User Manual: CH1700/7500/7600
Contents
1. termination temale blade disconnect Emergency New wire not included stop wire Recommend 16 AWG Gee installation notes CAUTION If engine fails to stop recheck all wiring Should the engine fail to start or stop or resume running with the lanyard fork removed consult your local marine dealer for assistance ISCH7500 Rev2 12 User Manual CH1700 7500 7600 General Control Dimensions CH1700 Side Mount Control General Dimensions 3 I GUNWALE THICKNESS VARIES FROM 1 4 TO 3 4 CH7500 7600 Top Mount Control General Dimensions ISCH 500 Rev2 13 User Manual CH1700 7500 7600 Exploded View CH1700 Friction Adjust Screw Adjustment of this screw enables the friction in the throttle operating mechanism to be increased and prevent unwanted handle movement To adjust place the lever in the forward or reverse throttle position just beyond the shift position Remove the cover and adjust the friction adjust screw turning the screw clockwise increases the friction Do not over tighten Friction Adjust Screw Mounting Plate The orientation of the switch is important ISCH7500 Rev2 14 User Manual 1700 7500 7600 Exploded View CH 500 7600 3 tQ a 3 n Friction A Adjust O Screw ASZ o e 5 99 Friction Adjust Screw Adjustment of this screw enables the friction in the throttle operating mechanism to be increased a2. 24 2 3 32 63 5 mm 2 4 mm ISCH7500 Rev2 18 User Manual CH1700 7500 7600 ETT CH1700 Mounting Template iS Side Mount Control Back Mount Installation 12 NN THIS TEMPLATE MAY NOT BE TO SCALE ITS PRESENCE IS FOR INFORMATION PURPOSES A Cw ML SEPARATE WORK TEMPLATE MT CH17 BACKMOUNT HAS BEEN INCLUDED WITH THIS QN COoNTROL NI s 3 1 2 89 3 4 44 5 mm 29 32 4X 7 1 mm ae EXE 3 2 i Forlignition 31 32 Interrupt Switch For Tilt Switch 89 mm 24 6 mm 1 24 mmi 14 2X 31 8 mm 0 114106 1116 PT 101 9 mm 61 9 mm 4 1 4 108 0 ISCH7500 Rev2 19 User Manual CH1700 7500 7600 CH1700 CH7500 CH7600 Mechanical Engine Controls Patent No D508 227 D510 310 D510 311 D510 558 D510 559 D510 557 User Manual Operation amp Instructions Part Number I8CH7500 Rev2 January 2006 APPLICABLE STANDARDS ABYC P 14 Propulsion Control Systems USCG 33 CFR Part 183 Subpart L 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 Teleflex Marine 640 North Lewis Road Limerick PA 19468 Phone 61
3. ENGINE TRIM SWITCH CH7600 shown here Used to move the engine IN or OUT to level the boat while underway This switch controls trim and tilt on most outboards 4 TRAILER TILT SWITCH Used to raise the engine for trailering the boat This switch normally is used on applications 5 OPTIONAL EMERGENCY IGNITION INTERRUPT SWITCH Used as a safety device To work as a safely device the lanyard clip must ba attached to the emergency ignition interrupt switch 5 and the lanyard see photo itself must be secured to the boat operator If the clip is pulled free of the control the engine will shut down ISCH7500 Rev2 4 User Manual CH1700 7500 7600 INSTALLATION Section 1 Location of Control 1 1 Allow adequate clearance for hand lever swing forward and reverse positions 1 2 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 1 3 After a suitable location for the control is determined use the separate mounting template 1 4 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 Tools for Installation Phillips head screwdrivers Power drill 5 8 or 16mm deep well socket Standard slot screwdriver 7 32 amp 17 64 drill
4. bits Ratchet wrench 474 Hole Saw optional Multimeter optional _ Section 2 Measuring the Cables Measure the cable routing path from the control head connection to the engine connection Outboards Measure from the control connection along an unobstructed cable routing to the center of the outboard engine Add four 4 feet to the measurement to allow for a loop which provides unrestricted engine movement Round 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 Inboards amp Stern Drives Measure from the control connection along an unobstructed 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 ISCH7500 Rev2 5 User Manual CH1700 7500 7600 Section 3 Shift amp Throttle Cable Connection Control End o PUSH PULL refer to the direction of cable motion to shift into forward or to open the throttle o Refer to the appropriate manufacturer s manual for shift and throttle direction and adjustments Numbered holes 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 o Cables and wiring should be
