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COX Flo-Torq SSR HD Owner's Manual

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OWNER'S
MANUAL
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coxmarine.com

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  • Page 1 OWNER’S MANUAL ––– – designed for purpose coxmarine.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS WELCOME INFORMATION OUTBOARD SAFETY TECHNICAL SPECIFICATION OUTBOARD INSTALLATION OPERATION MAINTENANCE STORAGE TROUBLESHOOTING WARRANTY 10.0 APPENDIX...

  • Page 3: Welcome Information

    Cox Powertrain. Cox Powertrain reserves the right to change specifications without notice in accordance with its policy of continuous product improvement. 1.0 WELCOME INFORMATION...
  • Page 4 1.0 WELCOME INFORMATION 1.1 CERTIFICATION OF CONFORMITY The Cox Outboard Engine is in conformity with the following requirements: USA EPA – 40 CFR 1042 Tier 3 IMO Annex VI Reg.13 Tier II (EIAPP) EU Directives: 2013/53/EU (RCD II). (ii) 2006/42/EC (Machinery).
  • Page 5 Examine for fouling regularly, clean if necessary and consider applying anti-fouling paints to keep the hull smooth and the vessel efficient. Consult the boat builder or an authorised Cox Powertrain dealer for paint recommendations.
  • Page 6 Contact the local environmental authority or an authorised Cox Powertrain dealer to review the local options: which may include waste management centers, recycling facilities, local automotive and marine businesses or collection services etc. Oil is a finite and valuable resource which many of these facilities can process for reuse.
  • Page 7 The serial number is replicated on a smaller label attached to the powerhead and viewable after removing the Top cowling. Figure: Serial number label.  Outboard serial number QR code. Outboard serial number. Model designation. 1.0 WELCOME INFORMATION COX OWNER’S MANUAL...
  • Page 8 Cox Powertrain have adequate safety and privacy policies, including encryption, to keep such data safe for a limited period of retention. The data will remain under the control of Cox Powertrain and third parties, of whom Cox Powertrain warrants to have in place safety and privacy policies that are equivalent to those of Cox Powertrain for data protection and safe keeping.

  • Page 9: Outboard Safety

    Never work on a propeller with the outboard running. Passengers may fall overboard and come into contact with a moving propeller. Remain aware and vigilant to minimize the risk of injury. 2.0 OUTBOARD SAFETY COX OWNER’S MANUAL...
  • Page 10 Triggering the kill switch will result in sudden and violent deceleration as outboard drive thrust is shut off, especially if traveling at high speed. Take care to avoid false triggering and always make sure the passengers are appropriately seated. 2.0 OUTBOARD SAFETY COX OWNER’S MANUAL...
  • Page 11 Be sure to have sufficient and appropriate personal flotation devices on board for all passengers, operator included. Cox Powertrain recommends the use of PFDs when boating, they may be a legal requirement in one or more of the territories in which the vessel will operate. Make sure all passengers are aware of the location of emergency equipment, and that the equipment is in a serviceable state, for example within any use-by periods.
  • Page 12 Make sure passengers are aware of basic safe outboard operation on the vessel in case of emergency, for example, to recover the operator in a man overboard situation. Always check weather forecasts and tidal charts before leaving port. Do not set out in adverse weather or tides. 2.0 OUTBOARD SAFETY COX OWNER’S MANUAL...
  • Page 13 Restart the outboard(s) using the master fob as soon as possible to reactivate fob functionality. In the event the master fob is misplaced, a new master can be paired using the procedure in section 4.4.2. 2.0 OUTBOARD SAFETY COX OWNER’S MANUAL...
  • Page 14 2 seconds at a time to send the start signal to the corresponding outboard.  WARNING Always keep the master fob on the operators person. 2.4 WARNING LABELS Please note the following safety labels placed on the outboard. 2.0 OUTBOARD SAFETY COX OWNER’S MANUAL...

