MPC 4000 GEN II Series Programming manual

90-891909001 AUGUST 2005 © 2005 Mercury Marine Page 1 / 26
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.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
Page 2 / 26 90-891909001 AUGUST 2005
! WARNING
WARNING ‑ indicates a potentially hazardous situation that, if not avoided, could result
in death or serious injury.
! CAUTION
CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result
in minor or moderate injury or property damage. It may also be used to alert against
unsafe practices.
IMPORTANT: Indicates information or instructions that are necessary for a particular
step or action.
NOTE: Indicates information that helps in the understanding of a particular step or action.
Selecting Remote Control Cables
Mercury ‑ Mariner ‑ Force ‑ Mercury MerCruiser
Refer to the Mercury Precision Parts Accessories Guide for the available shift and throttle
cables for your application. This control requires the use of Mercury/Quicksilver GEN II
shift and throttle cables.
IMPORTANT: Remote control cables must be the correct length, sharp bends on
too‑short cables result in kinks; too‑long cables require unnecessary bends and/or loops.
Both conditions place extra stress on the cables.
IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C With Teflon.
17431
95
95
95
95
b
c
a
a - Remote control end
b - Engine end
c - Adjusting barrel
Tube Ref No. Description Where Used Part No.
95 2-4-C with Teflon Shift cable/throttle cable
lubrication points 92-802859A1
NOTE: Allow for clearance of cables directly behind panel mount remote control. The
4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed
25.4 mm (1 in.) thickness. Cable radius at any one point must not be less than
305 mm (12 in.).

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
90-891909001 AUGUST 2005 Page 3 / 26
General Installation Information
IMPORTANT: Control handle friction adjustment must be made prior to installation.
Control Handle Friction Adjustment
1. Control handle friction is preset from the factory, however, it can be adjusted.
a. Use an 11/32 in. nut driver or socket wrench to carefully adjust the control handle
friction. To increase friction, turn the adjusting nut clockwise. To decrease
friction, turn the adjusting nut counterclockwise.
IMPORTANT: Control handle friction is necessary for proper mechanical control
operation. Insufficient friction may cause undesirable control arm operation.
17432
a
a - Control handle friction adjusting nut
Reinstallation of Control Handle
! WARNING
Avoid serious injury or death from sudden unexpected loss of throttle/shift control. The
control handle retaining bolt must be properly torqued and retained with Loctite
Threadlocker to prevent the control handle retaining bolt from loosening, thus resulting
in disengagement of the control handle.
1. If the control handle is removed and reinstalled for any reason, apply Loctite 271
Threadlocker on the threads of the control handle retaining bolt.
2. Tighten the control handle retaining bolt to specified torque.
3. Refer to Remote Control Module Installation for instructions.
Tube Ref No. Description Where Used Part No.
7Loctite 271 Threadlocker Control handle retaining bolt 92-809819
Description Nm lb. in. lb. ft.
Control handle retaining bolt 17 150
Control Module Mounting
IMPORTANT: Control handle friction adjustment must be made prior to installation.
1. Select mounting area for panel mount remote control. Select template for type of
application. Follow template directions when cutting and drilling mounting surface.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
Page 4 / 26 90-891909001 AUGUST 2005
2. Connect control cables and rear cover to remote control. Refer to Shift and Throttle
Cable Installation in this instruction sheet.
3. Mount the remote control following the mounting instructions for this panel control.
Make necessary wiring connections by selecting the correct wiring diagram for the
remote control model being installed.
4. Install and adjust the shift and throttle cables to the power package as outlined in the
instructions which accompany the power package or refer to the Product Service
Manual.
Final Checks and Adjustments
1. Re‑check tightness of control handle retaining bolt. Tighten to specified torque.
Description Nm lb. in. lb. ft.
Control handle retaining bolt 17 150
2. Before installing the back cover, re‑check the throttle cable and shift cable retaining
screws to ensure they are secure.
3. Check that the back cover screws are securely tightened.
4. Before the remote control is securely fastened, verify that the parts are in place. Verify
that the control cables and control wiring harness are routed correctly.
! CAUTION
To shift the remote control into reverse gear when the engine is not running, the
propeller or propshaft must be rotated in the proper direction. Forcing the shift
mechanism into reverse may damage the control system.
5. Operate the control handle several times (see Caution preceding). Any binding or
stiffness in the operation of the control handle is usually caused by the following:
a. Bends or tension on control cables near the control.
b. Excessive number of bends in cables.
c. Bends are too small in cables.
d. Tight engine linkage.
e. Cable ties strapped too close to the control module.
f. Control handle friction adjustment.
g. Improper adjustment at the engine.
! WARNING
Avoid serious injury caused by being struck by a rotating propeller. Stay clear of the
area around the propeller when checking the operation of the neutral start switch.
h. Check operation of the neutral start switch. The engine must only crank when
the remote control is in the neutral position.
Required Mounting Clearances for MPC 4000 GEN II Series
IMPORTANT: The minimum bend radius of the remote control cable is
305 mm (12 in.). For optimum performance, plan a cable route that does not require
bends smaller than the minimum. A bend radius less than the minimum creates cable
friction and may reduce cable life.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
90-891909001 AUGUST 2005 Page 5 / 26
IMPORTANT: Ensure that the remote control has adequate clearance and does not
contact other components. The cable path should be free of obstructions. See shaded
area.
(5.75 in.)
147 mm
(7.78 in.)
197.6 mm
(8.62 in.)
R 218.9 mm
(2.00 in.)
50.8 mm
69.9 mm
(2.75 in.)
353.1 mm
(13.9 in.)
303.3 mm
(11.94 in.)
17434
32.8 mm
(1.29 in.)
125.5 mm
(4.94 in.)
76.5 mm
(3.00 in.)
25.4 mm
(1.00 in.)
218.9 mm
(8.62 in.)
40.6 mm
(1.60 in.)
142.2 mm
(5.60 in.)
a
b
b
c
d
a - Maximum mounting panel thickness
b - If shift and throttle cables are not mounted in the same housing slot position,
do not use clamping straps ‑ an increase in shift and throttle load will be
noticed.
c - Hand clearance
d - Plus hand clearance