5. nn SolidBle 0 Suzuki Solid Brown Blue w Black Stripe or oolid Blue Black w Yellow Stripe Measure and cut two lengths of black 16 AWG marine quality wire of sufficient length to connect one Interrupt Switch terminal to the Emergency Stop Wire and the other terminal to a System Ground See Diagram B at right Strip one end of each wire and crimp on an insulated 1 4 inch female disconnect terminal A crimping tool designed for insulated terminals MUST be used Attach the female disconnects to each of the male terminals on the Interrupt Switch Attach the other end of one wire to the Emergency Stop Wire using a suitable insulated wire connecting device See Reference Table 1 and Diagram B Attach the other end of the second wire to the ground point using a suitable insulated wire connection device as shown in Diagram B at right Diagram B Recheck all connections Install the Lanyard with the Fork Clip seated Outboard Wiring over the Plunger Replace engine cover and reconnect battery Magno malch emergency Start engine If engine does not start a disconnect battery b remove Slop wire eng Lanyard engine cover c recheck all electrical connections d replace engine See color Switch 11 cover and e restart engine lable PIN 311375 2 Remove Lanyard Engine should stop immediately Black Terminale to suit Emergenc Engine slop Insulated 1 4 Inch sie
6. pre installed on control before final mounting is made Cable Connection Guide PUSH to OPEN THROTTLE Throttle CH1700 CH7600 CH7500 Lever CABLE THROTTLE CABLE THROTTLE NEST KIT LEVER NESTKIT LEVER MERCURY18 amp 25 HP T T 1 1 JOHNSON EVINRUDE T T 1 1 BRP OMC I O T T 1 1 YAMAHA 90 amp UP T T 1 1 US MARINE 1 T 1 1 SUZUKI 1 T 1 1 PULL to OPEN THROTTLE CH1700 CH7600 CH7500 MANUFACTURER NESTKIT LEVER NESTKIT LEVER MERCURY 1 0 amp 2 2 2 2 VOLVO I O 2 2 2 2 YAMAHA 70 amp UNDER 2 2 2 2 HONDA 2 2 2 2 NISSAN TOHATSU 2 2 2 2 PUSH for FORWARD SHIFT CH1700 CH7600 CH7500 MANUFACTURER LEVER NESTKT LEVER VOLVO 1 0 amp INBOARDS 3 3 4 4 3300 CABLES 3 3 4 4 MERCURY18 amp 25 HP 5 6 6 718 7 EVINRUDE JOHNSON 5 6 5 7 8 8 INBOARDS 3 3 4 4 PULL for FORWARD SHIFT CH1700 CH7600 CH7500 HIFT ABLE HIFT 1 pu ES KIT a 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 Cable Nest YAMAHA 4 4 3 3 Bracket INBOARDS 4 4 3 3 Cable Mounting Diagram ISCH7500 Rev2 6 User Manual CH1700 7500 7600 Section 3 Shift amp Throttle Cable Connection Control End Throttle Arm or Shift Arm Shift Arm Cable Terminal Connection for 33 C Cable Throttle Arm or Shift Arm Locknut KM Lo
7. the Inboard Outboard length of the lanyard or use another manufacturer s lanyard on this interrupt switch Normally OPEN Normally CLOSED Either may affect switch operation Misuse misapplication unauthorized modifications or incorrect installation of this safety devise could result in serious bodily injury or death 5 3 2 Installation Instructions for the Ignition Interrupt Switch All wiring connections and terminations should be done in accordance with ABYC Spec E 11 03 Before drilling check behind the gunwale or panel for sufficient clearance and space around wires tubes pipes and other obstructions If installing the switch as a retro fit remove the 4 mounting screws that retain the bezel Remove the bezel Overlay the cutout template supplied in the kit If the cutout profile does not match the template cutout the gunwale to suit the template profile If installing the control for the first time use the template to cutout the gunwale Insert the switch from the rear of the gunwale or from the front Your choice will depend on the design of your boat and access to the cavity between to hull and the gunwale Orient the switch according to the diagram before inserting the switch into the space provided in the control mounting plate the cutout and into the bezel Insert the 4 mounting screws through the bezel cutout and into the control mounting plate Assemble the bezel Insert onto the bezel and add the Int
