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Minn Kota Service Manual

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1. page 14 16 Foot Pedal Module page 14 17 To Re Orient Steering Potentiometer to Motor Position page 14 19 Lower Shaft Collar Replacement page 14 20 Master Reset Emergency Override page 14 21 Identifying Software Version Code page 14 22 Steering Potentiometer Testing amp Replacement page 14 23 Control Board Replacement amp Programming When replacing the control board you will need to do the Initial Programming and if the unit is an AutoPilot you will also need to do the Calibration Procedure A Control Board Replacement page 14 25 B Initial Programming Procedure page 14 27 C Calibrating AutoPilot Compass page 14 29 AutoPilot Steering Malfunction page 14 31 Genesis Repair Manual 11 07 07 GENESIS Error Codes amp Probable Causes NOTE Neither the steering motor nor the propeller should operate when the motor is in the stowed position If so it is a definite indication that the counter has lost its reference and a Master Reset 1s required see page 14 21 Also check to insure proper lift belt tension see page 14 7 Case I
2. vereor 2 190 parE wq og E nm 1 1 24 484 pause t votuqor ay 1 515 1431 83315 13389 _ 1H9IW 83315 MOTA 6 5045 usn 38 03349 _ QNNOUD 42V 18 NOII2Nf 3 40 102 SWHO 028 LNOBY 01 5 H313M WHO 21 1Y 03345 Mid OL 2 Wid 5 w4O OF 1 QYiu QInORS 53134 WHO 0 LV 03345 HIIM 1 Nid OL 2 Nid WOU 3HnSYJN SMHO 055 LNOGY 01 0 5 43134 WHO I Nid OL v Nid WOK JUDSY3N 9 Wid OL I Nid NOJJ LYOHS 1 83134 WHO FS JLYNIW 5 Wid OL I Nid NONJ LNOHS 5 YILIM ES 1 Mid OL Nid LYOHS 1 YILIM WHO ZS 1 Wid OL I Wid NOUJ LYOHS QINOHS 83136 15 311129 S 801103 SV 3UY 5 011 21 312395 NOII2NQ1 31995 1 X 129191538 JHL NO 135 WOA HII 036301834 S quvog 11024012 17034 1004 803 3Hfh03208d 1531 IHL 02 12 08 AutoPilot Repair Manual Corded Foot Pedal Test Procedure V2 models have a different pedal SONVLSIS3 I X VW JV 7HOLOST3S 33d KXiWwasovy Lz 20vJd34 UND OOO QL 059 38 CMOHS 3 3 Nid 9 Nid QL QL QL
3. 6 Wid OL I Nid NONI LNOHS Q nOHS YILIM S 3LYNLIY E Md 1 Mid OL Nid LYOHS 5 YILIM WHO 25 72 1 Nid OL 1 Nid MOU 13OHS 4700 5 YILIN 15 I 601104 SV 38 SMOI1V2 4 23dS MOII2Nn1 JHL 31V25 1 X 329191538 JHL NO 135 WOA 038301834 S Nid quvog 11024012 17034 1004 803 10430884 1531 PowerDrive Repair Manual 11 14 07 PART Motors manufactured prior to model year 2007 prior to s n AH PART II Case I Drive Housing fails to steer left or right Step 1 Step 2 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for any corroded connections Clean rewire if necessary Check motor with known good test foot pedal or test the original foot pedal by performing Foot Pedal PCB Test Procedure see page 8 6 C If test pedal properly steers motor or if the original pedal tests bad as outlined on page 8 6 then original foot pedal is faulty Disassemble faulty pedal to inspect if actuators are properly making contact on foot pedal board Visually inspect foot pedal control board for collapsed burnt dome switches Replace foot pedal board if necessary A 1 If dome switches are burnt check drive housing for short between either of the drive housing wires and the metal portion of the drive
4. Foot pedal is not sending information to motor Inspect pedal wire for damage Water may be in plug assembly Test with new foot pedal Test Pedal p n 2772040T Sensor board in control head is sending invalid information gt Check orange coil cord wire for continuity gt Tf orange wire is okay the lower unit may have been rotated more than one full turn Re orient steering potentiometer to motor position see page 14 19 gt Ifmotor spins in circles you may need to re set park position values see page 14 6 4 Sensor board in control head is not sending information Check coil cord brown and yellow wires for continuity gt Check to make sure that the steering potentiometer belt is in place and that all wire connections to the steering potentiometer board are tight gt Test steering potentiometer and replace if necessary see page 14 23 ERS Steering motor has power applied to it but steering is not functioning Lower unit assembly may be stuck in underwater obstructions Primary gear drive screws backed out see page 14 3 Check coil cord white and blue wires for continuity Anti rattle bushing not in proper place see page 14 3 amp 14 5 If ER5 occurs while motor is stowed it may be due to improper lift belt tension Adjust lift belt tension see page 14 7 Case I gt Check to ensure setscrew on the steering potentiometer gear is not stripped causing gear to spin on steering pot shaft without changing pot