  • Page 15: Technical Specification

    31.75 mm (1.25”) shaft, 19 tooth spline Propeller shaft output 406.4 mm (16”) Maximum propeller diameter SAE 80W90, API GL-5 or 75W90, API GL-5 Marine Gear Oil for colder climates Gear oil 2.5 L (2.6 US qt) Gear oil capacity 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 16 3.0 TECHNICAL SPECIFICATION 3.2 DESIGN OVERVIEW Main sub-systems  Figure: Main sub-systems. Top cowling. Power tilt-trim unit. Powerhead. Lower cowling. Top cowl latch. Spacer (if installed). Mid cowling. Transmission. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 17 3.0 TECHNICAL SPECIFICATION 3.3 DESIGN FEATURES Outboard interfaces - port side  Figure: Outboard Interface - Port Side. Power tilt-trim switch. Rear water inlets. Top cowl latch. Front water inlets. Propeller anode. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 18 3.0 TECHNICAL SPECIFICATION Outboard interfaces - rear side  Figure: Outboard Interface - rear side. Rear flush connector. Idle relief vent. Anti-cavitation plate. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 19 3.0 TECHNICAL SPECIFICATION Outboard interfaces - starboard side  Figure: Outboard Interface - starboard side. Front flush connector. Tell-tale stream. Top cowl latch. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 20 3.0 TECHNICAL SPECIFICATION Under cowl interfaces  Figure: Under-cowl interfaces. Air filters. Oil dipstick / Oil fill point. CCV canister. Oil filter. Fuel filter. Powerhead oil drain plugs / Oil drain point. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 21 3.0 TECHNICAL SPECIFICATION  Figure: Power tilt-trim (PTT) components. Tilt lock. Manual pressure relief valve. Tilt ram. PTT Manifold. Upper mounting fasteners. Lower mounting fasteners. Side brackets. PTT anode. Trim rams. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 22 Simultaneous tilt-trim switch. Gear position indicators. Neutral warm-up or troll mode. Take command button. Single lever control for multiple outboards. Neutral Indicator lamp. Neutral Indicator lamp. Take command indicator lamp. Single lever control indicator lamp. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 23 3.0 TECHNICAL SPECIFICATION Cox 2 Switch Trim Panel  Figure: Cox 2 Switch Trim panel. Port outboard tilt-trim switch. Starboard outboard tilt-trim switch. Cox 3 Switch Trim Panel  Figure: Cox 3 Switch Trim panel. Port outboard tilt-trim switch. Center outboard tilt-trim switch.
  • Page 24 Engines 3 & 4 control.  Engine 3 control.  Engines 5 & 6 control.  Engine 4 control. Wireless Fob  Figure: Wireless Fob. START Green LED. Start button. ON /OFF ON/OFF Button. Red LED. 3.0 TECHNICAL SPECIFICATION COX OWNER’S MANUAL...
  • Page 25 3.0 TECHNICAL SPECIFICATION Cox GDU (Graphic Display Unit) 4” screen  Figure: Helm display screen (4”). Main display screen. Function buttons (x8). 7” screen  Figure: Helm display screen (7”). Main display screen. Function buttons (x8). Menu button. Return button.
  • Page 26 3.0 TECHNICAL SPECIFICATION Cox GDU Home Screen  Figure: Display home screen. Port outboard ID. Starboard outboard RPM. Port outboard gear position. Starboard outboard trim position. Port outboard RPM. Vessel speed. Port outboard trim position. External PGN information. Starboard outboard ID.