8. without Trim CHreng 12138186 Black Replacement Handle without Trim 7214113 Chrome Maunt Cover CH 7 600 7214311 Chrome Top Mount Insert with or without Tilt CH7500 CH7600 7214518 Black Top Maunt Insert Kit with or without Tilt CH 7 600 1214718 Neutral Throttle Warm up Kit Top Mount CH7500 CH7600 ISCHTS0Q0 Rev2 16 User Manual 1700 7500 7600 e i CH1700 Mounting Template SAN Side Mount Control fpes ie NOTICE fi pL A f NS THIS TEMPLATE MAY NOT BE TO SCALE ITS PRESENCE IS FOR INFORMATION PURPOSES A um SEPARATE WORK TEMPLATE MT 17 75 76 Rev 0 HAS BEEN INCLUDED WITH THIS CONTROL Diameter 4 1 4 108 0 mm Diameter 9 32 V 1 3 7 1 44 5 13 4 A 44 5 mm 1 12 38 1 1 3 4 44 5 mm Au 9 32 7 1 mm 5 3 4 146 1 ISCH7500 Rev2 17 User Manual CH1700 7500 7600 7500 and CH7600 Mounting Template SEN Top Mount Single Lever Control NOTICE THIS TEMPLATE MAY NOT BE TO SCALE ITS PRESENCE IS FOR INFORMATION PURPOSES A SEPARATE WORK TEMPLATE MT 17 75 76 Rev 0 HAS BEEN INCLUDED WITH THIS CONTROL R 1 4 4 2 6 4 mm Diameter 7 32 T R 3 16 5 6 mm 12 7 mm 4 8 mir 1 3 8 9 5 mm 5 3 16 131 8 5 127 0 4 3 16 106 4 2 Eoo le
9. 0 495 7011 FAX 610 495 7470 www teleflexmarine com Teleflex Marine is a division of Teleflex Incorporated 02005 Teleflex Inc Melefle x ISCH7500 2 20
10. B Un 2 Connect VIOLET to power COLOR KEY 3 Not all engines are wired the same B BLUE especially older G GREEN engines Check with V VIOLET the engine R RED manufacturer for W WHITE wiring specifications A Use either the upper or lower Tilt switch to bring Tilt UP To bring Tilt DOWN use Trim DOWN switch ISCH7500 Rev2 9 5 3 Ignition Interrupt Switch This switch includes a lanyard clip which holds the plunger of the Switch in position to allow engine operation A lanyard extends from the clip and is connected securely to the operator If the operator moves away from the controls the clip is pulled free releasing the plunger and stopping the engine 5 3 1 Operation of the Ignition Interrupt Switch Emergency Emergency Ignition Interrupt Ignition Interrupt User Manual CH1700 7500 7600 s N N X X S 555 Before each motor start check that the Lanyard Fork Clip is properly seated over the switch and rotates freely Inspect the lanyard If it is cut worn or frayed it must be replaced iu Start the engine Test the switch by pulling the lanyard fork clip free from the switch The engine should stop Fork A WARNING If engine fails to stop recheck all wiring Should the engine fail to start or stop or resume running with the lanyard fork removed consult your local Switch Lm Switch E we marine dealer for assistance Do not change
11. USER MANUAL MEN 22222222 7500 a I i r u i i i EEG his manual must be accessible to the owner user of this Fr Teleflex Marine product E EIES Engine Controls Patent Mo D508 227 D510 310 D510 311 D510 55 D510 558 D510 558 CH7600 CH1700 EO Teleflex Inc ISCHT5OO Rev2 26009065 Meleflex MARINE User Manual CH1700 7500 7600 Notice to Boat Manufacturer Installer and Boat Operator Throughout this manual Warnings and Cautions accompanied by the International Hazard Symbol AN 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 DANGER WARNING compliance to these special instructions when installing Immediate hazards which Hazards or unsafe operating or performing WILL result in severe practices which COULD maintenance and using personal injury or death result in severe personal common sense are the most injury or death effective accident prevention measures CAUTION NOTICE Hazards or unsafe Information that is importan
