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Ray Electric Outboards E2 - User Manual

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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: info@rayeo.com
5/08
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Summary

SAFETY

Trouble Shooting

Guidance on diagnosing and resolving motor issues, emphasizing minor electrical problems.

The Most Likely Problems

Outlines common issues such as battery problems and their causes like neglect or corrosion.

Battery Problems

Charger Problems

Discusses blown diodes, fuse issues, and ventilation requirements for the charger.

Key Switch

Advises on preventing and fixing key switch corrosion due to moisture.

Electrolysis

Explains electrolysis as rapid corrosion caused by grounding the boat to a battery terminal.

HOW IT WORKS

Operation Sequence

Details the sequence of operations from turning the key to engaging forward and reverse.

Speed Control Mechanism

Explains how lever movement adjusts speed via potentiometer resistance affecting the PMC.

Wiring Diagram - Motor Group

Wiring Diagram - Console Group

Contactor Functions and Wiring

Plug;Socket Assignments

Details the pinout and function of sockets and plugs for motor and control cables.

Later Plug;Socket Assignments

Shows plug/socket assignments for later models with a covered rectangular plug.

Troubleshooting Contactor or PMC Failures

Other Control Circuits

Shorts in the Control Cable

Guides on detecting and rectifying shorts within control and motor cables.

The PMC and Associated Circuits

PMC and Potentiometer Troubleshooting

Details checks for PMC capacitor voltage, control wire resistance, and potentiometer function.

TROUBLE SHOOTING CHART

Symptom 1: Motor Wont Run, Battery Meter Low

Addresses the symptom of the motor not running and the battery meter indicating low charge.

Symptom 2: Motor Wont Run, Battery Meter OK

Covers scenarios where the motor fails to run but the battery meter shows normal status.

Symptom 3: Will Not Operate in Forward

Details troubleshooting steps for when the motor fails to operate in the forward direction.

Symptom 4: Will Not Operate in Reverse

Provides troubleshooting steps for when the motor fails to operate in the reverse direction.

Symptom 5: Electrolysis and Corrosion

Explains the cause and correction for electrolysis, identified by rapid underwater corrosion.

Symptom 6: Charger Not Charging

Addresses the symptom of the charger not functioning, indicated by a zero ammeter reading.

Symptom 7: Slow Motor Speed or Short Run Time

Guides on troubleshooting reduced motor speed or shorter operating times.

Battery Acid Level Issues

Discusses battery acid levels leading to premature failure and replacement.

Battery Lifespan Expiration

Addresses battery lifespan expiration and the need for replacement.

Reversed Battery Connections

Explains the issue of reversed battery connections and how to correct it.

System Wiring Diagrams

System 500, 60 Volts

Diagram showing the battery and wiring configuration for a 60-volt system.

System 400, 48 Volts

Diagram illustrating the battery and wiring setup for a 48-volt system.

System 300, 36 Volts

Diagram depicting the battery and wiring arrangement for a 36-volt system.

Ray Electric Outboards E2 Specifications

General IconGeneral
BrandRay Electric Outboards
ModelE2
CategoryEngine
LanguageEnglish