Installation Manual

Twin Disc, Incorporated

Component Installation

Single/Dual Lever Control Head Assembly

The Control Head may be either a single or dual lever version. This installation procedure applies to both versions.

Note: If this is a new installation, ensure that all required components are properly located before cutting the first hole. Other components that may require installation include a display, an ignition switch or instrumentation gauges.

Note: At least 25.4 mm (1 in.) of clearance is required at both ends of the lever travel for the operator’s hands (see

Figure 3). Clearance must be provided beneath the

Control Head to accommodate the base, an electrical connector and a harness. The Control Head should be installed at least 1 m (3.3 ft) away from any communications equipment and associated leads.

1.

Select a mounting location that is flat, readily accessible, permanent, and solid.

154.9

(6.10)

160.8

(6.33)

72.4

(2.85)

PORT

LEVER

N

GEAR SHIFTER IS IN

WHEN INDICATOR ON.

SY

PRESS

CRUISE

TROLL

STATION

N

PORT STBD

TWIN DISC EC300

POWER COMMANDER R

MODE

SELECT

SWITCH

STATION SELECT

INDICATOR LED

(2 PLACES)

127

(5.0)

MINIMUM RECOMMENDED

MAINTENANCE CLEARANCE

NEUTRAL

INDICATOR LED

(2 PLACES)

SYN

C

EXP

RES

S

TRO

LL

CRU

ISE

R

STBD

LEVER

STATION

SELECT

BUTTON

Figure 2. Front View of Dual Lever Control Head With Levers in Neutral

EC300 Marine Control System Installation Manual #1024168

29

Component Installation

Twin Disc, Incorporated

2.

3.

Cut out the Control Head Mounting Template in Engineering Drawings in the back of this manual, and tape it in the desired location.

Note: The template provided with the control is direction specific. Ensure that the “ahead” direction on the template is pointing toward the bow in order to ensure that the forward motion of the lever is directed ahead.

Ensure that the control head location provides clearance for the operator’s hands over the full range of lever travel.

ASTERN DETENT POSITION

AHEAD DETENT POSITION

15 o

15 o

ASTERN

55 o

AHEAD

55 o

30

25.4

(1.0)

72.4

(2.85)

25.4

(1.0)

CLEARANCE REQUIRED

TO AVOID PINCH POINTS

(BOTH SIDES)

127

(5.0)

MINIMUM RECOMMENDED

MAINTENANCE CLEARANCE

Figure 3. Side View of Control Head With Lever Clearance Shown

4.

Center punch the four (4) mounting holes and scribe the base cutout outline.

EC300 Marine Control System Installation Manual #1024168

Twin Disc, Incorporated

Component Installation

5.

Remove the template.

Note: The hole cannot be smaller than shown on the template and must be properly aligned with the mounting holes.

Drill and cut the holes using the template markings.

6.

7.

8.

Check the hole locations with the template.

Remove any splinters or sharp edges from the holes.

9.

Check the fit by carefully placing the Control Head in the hole.

10.

Remove the Control Head from the cutout.

11.

Correct the fit as necessary.

12.

Set drag per Control Head Lever Drag Adjustment. See Control Head

Lever Drag Adjustment.

Note: Drag adjustment is provided at each lever. Proper adjustment is necessary to ensure that the lever remains in the intended position without operator assistance.

13.

Install and mount the Control Head using the supplied gasket and four (4) oval head #10 screws or equivalent.

Note: All fastening hardware must be corrosion resistant.

Note: The type of fastener to be used depends on material used for the support. Each Control Head is supplied with stainless steel 38 mm (1.5 in.) screws suitable for mounting in a dash up to 19 mm (0.75 in.) thick. Use the appropriate fastener for the specific installation.

14.

Torque the fasteners to 1.13 Nm (10 lb-in.) maximum.

15.

Install and mount the Control Head using the supplied gasket and four

(4) oval head #10 screws or equivalent.

16.

Torque the fasteners to 1.13 Nm (10 lb-in.) maximum.

Reference Control Head Harness (J1, J2, or J3) Installation for cable installation.