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
Page 6 / 26 90-891909001 AUGUST 2005
MPC 4000 GEN II Series Mechanical Panel Control Installation
NOTE: This remote control can be Starboard or Port mounted.
a
a
17435
Starboard side mounting Port side mounting
a - Bow of boat
IMPORTANT: When selecting mounting area for panel mount remote control, the area
located directly behind the mounting panel must have sufficient clearance for control
module, wiring harness, control cables and control cable movement. Refer to Required
Mounting Clearances.
IMPORTANT: Allow sufficient clearance for handle movement to avoid interference with
boat components or other accessories. Make sure handle clears dash, seats, steering
wheel and any other obstructions when rotating.
NOTE: When mounting the panel control on the port side, decal 37‑891905002 must be
ordered and attached to the bezel.
Bezel Location and Drilling Mounting Area
IMPORTANT: Mounting panel thickness must not exceed 25.4 mm (1 in.).
NOTE: The remote control template supplied with this instruction sheet will allow the
installer to rotate and mount the remote control in 30° increments. Allow for proper
clearance behind the mounting area when selecting the mounting area for control.
1. Locate area of boat where the panel mount remote control is to be mounted. Allow
sufficient clearance for handle movement and clearance for remote control module
and control cables behind the mounting area.
2. Use the template (supplied) for mounting application.
3. Place template over mounting surface; cut and drill as instructed on template.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
90-891909001 AUGUST 2005 Page 7 / 26
IMPORTANT: After cutting mounting area, use a suitable tool to remove all sharp edges
(inner and outer) from material being cut and drilled to prevent chaffing of harnesses.
17436
a
b
c
a - Mounting surface
b - Maximum mounting panel
thickness 25.4 mm (1 in.)
c - Template
Installing Bezel
1. Install bezel to mounting surface as shown. Tighten bezel mounting screws to
specified torque.
17438
a
bc
d
a - Screw 0.250‑20 x 1.750 in. (3)
b - Washers (3)
c - Nuts 0.250‑20 (3)
d - Mounting surface
Description Nm lb. in. lb. ft.
Bezel mounting screw 5.6 50
NOTE: On some boat installations, it may be helpful to first make the cutout for remote
control (using supplied template) and route the control cables through the boat before
installing cables to control module.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
Page 8 / 26 90-891909001 AUGUST 2005
! WARNING
Avoid serious injury or death from sudden unexpected loss of throttle/shift control.
Control cable fastener screws must be properly torqued and retained with Loctite
Threadlocker to prevent control cable fastener screws from loosening, thus allowing the
cable ends to disconnect.
2. Following shift and throttle cable installation instructions, connect shift and throttle
cables to remote control module. Tighten cable fastener screws to specified torque.
Refer to Shift and Throttle Cable Installation in this instruction sheet.
Tube Ref No. Description Where Used Part No.
7Loctite 271 Threadlocker Control cable fastener screws 92-809819
Description Nm lb. in. lb. ft.
Control cable fastener screws 2.8 25
Remote Control Module Installation
1. Route the trim switch leads from the handle assembly through the bezel cover and
bezel opening as shown.
2. Allow sufficient slack in leads to permit free movement of trim leads through the full
range of shift handle motion.
17440
a
d
c
b
a - Bezel opening
b - Trim switch
c - Trim leads
d - Bezel cover
IMPORTANT: Verify trim/trailer wires are not pinched when mounting remote control
module to panel of boat. Trim wires must be free to move with the remote control handle.
3. Install the remote control cables. Refer to Shift and Throttle Cable Installation in this
instruction sheet.
4. Secure back plate to control module with washers and screws. Refer to Shift and
Throttle Cable Installation in this instruction sheet.
5. Make wiring connections for neutral start safety switch, lanyard stop switch (if
equipped), and trim switch (if equipped). Attach power trim harness connector (if
equipped). Refer to Instrument/Lanyard Stop Switch Wiring Diagrams.
NOTE: Control handle friction adjustments must be made prior to installation. Refer to
General Installation Information for instructions.

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
90-891909001 AUGUST 2005 Page 9 / 26
6. With remote control cables connected to the control module and the remote control
in neutral, install the control module. Secure with three screws. Tighten the screws to
specified torque.
17441
a
b
a - Control module mounting screw
(3)
b - Control module
Description Nm lb. in. lb. ft.
Control module mounting screw 5.6 50
7. Connect the trim switch wires to appropriate wiring harness.
17445
ba
c
a - Trim lead connector
b - Trim pump lead
c - Trim switch wires

MPC 4000 GEN II SERIES LOCK BAR MECHANICAL PANEL CONTROL INSTALLATION AND OPERATION
Page 10 / 26 90-891909001 AUGUST 2005
8. Install the bushing into the 4000 GEN II Module Assembly. Apply a small amount of
2‑4‑C with Teflon to inside of bushing.
17446
95
a
a - Bushing
Tube Ref No. Description Where Used Part No.
95 2-4-C with Teflon Inside of the 4000 GEN II
Module Assembly bushing 92-802859A1
9. Align the tabs on the bezel cover with slots on the bezel. Snap the bezel cover in
place.
17540
a
b
c
a - Bezel
b - Tabs (4)
c - Bezel cover