Ray Electric Outboards E2 Repair Manual Download | Manualshive

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RAY ELECTRIC OUTBOARDS, INC.

ELECTRICAL REPAIR MANUAL

Model E2 (Variable Speed)

Applicable to Serial #400 and greater

Ray Electric Outboards, Inc.

908 NE 24

th

Lane Cape

Coral, FL 33909

(239) 574-1948

FAX (239) 574-8359

Email

5/08

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Summary of Contents for E2

Page 1: ...TBOARDS INC ELECTRICAL REPAIR MANUAL Model E2 Variable Speed Applicable to Serial 400 and greater Ray Electric Outboards Inc 908 NE 24th Lane Cape Coral FL 33909 239 574 1948 FAX 239 574 8359 Email info rayeo com 5 08 ...

Page 2: ...uide you are having a hard time finding the trouble call us and call before you disassemble something or replace parts based on assumptions Give us all the symptoms and chances are together we can solve the problem It may take some tests and more calls but we have been successful many times When you need a part to fix the trouble look it up in the Parts Manual and order giving part number and name...

Page 3: ... cover pontoon boats when not in use WD40 is recommended Apply liberally to keyhole so WD40 penetrates to bottom of switch This is a good preventative measure and may even revive a failed switch Electrolysis Experience has shown that if any part of an aluminum boat is grounded to any battery terminal electrolysis will occur on parts of the motor left underwater in areas where paint has been chippe...

Page 4: ...cable and motor cable green wire The forward contactor turns on and completes the primary power circuit to the electric motor Push lever The potentiometer raises the control resistance to the PMC forward sufficiently for the PMC to start turning the motor This slightly operation uses the blue and brown wires of the control more cable motor cable Push lever Motor speeds up because pot rotates furth...

Page 5: ...rol circuits will cause the 10 amp fuse to blow Without the fuse complete motor and control cables are at risk The diode just below the fuse prevents damage from reversed battery polarity by preventing the cut off contactor from operating otherwise connecting 48V in reverse to the outboard would destroy the PMC when the key is turned on The varistor 275 is for protecting the plugging diode in the ...

Page 6: ... Ga Controlwires 6 Ga_ Power wires MOTOR MOUNT W116 275 W268 WHn l W264 MOTOR ASSEMBLY A211 G E MOTOR CABLE A104 W280 W113 WHJn W267 W280 FORWARD I REVERSE CONTACTERS 235 48V A241 CUTOFF CTR 239 48V or 237 36V I J BlACK WlRE COLOR CODE Red RD Orange OR Green GR Blue BL Brown BR Black BK White WH ...

Page 7: ...Model E 2 including Serial 400 on METER BK RD KEY SWITCH NOTE Meter and Key Switchare mounted in console cover BR CABLE CLAMP CONTROL CABLE A601 CONSOLE PARTITION SWITCH WAFER A412 WIRE COLOR CODE Red RD Orange OR Green GR Blue BL Brown BR Black BK White WH ...

Page 8: ...n Forward Off Lower contacts function in reverse circuit Forward CF Green Upper Right Front On Reverse Off Lower contacts function in forward circuit Reverse CR Orange Lower Right Front On PMC on Off PMC off Cutoff Cp Red Plug Socket Assignments Also see next page Socket on Motor Cable Looking into Socket Plug on Control Cable 8 ...

Page 9: ...Meter Orange CR Blue PMC Pot 4 Green CF I5 6 I Red Key Swiched 17 81 Looking at Ends of Prongs Socket on Motor Cable 2 1 Blue PMC Pot I I I I 4 3 Brown PMC Pot I I I I Brown PMC Pot NOT USED White in Black Meter Orange CF NOT USED White in 06 5 0 08 70 Looking into Socket 9 Green CF Red Key Swithced ...

Page 10: ...or before replacing contactor If there is no mechanical blockage or mechanical problems that can be repaired replace the contactor If you do not get voltage at the coil start checking control voltage at other points along the orange wires proceeding from the contactor coil terminals toward the console First check the negative feed to the coil Place the positive voltmeter lead on the white primary ...

Page 11: ...otor cable or control cable can cause various unexplained malfunctions of the system To check for shorts in the control cable and motor cable unplug the control cable connector Remove cable wires from the motor terminal strip and check for shorts between wires in the motor cable with an ohmmeter There should be no shorts Remove control cable wires from terminal strip at console and check for short...

Page 12: ...MC Remove the blue and brown control wires from the PMC With ohmmeter check resistance across ends of blue and brown wires with speed lever on off You should get approximately 0 ohms Now advance lever to full speed while observing ohmmeter resistance should increase to 5000 ohms in either forward or reverse If resistance is correct and all voltages at the PMC are correct as above a bad PMC is indi...

Page 13: ... unplugged or damaged 4 Insert plug into socket Replace if necessary 5 Anderson plug un plugged at motor or damaged 5 Plug in plug Replace if necessary 2 Won t run 1 PMC not operating 1 See The PMC and Battery meter associated circuits registers OK 2 Green and orange 2 See Shorts in control wires shorted causing cable CF CR to be on simultaneously 3 Loose primary 3 Inspect and repair terminal insi...

Page 14: ...not making contact 2 Visually check contacts UNPLUG POWER TO MOTOR File contacts with point file Replace contactor if necessary 3 CF normally closed Contacts not making contact 3 Same as 2 5 Electrolysis rapid corrosion on underwater parts of motor where paint is off 1 Boat grounded to a battery terminal such as through the base of an automotive type light Some marine running lights also connected...

Page 15: ...oltage before it will regular charger 6V turn on batteries can be brought up 2 at a time with a 12V charger 7 Motor operates 1 Bad cell in one 1 Check all battery slower than normal battery cells with a hydrometer or running time is after charging Replace shorter than it battery with bad cell should be 2 Corroded or loose 2 Locate bad connection battery terminal or visually and correct loose prima...

Page 16: ...e failure for care of batteries 5 Battery life 5 Replace batteries expired 4 to 6 years typical for private use 6 One battery reversed 6 Check to see that connected plus to plus batteries are all wired instead of plus to in series plus to minus minus Reversed battery may have to be replaced First try to bring it up to charge with a 6 volt charger ...

Page 17: ...L CABLE REMOTE ONLY RED MOTOR PANEL 1 2 3 4 o o CHARGER PLUG _ Jumper Wires 5 6 7 8 BLACK W B O o o PLUG CONSOLE REMOTE ONLY WHITE CONTROL CABLE BLACK RED MOTOR PANEL 1 2 3 o o Jumper Wires W B O o o PLUG _ 4 5 6 CONSOLE CHARGER PLUG BLACK 17 WHITE BLACK CONTROL CABLE REMOTE ONLY SYSTEM 400 48 VOLTS 6 VOLT BATTERIES SYSTEM 300 36 VOLTS 6 VOLT BATTERIES ...

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