  • Page 27: Outboard Installation

    4.2 FUEL AND OIL Diesel fuel The Cox Diesel Outboard has been validated and certified using diesel fuels complying with fuel standards EN 590 and ASTM D975 No.2-D. Operating on fuels with properties outside of these standards may lead to unsatisfactory emissions levels, increased fuel consumption, accelerated outboard wear and outboard damage which may invalidate the warranty.
  • Page 28 Transmission oil Cox Powertrain recommends the use of Shell Spirax S3 AX gear oil. The transmission oil must comply with the SAE 80W90 viscosity standard and API service classification GL-5. Alternatively, Cox Powertrain recommends using API GL-5, 75W-90 Marine Gear Oil for use in colder climates.
  • Page 29 When the propeller is changed, check the powerhead speed at maximum power with minimum vessel loading is within the propping speed range. When installing propellers to Cox Diesel Outboards, make sure that the defined propeller hub is used, as per the below specification. Make sure that the hub manufacturer’s installation instructions are followed correctly.
  • Page 30 4.0 OUTBOARD INSTALLATION CAUTION  Cox only recommend the use of the Quicksilver FLO-TORQ SSR HD (8M0101603) hub. Failure to comply with this may lead to adverse gear shifting and increased vibrations which may be damaging to the transmission and engine.
  • Page 31 4.0 OUTBOARD INSTALLATION 4.4.1 CHANGING PIN The factory default PIN for the fob system is 2431. Cox Powertrain recommends a personalized PIN is created. Follow the process below to change the PIN on the control panel. START ON/OFF  Figure: PIN change steps.
  • Page 32 Test the system by pressing the Start button on the fob. The control panel will unlock in response.  NOTE Repeat this process to pair all master fobs. The control panel can be paired with up to 10 master fobs. 4.0 OUTBOARD INSTALLATION COX OWNER’S MANUAL...

  • Page 33: Operation

    5.1 USAGE CYCLE Cox Diesel Outboards for commercial operation are provided on the basis that their usage profile is up to two hours at maximum power in every twelve hours. Outboards will typically have a load factor of up to 50% and are expected to run up to 1500 hours per year.
  • Page 34 Inspection of battery cables Examine the battery cables for loose or corroded terminals. When the ignition is on and before starting the outboard(s), check the battery voltage readout on the Cox GDU is between 12 V and 15 V. ...
  • Page 35 Make sure that the throttle lever(s) is(are) in the neutral position before attempting to start the outboard(s). Note that by law, all Cox Diesel Outboards feature start-in-gear protection, which will prevent the outboard(s) from cranking if the control lever(s) is(are) not in the neutral position.
  • Page 36 Check that the vessel fuel tank vent line is not blocked. When re-fuelling, note that the fuel level on the Cox GDU updates every 30 seconds, therefore anticipate a delay upon the display registering a change in fuel level.
  • Page 37 To start the outboard(s) the use of either the control panel or a master fob are applicable. Outboard Outboard Outboard installation installations installations START ON/OFF START ON /OFF  Figure: Starting outboards with the control panel or master fob. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 38 Within 60 seconds, press and release the LED will continue to blink orange. ON/OFF button to turn on the ignition of all installed outboards. The LED will light yellow to indicate the ignition is on. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 39  Figure: Starting multiple outboards individually using the control panel. Carry out all pre-start checks in section 5.2. Check for any warning alarms or notifications on the Cox GDU and action accordingly. Turn the battery isolation switch to the ON position.
