainder shall remain in full force and effect Teleflex Marine products returned under this warranty must be tagged with the customer s name street address and phone number to ensure proper handling and returned freight prepaid to the selling dealer or to the appropriate Teleflex Marine manufacturing facility Warranty Items Teleflex Mechanical Electrical Hydraulic Only Teleflex Marine field representatives are authorized to investigate any allegedly defective merchandise in the field They can request credit disposal and or return of these products during the course of their regular visits to the customer s facilities once they have the facilities approval User Manual ISCH7800 Mechanical Controls Rev 0 0 2007 Teleflex Inc CH7800 Mechanical APPLICABLE STANDARDS Engine Controls ABYC P 14 Propulsion Control Systems User Manual USCG 33 CFR Part 183 Subpart Start in Gear Protection SAFE BOATING STATEMENT This device meets or exceeds the applicable ABYC ISO and USCG safe boating rules regulations standards and guidelines SAFE BOATING ON THE WEB U S Coast Guard www uscg mil U S Power Squadron www usps org American Boat amp Yacht Counsel www abycinc org Melefle x MARINE Teleflex Marine 640 North Lewis Road Limerick 19468 Phone 610 495 7011 FAX 610 495 7470
12. to the next whole MEASURE CABLE PATH ROUND UP LOOPAT ENGINE TO PREVENT KINKING foot and order the required cable part number Last two digits of the Teleflex cable number equal the length of the cable in feet Inboards amp Stern Drives 1 Measure from the control connection along an unobstructed TYPICAL STERN DRIVE INBOARD CONTROL CABLE ROUTING MEASURE CABLE PATH ROUND UP TO NEXT EVEN FOOT cable routing to the SHIFT or THROTTLE connection Round this dimension UP to the next whole foot and order the required cable part number Last two digits of the Teleflex cable number equal the length of the cable in feet User Manual ISCH7800 Mechanical Controls Rev 0 0 I Shift Cable Connection e PUSH PULL refer to the direction of cable motion to shift into Control End forward or to open the throttle e Refer to the appropriate manufacturer s manual for shift and throttle direction and adjustments Numbered holes on mechanism chassis correspond to holes shift and throttle levers for example connect cable mount to hole 4 on chassis and cable end fitting to hole 4 on lever e Cables and wiring should be pre installed on control before final mounting is made Cable Mounting Diagram PUSH for FORWARD SHIFT PORT STARBOARD THROTTLE MANUFACTURER CABLE SHIFT CABLE SHIFT NEST KIT LEVER NEST KIT LEVER VOLVO 1 0 amp INBOARDS 3 3 4 4 DPX DP G DP E 290 3300 CABLES
13. with fresh water on a regular basis Periodically check the Control Head Mechanism for loose fasteners and signs of wear on moving parts Keep these moving parts well lubricated with a high quality moisture displacing lubricant such as marine grease Periodically check the cables and engine connections for signs of wear and corrosion Replace as necessary NENNEN Service Parts Kits All service parts can be purchased from your local Teleflex Marine Distributor PART DESCRIPTION PART NUMBER Cable Nest and Connection Kit 212151 003 includes Mercury Gen II Nest Chrome Insert Kit with and without tilt cut out 7214311 Black Insert Kit with and without tilt cut out 7214518 Neutral Throttle Warm up Kit Flexible Button 309172 White Plunger 309184 Tilt switch with Inserts 1 Chrome 1 Black 7206216 NOTICE A quantity of 2 is needed for ALL above products for complete control User Manual ISCH7800 Mechanical Controls Rev 0 0 purposes A separate work template part number 309569 This template is NOT to scale Its presence is for information has been included with this control MOUNTING TEMPLATE NOTICE Bow of Boat 4 5 12 in 130 05 mm 5 00 in 127 0 mm 2 50 63 50 mm 0 12 in 3 05 mm Radius 0 50 in 12 70 mm 4 holes 2 20 in 55 88 mm 4 4 in 111 78 mm 2 20 in 55 88 mm
14. www teleflexmarine com Teleflex Marine is a division of Teleflex Incorporated 2007 Teleflex Inc 20 User Manual ISCH7800 Mechanical Controls Rev 0 0
15. y powered test light or test meter to check continuity 1 With the Control in NEUTRAL connect one wire of the tester to the common terminal and one wire to the NO Normally Open Terminal The test light MUST light 2 Connect the neutral safety switch between the ignition switch start lead and the starter solenoid Safety switch Start Normally Common Ignition ee of Starter solenoid A CAUTION Use a multi meter or continuity tester to make sure that there is electrical continuity only when the control is in neutral position When the control is in forward or reverse gear there must not be electrical continuity The multi meter or tester should show an open circuit 2007 Teleflex Inc Trim and Tilt Refer to the wiring diagrams below for the correct Trim and Tilt switch connections and wire accordingly NOTICE On both 3 wire AND 5 wire systems reverse the blue and green connections for opposite trim operation Trim Tilt NOTE FOR TILT C WHITE and 1 Connect an TRIM Ke TILT GREEN together DN UP 2 Connect VIOLET to power 3 Not all engine are wired the same especially ABBREVIATIONS older engines Check with the engine DN UD manufacturer for T wiring specifications COLOR KEY 4 Use either the upper or lower Tilt switch to bring B BLUE BRG GVW Tilt UP G GREEN To bring Tilt DOWN use V VIOLET Trim DOWN switch R RED W WHITE UP DN UP
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