EEC300 Marine Control System Installation Manual #1024168

31

Component Installation

Twin Disc, Incorporated

LEVER

Side Mount Control Head Assembly (Binnacle/Console Station)

The side mount Control Head Assembly consists of a Lever, Interface

Assembly, Interface harness and Selector Assembly. The lever may be supplied by Twin Disc or other sources. Specific lever attachment instructions should be supplied with the lever and the lever must be capable of attaching to the 15.87

mm (0 .625 in.) diameter shaft of the Interface Assembly. The Interface Assembly comes with a mounting plate for sandwiching the console wall between the assembly and the mounting plate. The Selector Assembly mounts directly to the surface of the console.

1.

2.

Locate a position on the side of the console which provides the operator with unrestricted access to the lever(s), while providing full range (70 degrees either side of neutral) of lever motion.

Locate a position on the top or front surface of the console which provides unrestricted access to the Selector Assembly. Confirm that the desired location will allow the Interface Harness to reach between the Interface Assembly and the Selector Assembly.

HARNESS, WIRING

SIDE MOUNT

HARNESS, WIRING

SIDE MOUNT

SELECTOR ASSY

DUAL SIDE MOUNT

N

GEAR SHIFTER IS IN

NEUTRAL POSITION

WHEN INDICATOR ON.

SYNC

EXPRESS

CRUISE

TROLL

N

PORT

STATION

SELECT

STBD

TWIN DISC EC300

POWER COMMANDER

R

LEVER

32

INTERFACE ASSY INTERFACE ASSY

MOUNTING PLATE

HARNESS, WIRING

DUAL LEVER

TO STBD CONTROL TO PORT CONTROL

Figure 4. Side Mount Control Head Assembly

MOUNTING PLATE

EC300 Marine Control System Installation Manual #1024168

Twin Disc, Incorporated

Component Installation

3.

4.

5.

Cut out the Interface Assembly Mounting Template and Selector

Assembly Mounting Template from the Engineering Drawings and tape in the selected positions.

Note: For twin engine applications, the template to mount the

Starboard Interface Assembly is flipped over and then rotated 90 degrees counterclockwise from the Port

Interface Assembly. See Figure 5.

Use the scale marks on the template to verify that the template is the correct size. (Scale = 1:1)

Using the templates, mark all necessary holes and cutouts.

Locate * in Upper

Front Corner of Console

Port

*

Locate * in Upper

Front Corner of Console

*

Starboard

Drawing Not To Scale

7.

8.

Figure 5. Side Mount Interface Assembly Mounting Template Position

6.

Drill and cut the holes using the template markings.

Check the hole locations with the template.

Remove any splinters or sharp edges from the holes.

EC300 Marine Control System Installation Manual #1024168

33

Component Installation

Twin Disc, Incorporated

9.

Check the fit of the holes by carefully inserting the Interface and Selector assemblies.

10.

Correct the fit as necessary.

157.10

(6.185)

46.23

(1.82)

22.22

(.875)

19.04

(.750)

NOMINAL

SCREW, FLAT HEAD

10-32 X 1 1/2

4 PLACES

15.87 ( .625) SHAFT

WITH 3/16" KEYWAY

34

INTERFACE ASSEMBLY

MOUNTING PLATE

CONSOLE

Figure 6. Side Mount Interface Mounting

11.

Install the Selector Assembly using the gasket and stainless steel hardware provided with the unit.

12.

Set drag per Control Head Lever Drag Adjustment. See Control Head

Lever Drag Adjustment on page 33.

Note: Drag adjustment is provided at each lever. Proper adjustment is necessary to ensure that the lever remains in the intended position without operator assistance.

13.

Install the Interface Assembly/Assemblies using the mounting plate and stainless hardware provided.

14.

Connect the Interface Harness between the Interface Assembly and the

Selector Assembly and secure/strain relieve as necessary.

15.

Attach the Lever to the 15.87 mm (0 .625 in.) diameter shaft of the

Interface Assembly, following the instructions provided with the lever.

EC300 Marine Control System Installation Manual #1024168