  • Page 40 The control panel’s LED will also outboard. light orange to indicate ignition is on. After starting the outboard, check that the control panel LED is solid green, indicating that MOB protection functionality is active. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 41 Check the Cox GDU for warning alarms and visually examine the outboard(s) and rigging for normal operation. Check that the control panel LED is lit green to indicate MOB protection is active and a master fob is linked.
  • Page 42 When the outboard is shut down, follow the post-use flushing procedure in section 5.10 before tilting the outboard(s) out of water.  WARNING Shutting down soon after hard running can cause significant damage to the outboard(s). 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 43 Each Cox Diesel Outboard follows a run-in process before being shipped from the factory. Nevertheless, Cox Powertrain recommends to limit load during a break-in period of 10 hours of operation, as well as limiting or avoiding periods of extended idle where possible.
  • Page 44 This can also induce unpredictable bow steering. To trim all outboards together, use the switch provided on the port-side control lever.  Figure: Simultaneous outboard trim control. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 45  WARNING Excessive trim in or out can lead to vessel instability, difficult or unpredictable steering and increased risk of accident. Slow down and reduce trim if any of these effects are experienced. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 46 When tilting the outboard(s), make sure the outboard(s) are shut down and the areas ahead of and behind the outboard(s) are well clear, including the stern of the vessel. Keep well away from an outboard if tilting using the outboard-mounted switch and make sure no others are in the vicinity. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 47 In this neutral range, the outboard(s) speed will not change. Note that drag torque in the transmission will often cause the propellers to turn slowly, even when in neutral. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 48  Figure: Helm control head with Neutral warm-up or troll mode switch (1).  NOTE All control levers must be in the neutral position to activate or deactivate troll mode. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 49 Shifting one outboard into forward and the other into reverse can be used to turn the vessel in a tight space. Shifting both outboards into forward or reverse and then using different speed demands on the levers can be used to steer the vessel without turning the outboards. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 50 Check that water is flowing out from the tell-tales; if the water streams are not seen, check that the flush connectors are correctly attached and the supply hoses are not kinked or leaking. If the issue persists, there may be an internal blockage within the cooling circuit. Contact an authorised Cox Powertrain dealer for further support.
  • Page 51 A missing or loose flush plug will result in overheating, limited performance and possible outboard damage or failure.  CAUTION The outboard’s warranty may be invalidated if damage is caused by the use of flushing additives. Flush with fresh water only. 5.0 OPERATION COX OWNER’S MANUAL...
  • Page 52 5.0 OPERATION 5.12 WARNING ALARMS In the unlikely event of a malfunction, the Cox GDU will issue an audible and visual on-screen alarm. The on-screen alarm includes detail of the malfunction and depending on severity, the outboard may enter into a “Limp-home Mode”, with restrictions on available speed and power.
  • Page 53 The control system has detected an error which is not contained in the categories above and further diagnosis is required. The ECU may limit performance, enter limp-home mode or Check engine shut the outboard down. Contact an authorised Cox Powertrain dealer for further support. 5.0 OPERATION COX OWNER’S MANUAL...

