MPC 4000 GEN II Series

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MPC 4000 GEN II SERIES LOCK BAR

MECHANICAL PANEL CONTROL

INSTALLATION AND OPERATION

NOTICE

After completing installation, these instructions should be placed with the product for the owner's future use.

NOTICE

This document is written to aid our dealers, boatbuilders, and company service personnel in the proper

installation or service of our products. Persons who are not familiar with these or similar products produced

by Mercury Marine, and who have not been trained in the recommended servicing or installation procedures

should 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 the installer

or persons operating the product.

Lock Bar Remote Control

17428

Notice to Installer/Owner

Safety Alerts and Notices

Throughout this publication, "Warnings" and "Cautions," accompanied by the

international HAZARD symbol

, are used to alert the technician to special

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.

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MPC 4000 Gen II Series Lock Bar Mechanical Panel Control Installation and Operation1

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Do you have a question about the MPC 4000 GEN II Series and is the answer not in the manual?

The device described in the manual is the MPC 4000 GEN II Series Lock Bar Mechanical Panel Control. This is a remote control unit designed for marine applications, specifically for controlling the throttle and shift functions of various Mercury and Mariner outboard engines, as well as MerCruiser inboard/outboard engines.

Function Description

The MPC 4000 GEN II Series Lock Bar Mechanical Panel Control provides a mechanical interface for the operator to control the propulsion system of a boat. It integrates throttle and shift functions into a single handle, allowing for intuitive operation. Key functions include:

Throttle Control: Adjusts engine speed.
Shift Control: Engages forward, neutral, and reverse gears.
Neutral Lock Bar: Prevents accidental shifting out of neutral without deliberate action, enhancing safety.
Throttle Only Button: Allows the operator to advance the throttle without engaging the shift mechanism, useful for starting the engine or warming it up in neutral.
Power Trim and Trailer MCM Only Switch: (If equipped) Provides control for the engine's power trim and trailer functions, allowing for adjustment of the engine's angle for optimal performance, shallow water operation, or trailering.
Lanyard Stop Switch: A safety feature that, when activated (e.g., if the operator falls overboard), stops the engine to prevent runaway operation.
Control Handle Friction Adjustment Nut: Allows the operator to adjust the tension on the control handle, preventing "creep" of the handle and ensuring stable throttle settings.

The control is designed for panel mounting and can be configured for either starboard or port side installation. It accommodates various engine types and configurations, including standard rotation and counter-rotation setups.

Important Technical Specifications

Mounting Panel Thickness: Must not exceed 25.4 mm (1 in.).
Control Handle Retaining Bolt Torque: 17 Nm (150 lb. in.).
Control Cable Fastener Screws Torque: 2.8 Nm (25 lb. in.).
Bezel Mounting Screw Torque: 5.6 Nm (50 lb. in.).
Minimum Bend Radius for Remote Control Cable: 305 mm (12 in.). A bend radius less than this minimum creates cable friction and may reduce cable life.
Maximum Mounting Panel Thickness (Dimension 'a' in diagrams): 25.4 mm (1.00 in.).
Lanyard Cord Length: Typically between 122 cm (4 ft.) and 152 cm (5 ft.).
Cable Type: Designed for use with 2-4-C with Teflon.
Threadlocker: Loctite 271 Threadlocker is specified for control handle retaining bolt and control cable fastener screws to prevent loosening.

Usage Features

Starboard or Port Mounting: The control can be installed on either the starboard or port side of the boat, offering flexibility in helm design. A specific decal (37-891905002) must be ordered and attached to the bezel for port side mounting.
30° Incremental Rotation: The control module can be rotated and mounted in 30° increments using the supplied template, allowing for precise positioning and ergonomic comfort.
Single Handle Operation: Combines throttle and shift into one handle for simplified control.
Safety Features: Includes a neutral lock bar to prevent accidental shifting and a lanyard stop switch for emergency engine shutdown.
Throttle Only Mode: A dedicated button allows for throttle advancement in neutral, useful for engine starting and warm-up.
Trim/Trailer Switch Integration: (If applicable) Allows for convenient control of engine trim and trailer functions directly from the remote control.
Cable Installation Flexibility: The manual provides detailed instructions and diagrams for installing shift and throttle cables for various engine types (outboard and MerCruiser), including different anchor attachment points and lever stud numbers for standard and counter-rotation setups.
Electrical Connections: Includes wiring diagrams for neutral start safety switch, power trim, and lanyard stop switch connections for different engine models (Mercury/Mariner Outboards, Mercury MerCruiser Single Engine Gasoline, D1.7L/103, D3.0L/150, D3.6L/180, D4.2L/220 Diesels, and D7.3L/270 Diesel).

Maintenance Features

Control Handle Friction Adjustment: The control handle friction can be adjusted via a nut to increase or decrease tension, which helps prevent handle creep and ensures stable throttle settings. This adjustment is crucial for proper mechanical control operation and should be performed prior to installation.
Cable Inspection: Regular inspection of control cables for proper routing, freedom of movement, and absence of excessive bends is important to prevent friction and ensure longevity. The minimum bend radius of 305 mm (12 in.) must be maintained.
Fastener Security: The manual emphasizes the use of Loctite 271 Threadlocker on control cable fastener screws and the control handle retaining bolt to prevent loosening, which is critical for maintaining control integrity and preventing serious injury or death.
Back Plate Fastening: The back plate must be secured with five screws to prevent it from loosening, which could lead to control cables slipping out of their mounting slots.
Neutral Start Safety Switch Check: The neutral start safety switch must be correctly connected and verified to prevent engine startup when in gear, a critical safety check.
Wiring Harness Management: Instructions advise leaving the trim harness loose behind the panel and avoiding cable ties near the control module to ensure free movement when the handle rotates.
Sharp Edge Removal: After cutting mounting areas, all sharp edges (inner and outer) must be removed to prevent chafing of harnesses and cables.