Summary of Contents for Ray Electric Outboards E2
- Page 1 RAY ELECTRIC OUTBOARDS, INC. ELECTRICAL REPAIR MANUAL Model E2 (Variable Speed) Applicable to Serial #400 and greater Ray Electric Outboards, Inc. 908 NE 24 Lane Cape Coral, FL 33909 (239) 574-1948 FAX (239) 574-8359 Email: info@rayeo.com 5/08...
- Page 2 SAFETY ALWAYS OBSERVE THESE SAFETY PRECAUTIONS WHEN TROUBLE SHOOTING THE RAY MOTOR 1. BEFORE REMOVING THE TOP COVER, BE SURE KEY SWITCH IS OFF TO AVOID POSSIBLY SHORTING TERMINALS INSIDE THE MOTOR AS A METAL TOP IS REMOVED. STRONG ARCS CAN RESULT IN DAMAGING EQUIPMENT AND POSSIBLY CAUSING INJURY.
- Page 3 Charger Problems: Closely related to battery problems are charger problems. The most likely is a blown diode due to overheating (these can be easily replaced). As soon as a diode goes the fuse goes. If you replace the fuse without replacing the diode the fuse will blow again – replace both at the same time.
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Page 4: How It Works
HOW IT WORKS (Refer to wiring diagrams) Plus 48 (example voltage) volts are picked up from the primary (power) wire system for operation of the control circuits at the rear terminal of the cut off contactor and run via the fuse and white 20 ga. - Page 5 Pull lever The motor speeds up in an identical way as forward using back further: same brown & blue wires, however the other half of the center tapped pot is automatically used. The contactor coils are supplied minus 48V via a 20 ga. black wire harness attached to the B- terminal of the PMC.
- Page 6 Ray Electric Outboards, Inc. diagram - Motor Group Wiring Model #E-2, including Serial #400 & KEY: 20 Ga. Controlwires Power wires W116 W268 WHn'l MOTOR MOUNT W264 MOTOR ASSEMBLY A211 MOTOR CABLE W280 A104 W113 WHJn: W267 W280 FORWARD REVERSE...
- Page 7 Ray Electric Outboards, Inc. Wiring diagram - Console Group Model #E-2, including Serial #400 & KEY SWITCH METER NOTE: Meter and Key Switch are mounted in console cover CABLE CLAMP CONSOLE CONTROL SWITCH PARTITION CABLE WAFER A601 A412 WIRE COLOR CODE...
- Page 8 Contactor Functions CONTACTOR COLOR OF LOCATION FUNCTION DESIGNATION CONTROL WIRE Upper Left Front On: Forward Forward (CF) Green (looking at front Off: Lower contacts function of outboard) in reverse circuit Upper Right Front On: Reverse Reverse (CR) Orange Off: Lower contacts function in forward circuit Lower Right Front On: PMC on Cutoff (Cp)
- Page 9 Looking into Plug Plug/Socket Assignments Later Motors with Covered Rectangular Plug Black Meter Blue PMC Pot Orange CR Brown PMC Pot Green CF USED 17 81 Key Swiched White+ Looking at Ends of Prongs Socket on Motor Cable Blue Black Meter Brown PMC Orange...
- Page 10 When a Contactor or the PMC Fails to Operate, How Do You Find Where the Trouble Is and Correct It? Any failure (open) in any individual contactor control circuit will cause the associated contactor to fail to turn on. The Trouble Shooting Chart (TSC) associates the symptoms with each contactor so there should be no trouble finding out which circuit is at fault.
- Page 11 If problem is not found, check the cable on the motor for continuity. BE CAREFUL NOT TO SHORT THE SOCKET WITH OHMETER PROBE. (Battery voltage normally exists on the black and white terminals) Check the orange wire in the cable. With plug unplugged, check with an ohmmeter for continuity from the motor terminal strip to the socket hole corresponding to orange.
- Page 12 With the key switch on, check for battery voltage between the black and white primary wires attached to the two rearmost terminals at the top of the PMC. Check for good connections at these terminals and the two other primary terminals on the PMC. If voltage is not obtained, the trouble is in the PMC shut off contactor (Cp) or in the primary wires leading to this contactor.
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Page 13: Troubleshooting Chart
TROUBLE SHOOTING CHART Symptoms Cause Correction 1. Won't run. 1. Batteries dead 1. Charge or replace Battery meter batteries as necessary Registers far left "charge" 2. Open at a battery 2. Repair terminal terminal 3. Key switch not 3. Short across switch operating terminals to verify. - Page 14 Symptoms Cause Correction 3. Will not operate 1. CF not operating 1. Check green circuit in Forward Control See "Checking Circuits" 2. CF normally open 2. Visually check Contacts not making contacts. UNPLUG BAT- contact TERIES. File contacts with point file. Replace contactor, if necessary.
- Page 15 reading) overheating or due to if bad. Replace fuse. voltage spikes such as Make sure charger has from lightning. adequate ventilation Charger fuse will when in use. usually also be blown. See Charger Problems Symptoms Cause Correction 2. Open in charging 2.
- Page 16 Symptoms Cause Correction 4. Battery acid 4. Replace batteries. allowed to remain See Operating and below plates (pre- Maintenance Instructions mature failure). for care of batteries. 5. Battery life 5. Replace batteries. expired (4 to 6 years typical for private use).
- Page 17 SYSTEM 500, 60 VOLTS MOTOR PANEL 6-VOLT BATTERIES Jumper Wires PLUG CONSOL (REMOTE CHARGER PLUG ONLY) CONTROL WHITE CABLE BLACK BLACK SYSTEM 400, 48 VOLTS MOTOR PANEL 6-VOLT BATTERIES CHARGER PLUG PLUG Jumper Wires CONSOL (REMOTE ONLY) WHITE CONTROL CABLE BLACK BLACK SYSTEM 300, 36 VOLTS...