Hydraulic
Engine Controls
Installation and Service
04 SERIES

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
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
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 ITwin Engine, One Station........................ 28
Plan IITwin Engine, Two Station ...................... 29
Plan IIITwin Engine, Three Station ................... 30
Plan IVTwin Engine, Four Station..................... 31
SUPPLEMENTAL THROTTLE CONTROL
CIRCUITS ................................................................. 32
Plan I-S ............................................................... 32
Plan II-S .............................................................. 32
Plan III-S ............................................................. 33
Plan IV-S ............................................................. 33
TROUBLESHOOTING .............................................. 34