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Mercury 4000 MPC GEN 2 Installation & Operation Instructions

Pistol grip remote control
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4000 MPC GEN 2 PISTOL GRIP REMOTE
CONTROL INSTALLATION/OPERATION
INSTRUCTIONS
IMPORTANT: This document guides our dealers, boatbuilders, and company service
personnel in the proper installation or service of our products. If you have not been trained
in the recommended servicing or installation procedures for these or similar Mercury
Marine products, 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 those installing or operating the product.
NOTE: After completing installation, place these instructions with the product for
the owner's future use.
Pistol Grip Remote Control with Finger Tip Neutral Lock Release
Notice to Installer/Owner
Safety Alerts and Notices
Throughout this publication, "Warnings" and "Cautions," accompanied by the
international HAZARD symbol
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.
90-899782001 APRIL 2008
24953
!
, are used to alert the technician to special
© 2008 Mercury Marine
Page 1 / 23

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Summary of Contents for Mercury 4000 MPC GEN 2

  • Page 1 If you have not been trained in the recommended servicing or installation procedures for these or similar Mercury Marine products, have the work performed by an authorized Mercury Marine dealer technician.
  • Page 2 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
  • Page 3 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS 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.
  • Page 4 Control handle friction adjusting nut Selecting and Routing Remote Control Cables Mercury ‑ Mariner ‑ Force ‑ Mercury MerCruiser Refer to the Mercury Precision Parts and Accessories Guide for the available shift and throttle cables for your application. Page 4 / 23...
  • Page 5 The minimum bend radius of the remote control cable is 30.5 cm (12 in.). For applications that require smaller than the minimum radius, multiple bends or lengths longer than 5.5 m (18 ft.), Mercury/Quicksilver GEN 2 Platinum or Premium cables are required. Refer to the Mercury Precision Parts and Accessory guide.
  • Page 6 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS IMPORTANT: Ensure the remote control has a minimum of 45.7 cm (18 in.) straight routing clearance for the control cables and does not contact other components. Refer to the shaded area.
  • Page 7 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS GEN 2 Series Panel Mount Remote Control Bezel Installation NOTE: This remote control should be installed on the starboard side only. IMPORTANT: When selecting the mounting area for the panel mount remote control, the area located directly behind the mounting panel must have sufficient clearance for the control module, wiring harness, control cables, and control cable movement.

  • Page 8: Bezel Installation

    4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS IMPORTANT: After cutting and drilling the mounting platform, use a suitable tool to remove all of the sharp edges on the inside and outside of the mounting platform cutout to prevent chafing of the harnesses.
  • Page 9 Mariner and Mercury outboards (standard rotation models) ‑ All models through 225 hp (with pull throttle) includes 1994‑1/2 20/25 Mariner and Mercury outboards ‑ 18 hp, 20 hp, 25 hp (U.S. origin) (with push throttle cable) Mariner and Mercury outboards (counter rotation gearcase) ‑ All models through 225 hp Mariner and Mercury outboards (standard rotation gearcase) ‑...
  • Page 10 2, OptiMax GEN 2 units, refer to the instructions for standard rotation control cable installation. 2. Mercury MerCruiser models standard rotation ‑ The control cable must be installed in the remote control so the cable end will move in the direction of X when the shift handle is placed in the forward position.
  • Page 11 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS NOTE: New cable fastener screws have a patch locking compound on the threads. Cable fastener screws that have been installed and removed must have Loctite 271 Threadlocker applied to the threads.
  • Page 12 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS WARNING Improper installation can result in sudden, unexpected loss of throttle and shift control, resulting in serious injury or death. Install all control components properly. 17557 Back plate Washer Screw (5) Description lb.
  • Page 13 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS 2. Allow sufficient slack in the trim switch leads to permit free movement through the full range of the control handle motion. Do not restrain the trim switch leads with cable ties.
  • Page 14 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS 4. Connect the trim switch connector to the trim motor harness connectors. 24970 Lanyard stop switch leads Neutral start safety switch leads Trim switch connection 5. Install the bushing into the module assembly. Apply a small amount of 2‑4‑C with Teflon to the inside diameter of the bushing.
  • Page 15 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS 6. Align the tabs on the bezel cover with the slots on the bezel. Snap the bezel cover in place. 24971 Bezel Tabs (4) Bezel cover 7. Apply Loctite 271 Threadlocker on the threads of the control handle retaining bolt.
  • Page 16 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS IMPORTANT: Ensure the trim switch wires do not become pinched between the bezel and the control handle during the installation of the control handle onto the remote control. Failure to ensure the trim switch wires do not become pinched during the installation of the control handle onto the remote control, may result in the trim switch wires shorting out and causing a trim system failure.
  • Page 17 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS Tube Ref No. Description Where Used Part No. Control handle retaining bolt Loctite 271 Threadlocker 92-809819 threads Description lb. in. lb. ft. Control handle retaining bolt 10. Install the throttle‑only button. Push the throttle‑only button in completely.
  • Page 18 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS WARNING Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a neutral‑safety‑protection device. 25591 Remote control module assembly neutral start safety switch leads...

  • Page 19: Wire Color Code Abbreviations

    4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS NOTE: The control handle is a painted component. Protect the control handle paint from damage when removing the throttle‑only button. 24975 Throttle‑only button Bezel Wire Color Code Abbreviations Wire Color Abbreviations...
  • Page 20 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS Lanyard Stop Switch Wiring Diagrams Mercury/Mariner Outboards 40 HP through 225 (3.0 Liter), Force (1993 and Newer) YEL/RED YEL/RED YEL/RED YEL/RED BLK/YEL BLK/YEL 24976 Neutral start safety leads Power trim connector...
  • Page 21 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS Mercury MerCruiser D1.7L/103, D3.0L/150, D3.6L/180 and D4.2L/220 Diesels BLK (1) TAN/WHT (6) LT BLU (8) GRY (2) BLK (7) WHT/GRN (5) BRN/WHT (10) YEL/RED (7) TAN (3) BRN (4) BLK (8)
  • Page 22 4000 MPC GEN 2 PISTOL GRIP REMOTE CONTROL INSTALLATION/OPERATION INSTRUCTIONS Mercury MerCruiser D7.3L/270 Diesel PUR/WHT BLK (1) TAN/WHT (6) LT BLU (8) GRY (2) BLK (7) WHT/GRN (5) BRN/WHT (10) YEL/RED (7) TAN (3) BRN (4) BLK (8) BLK/YEL (1)
  • Page 23 Products of Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, W6250 Pioneer Road K-Planes, MerCathode, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.