12. cation Shown Hexagon Head OS or KM Cable Shift Arm Cable Terminal Connection for OS is BRP OMC Johnson and Evinrude and KM is Mercury Note For GEN nest is neutral in Clip for 33C Cables 33C Cable d Flat Head Screw Note Nest is black Swivel Bearing Nest Kit Cable End Options 33C Universal note black nest color BRP OMC JOHNSON EVINRUDE note black nest color MERCURY note black nest color MERCURY GEN Il note neutral nest color Each cable type connects differently ISCH7500 Rev2 7 User Manual CH1700 7500 7600 Section 4 Shift amp Throttle Cable Connection Engine End The throttle cable must be disconnected from the motor before making motor A Caution Caution idle adjustments Adjustment of the motor idle while the throttle cable is Engine Throttle Lever Throttle Cable connected to the motor may cause jamming action against the Person idle stop As a result the control may not function properly and damage to the control the cable and or the motor may occur 4 1 Make sure the Control is in NEUTRAL DETENT 4 2 The Engine Throttle Lever should rest lightly against the Idle Stop on the carburetor 4 3 Connect the Throttle Cable to the Engine Throttle Lever Idle Stop MINIMUM PRESSURE HERE Please Note This figure does not represent any particular eng
13. errupt Switch retaining nut Torque to 40 50 inch pounds 3 5 to 4 foot pounds Insert the lanyard clip under the Interrupt Switch plunger Pull firmly on the lanyard to verify that the clip snaps free Ensure the nut remains tight re torque if necessary Reattach the lanyard clip to the switch Complete the Interrupt Switch wiring into the engine electrical circuit according to the instructions below Complete all testing of the Interrupt Switch function according to the instructions on the following page s ISCH7500 2 10 Lanyard Snap User Manual CH1700 7500 7600 5 3 3 Electrical Connections I O or Inboard Use Use 16 AWG Purple stranded insulated marine quality wire for IO or inboard applications Type HDT THW UL 1426 or equivalent WARNING Be sure this wire goes directly to the coil and not to the instrument or alternator circuit Selecting the incorrect wire will result in improper switch operation which could lead to serious injury I O or Inboard Use ONLY Normally OPEN Disconnect all batteries and any auxiliary on board or dockside power supplies Locate the purple ignition switch to coil wire See Diagram A below 3 Cut the purple wire strip the ends and install two 2 insulated crimp on 1 4 inch female disconnect terminals crimping tool designed for insulated terminals MUST be used 2 4 Attach the female disconnects to each of the male terminals on the Interrupt Switch Rechec
14. ine NOTICE Throttle Cable must be free of load NO LOAD when throttle lever is in the idle position to prevent hard shifting Section 5 Electrical Connections 5 1 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 battery powered test light or test meter to check continuity Safety 5 1 1 With the Control in NEUTRAL connect one wire of the Siar tester to the common terminal and one wire to the NO Normally Open Terminal The test light MUST light Switeh ON e Normally mM Common OPEN 5 1 2 Connect the neutral safety switch between the ignition switch start lead and the starter solenoid OFF Starter Solinoid Use a multi meter or continuity tester to make sure that there is A Caution 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 multimeter or tester should show an open circuit ISCH7500 Rev2 8 User Manual CH1700 7500 7600 5 2 Trim and Tilt Refer to the wiring diagrams below for the correct Trim and Tilt switch connections and wire accordingly On both 3 wire AND 5 wire systems reverse the blue and green connections for opposite trim operation Trim Tilt NOTE for Tilt ABBREVIATIONS 1 Connect WHITE and GREEN together DN U
15. k all connections A Install Lanyard with the Fork Clip seated on the Plunger 7 Reconnect battery 00000000000 Reconnect battery Start engine If engine does not start disconnect battery recheck all electrical connections reconnect battery and restart engine n Remove Lanyard Engine should stop immediately Diagram A and Inboard Wiring Swilch basic wiring no specific manufacturer PIN 311375 1 Lanyard Ignition switch Purple To Instruments White of Yellow Red black To Starter Ret Altemators System Main Power ground Insulated 1 4 inch Ignition coil female blade or CD unit disconnect ISCH7500 Rev2 11 User Manual CH1700 7500 7600 5 3 4 Electrical Connections Outboard Use Outboard Use ONLY Normally CLOSED Ae le CAUTION Use 16 AWG Black stranded insulated marine quality wire for all ood outboard motors equipped with grounding type outboard applications Type HDT THW UL 1426 or equivalent emergency stop circuits only Disconnect all batteries and any auxiliary on board or dockside power supplies Reference Table 1 Wire Color Table Locate the correct color emergency stop wire for your motor See Daihatsu Solid Brown Reference Table 1 at right Evinrude Black w Yellow Stripe Before 1969 Fore Solid White Johnson Before 1969 Mariner Blackw YellowStripe Nissan Sold Brown ___ Black w Yellow Stripe