  • Page 54: Maintenance

    Greasing point PTT operation — PTT oil level — Ground strap — I = Inspect* R = Replace* G = Grease* CL = Clean and Inspect* = Emissions related part *As per the service manual 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 55 — Electronic control cables Anti-vibration mounts Vessel fuel filter — Battery terminals I = Inspect* R = Replace* G = Grease* CL = Clean and Inspect* = Emissions related part *As per the service manual 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 56 The choice of service or repair shop or person does not in itself affect the product warranty, although Cox Powertrain recommends an authorised Cox Powertrain dealer is chosen. Should the choice to not use an authorised Cox Powertrain dealer be taken, the service or repair shop used must work in line with Cox standards.
  • Page 57 • Maximum 2 hours at full power in any 12 hour period • Maximum 7 hours at 75+% power in any 12 hour period For regular usage heavier than the above or in severe conditions, contact an authorised Cox Powertrain dealer for further maintenance advice.
  • Page 58 Certain areas of the outboard(s) require regular application of grease for best performance and longevity. Refer to the maintenance schedule for greasing intervals. Always use a water-resistant marine grade grease. Contact an authorised Cox Powertrain dealer for product recommendations. Adding grease: Prepare a hand-operated grease gun, installed with an extension hose to suit a standard grease nipple.
  • Page 59 Operating the outboard on water without the cowling in place can result in death or serious injury. The Top cowl is heavy (~20 kg/~44lbs) and appropriate lifting precautions must be taken. Plan the lift before actioning. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 60 Removal of the port Mid side cowling requires removal of fasteners and connection to the tilt-trim switch. Make sure the connection to the tilt-trim switch is made and the fasteners are torqued to 5 Nm on installation. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 61 5 Nm on installation. Removal of the starboard Lower cowling requires the removal of the port Lower cowl and then the fasteners. Make sure the fasteners are torqued to 5 Nm on installation. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 62 � Between marks: Oil level satisfactory. � Below lower mark: Fill required. Running with too little oil can cause rapid and severe engine failure.  Figure: Reading the powerhead oil dipstick. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 63 Position the outboard vertically. If the outboard has been tilted for storage or recently operated, allow 20 minutes for the oil to drain into the sump before commencing the oil change. Remove the Top cowl as necessary, refer to the procedure in section 6.4.1. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 64 When the oil level is satisfactory, fully install and secure the dipstick, clean any oil residue in the work area, then install the Top cowl and close the latches.  WARNING Operating without sufficient oil can cause rapid and severe outboard failure. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 65  NOTE If there is significant oil contamination, capture photographic evidence and contact an authorised Cox Powertrain dealer for advice. When the used oil has completed draining, remove the second oil drain plug on the opposite side of the outboard, clean the magnet and replace the seal. It is advised to prepare absorbent material for any oil leakage.
  • Page 66 When the oil level is satisfactory following the procedure in section 6.4.2, install the dipstick and install the CCV separator lid clockwise by hand. Clean any oil residue in the work area, then install all the cowling following the procedure in 6.4.1 as necessary. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 67 Clean any oil residue in the work area and install the Top cowl following the procedure in section 6.4.1 as necessary.  NOTE Cox Powertrain recommends that only Cox approved oil filters are used on the outboard. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 68 The Cox Diesel Outboard transmission contains gear oil which lubricates the internal gears, bearings and shift parts. A full transmission service should be carried out by an authorised Cox Powertrain dealer in accordance with the maintenance schedule. However, it may occasionally be necessary for the owner to replace the transmission oil, for instance when preparing for storage.
  • Page 69 While the used oil is draining, clean both of the vent and drain plug magnets.  NOTE If there is significant contamination, capture photographic evidence and contact an authorised Cox Powertrain dealer for advice. Replace the Dowty washer seals on both plugs.
  • Page 70 Check the outboard filter for any leaks around the canister or filter head. Do not physically disturb this filter. Check that the hose fittings (hose barbs) are tight inside the filter heads. Check that all filter drain ports are securely tightened. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 71 The maximum capacity of the water bowl is 120 ml (4.0 fl oz). Clean the work area. Discard the container contents and cloth responsibly and in accordance with local laws and regulations. Contact an authorised Cox Powertrain dealer if in doubt.  NOTE The above procedure should be repeated for each installed outboard and vessel-mounted fuel lift pump-filtration unit.
  • Page 72 Using the outboard-mounted tilt-trim switch, tilt the outboard(s) fully in and listen for smooth pump operation and movement. The motor’s pitch will change when moving from tilt to trim. Tilt the outboard(s) fully out and listen for smooth pump operation and movement. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 73 Remove the Top cowling and examine the electrical harnesses and wiring regularly for any damage or loose fasteners. If in any doubt contact an authorised Cox Powertrain dealer for further advice.  NOTE Do not physically push or pull any harnesses or connectors during inspection.
  • Page 74 Visual inspection for any fluid leaks from the battery. Check that any leaks are from the battery itself and not another nearby source. Replace the battery as necessary. Voltage check on the Cox GDU with ignition on but the outboard(s) off. This voltage must read at least 12 V.
  • Page 75 (-) or black cable. Make sure both connectors are tightened to prevent loosening during operation and that any battery caps are secure. Check that the battery support is secure to the vessel, including any brackets. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 76 There are multiple fuses located on the vessel specified in the rigging installation. Refer to the Vessel Owners' Manual for troubleshooting vessel based fuses. In the event of any issues not covered by the troubleshooting section of this manual, contact an authorised Cox Powertrain dealer for advice. 6.0 MAINTENANCE COX OWNER’S MANUAL...
  • Page 77 The anodes will deplete during normal operation and must be maintained and replaced in line with the maintenance chart to make sure the outboard is fully protected. When replacing anodes, consult an authorised Cox Powertrain dealer for the correct type and material.  NOTE Only use zinc anodes on the outboard(s).
  • Page 78 Install the propeller. Check that the forward bore of the propeller is inside the transmission and that the radial gap is minimal. A gap may result in exhaust gases ventilating the propeller leading to a significant loss of thrust. If in doubt, contact an authorised Cox Powertrain dealer for further advice.