16. nd prevent unwanted handle movement To adjust place the lever in the forward or reverse throttle position just beyond the shift position Remove the cover and adjust the friction adjust screw turning the screw clockwise increases the friction Do not over tighten Maintenance and Corrosion Protection e For maximum protection especially in a saltwater environment the control head and hand lever should be washed lightly with fresh water on a regular basis Periodically check the control head mechanism for loose fasteners and signs of wear on moving parts Keep moving parts well lubricated with a moisture displacing lubricant Periodically check the cables and engine connections for signs of wear and corrosion Replace as necessary ISCH7500 Rev2 15 User Manual CH1700 7500 7600 SERVICE PARTS KITS All service parts can be purchased from your local Teleflex Marine Distributor Kit 2 Kit Name and Description Model Used On 212151 001 Cable Nest And Connection Kil All CH1700 Replacement Parts 7212616 Chrome Replacement Handle without Trim CH1700 T212710 Black Replacement Handle without Trim CH1700 7213017 Chrome Side Mount Insert Kit CHT OO 17213111 Black Side Mount Insert Kit CH1700 7213214 Throttle Only Button Kit Side Mount CH1700 CH7500 CH7T600 Replacement Parts 7213318 Chrome Replacement Handle without Trim CHFSOO 7213411 Black Replacement Handle without Trim CH 50x 7213712 Chrome Replacement Handle
17. ntrol will connect to ANY current 3300 OEM type control cable A cable nest kit also Known as a quick connect adapter part 212151 001 which mates to the engine s shift and throttle cable is included with this control Unique cable nests which are required for Mercury Gen Engines only are included with the control connection kit ISCH7500 Rev2 3 User Manual CH1700 7500 7600 CONTROL FEATURES AND OPERATION Option Numbers correspond to diagrams below 1 NEUTRAL THROTTLE WARM UP BUTTON This feature provides a throttle only option to warm up the engine before driving the boat When the Contro Hand Lever is in d Neutral push and hold the button at the base of the handle While CH1700 holding the button 1 move the lever forward to throttle up the Side Mount Control engine Features When you return the handle to the Neutral position the button will reset automatically 2 Once button resets the hand lever will work both shift and throttle functions Note On models with netural interlock you must depress both the Neutral Interlock 2 and the Neutral Warm up Button 1 together and move fhe handle forward Hey ry lg a j p a i lr 2 NEUTRAL INTERLOCK BUTTON To prevent bumping the side mount control out of neutral the button must be depressed and held to shift into forward or reverse option on top mount CH7500 CH7600 Top Mount Control Features 3
18. t practices which COULD to proper installation result in injury product operation or maintenance and or property damage but is not hazard related For example a A CAUTION 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 ISCH7500 Rev2 2 User Manual CH1700 7500 7600 INTRODUCTION This Teleflex Marine Control provides both shift and throttle operation for inboards outboards and inboard outboards We recommended the use of Teleflex TFXtreme engine cables Side Mount Top Mount CH7500 CH7600 single Lever Shift and Throttle Operation Neutral Safety Switch to prevent starting in gear SS a Control Options Emergency Ignition Interrupt Switch amp Lanyard Other Parts Required for Installation Quantity Control Features 5 lt Friction Adjust Screw to prevent throttle creep i Control Cables Check section 2 of installation instructions for routing and length Teleflex TFxtreme cables are recommended Adaptability Control Cable This co
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