  • Page 79: Storage

    When intending to store the outboard(s) for one month or longer, it is important to prepare correctly in order to prevent potential degradation and damage during the period of storage. Cox Powertrain recommends that an authorised Cox Powertrain dealer prepares the outboard(s) for storage. If the owner chooses to prepare for storage, the following precautions should be taken to minimize the risks: Visually examine the outboard(s) for paint damage, such as scratches and chips.
  • Page 80 Examine the exterior of the outboard(s) for any damage or degradation, including corrosion. Contact an authorised Cox Powertrain dealer if any areas of concern are identified. Examine the fuel system lines and correct any issues before attempting to operate the outboard(s).
  • Page 81 If a propeller is attached to the outboard(s) Cox Powertrain recommends a high visibility propeller cover is placed over the propeller to make sure it is seen by other road users and keeps the risk of injury to a minimum.

  • Page 82: Troubleshooting

    In the event issues are experienced with the outboard(s), consult the troubleshooting table (pages 83-84) for suggested solutions. In the event a warning alarm is on the Cox GDU consult the warning alarms table (pages 52-53) for explanation of the possible causes.
  • Page 83 Examine fuel lines and clamps, check operation of lift flow. pump, examine fuel filters. Powerhead operates Fuel tank nearing empty. Fill tank with fresh fuel to specification. erratically Fuel tank vent partially Check fuel tank vent for any obstructions and clear. obstructed. 8.0 TROUBLESHOOTING COX OWNER’S MANUAL...
  • Page 84 Check voltage and replace if necessary, check battery Low battery voltage. cables and terminals. Contact an authorised Cox Powertrain dealer for propeller Poorly matched propeller. matching advice. Examine for blade wear and replace the propeller if Damaged propeller.
  • Page 85 In the event of a failure not covered by this manual or one with which further support is needed, contact an authorised Cox Powertrain dealer, details of which can be found in the warranty documentation, on coxmarine.com, or on the Partner Resource Portal. This includes any instances where the requirement is to make a warranty claim.

  • Page 86: Warranty

    9.1.1 IF A RESIDENT IN THE USA OR CANADA The Cox product is designed to operate on the grades of diesel fuel specified in this manual only. Use of any other fuel may result in the product no longer operating in compliance with the Environmental Protection Agency’s (EPAs) or California’s emissions requirements.

  • Page 87: Appendix

    10.0 APPENDIX 10.0 APPENDIX COX OWNER’S MANUAL...
  • Page 88 10.0 APPENDIX 10.0 APPENDIX COX OWNER’S MANUAL...
  • Page 89 10.0 APPENDIX 10.0 APPENDIX COX OWNER’S MANUAL...
  • Page 90 10.0 APPENDIX 10.0 APPENDIX COX OWNER’S MANUAL...
  • Page 91 COX POWERTRAIN LIMITED The Cecil Pashley Building Unit 8, Cecil Pashley Way Brighton City Airport Lancing, West Sussex BN43 5FF United Kingdom  +44 (0) 1273 454 424  info@coxpowertrain.com     www.coxmarine.com TCD001796/C JAN_2024...

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8m0101603

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