5. ON l1MVd 403 C3SY3T3H d 1872 111108 1 WYN LYVd JuvW 1 Nid AJM 104 137 9N171IUV 10 Throttle Cable Pin Out Diagram P N 2041402 19 12 E Drive 11 14 07 Least RW Ma A ot ui os LEES Plug Pin Out Diagram on bottom of throttle assembly 19 13 Battery Chargers 11 19 07 Chapter 20 Battery Chargers Minn Kota battery chargers are not serviceable in the field However by following these steps repair centers can determine if a charger is operating properly For safety purposes battery chargers require at least 8 volts to be present for charging to commence Testing Charger for proper output Step 1 Step 2 Step 3 Step 4 Step 5 Verify the charger battery leads are properly connected to the battery Red to positive black to negative Verify the in line 30 amp fuses are not blown and that the fuse holder is not melted Verify that neither the AC power cord nor the DC battery output leads have been extended incorrectly splicing the battery output leads between the charger and the thermistor voids the warranty If the DC battery leads are not long enough they should be brought to a terminal block and extended from the terminal block with 12 AWG minimum wire The maximum extension is 15 feet Minn Kota offers an accessory kit for the purpose of extending the output leads Fuses Thermistor
6. PART I Motors manufactured for model year 2001 and later s n AB and later These motors incorporate either the Grip Glide handle or the Deploy Assist lever PART I Case I Drive Housing will not steer in either or both directions with the AP switch turned ON or OFF This is not a defect in the main control board The steering logic is NOT in the main control board Step 1 Check to ensure proper voltage and polarity at battery Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Visually check to see that all wires are attached proper control board terminals Consult the appropriate wiring diagram for the model and board being tested Clean rewire if necessary Step 2 Check motor with known good test foot pedal or test pedal by performing Foot Pedal PCB Test Procedure see page 9 6 or 9 7 A If test pedal properly steers motor or if the original pedal tests bad the original foot pedal is faulty Disassemble defective pedal to inspect actuators and dome switches Replace foot pedal if necessary If test pedal does not properly steer the motor or if the original pedal tests okay proceed to next step Step 3 Test the drive housing for proper operation Disconnect the drive housing lead wires and apply 12 volts directly to the white and black wires Observe drive housing for rotation Reverse the polarity and the drive h
7. x T Se lt lt 1 lt gt If v Fig 3 ig Step 5 Once again prior to further disassembly note how the 3X motor wires are routed and held in position by the wire clamp located on the coupler socket retainer indicator light bracket assembly P N 2992900 see Fig 4 page 6 3 Also note how the directional indicator light wires are twisted and wire 6 2 3X Steering Repair Manual 11 06 07 tied to the motor wire to prevent the indicator light wires getting in the circular rack and pinion steering gear mechanism A Remove the P N 2372100 phillips head screw 48 18 x 5 8 holding the retainer light bracket wire clamp assembly P N 2992900 in place B IMPORTANT With the control box parallel to the motor lower unit note how two sides of the hexagon ID of the coupler socket P N 2070800 black coupler socket for bow mount motors P N 2070801 white couple socket for transom mount motors are parallel to in line with the control box pivot screws P N 2073408 When reassembling a 3X motor the coupler socket which drives the directional indicator must be repositioned in this exact same manner for proper orientation of the directional indicator arrow Directional arrow is parallel to the motor lower unit pointing towards the direction of boat travel when in the water with the motor running 2 After removing the retainer light assembly remove the coupler sock
8. 14 5 Genesis Repair Manual 11 07 07 Case VIII Motor steers in circles when foot pedal is turned ON Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 If motor continues to spin in circles until 5 is displayed check to ensure the setscrew on the steering otentiometer pulley gear is not stripped causing pulley to spin without changing pot values If motor steers until the steering pot hits the end of the 10 turn pot may display ER3 proceed to Step 1 Test the steering potentiometer resistance values per Steering Potentiometer Testing and Replacement Step 3 on page 14 23 A If steering pot tests bad follow instructions as directed page 14 23 B If steering pot tests good proceed below to Step 2 With Master Switch OFF remove the control box cover A Slip the belt off the primary gear and steering potentiometer gear B Place the motor lower unit in line with the bowmount base housing with the prop towards you when looking straight at the LCD NOTE you may need to forcefully turn the motor by hand to place it in this position C Turn steering potentiometer counter clockwise to its rotational stop D From the rotation stop turn the potentiometer exactly five complete turns clockwise and slip the belt back onto the steering potentiometer and primary gear without turning the steering potentiometer or lower motor assembly out of position Reset the Left and Right Park Position values
9. and then defaults to ER6 Step 1 Check all battery connections for proper voltage security and corrosion Correct any faults and retest Step 2 If all connections check O K the foot pedal TrimUp switch is faulty and the foot pedal assembly p n 2772040 needs to be replaced A Replace foot pedal with latest pedal from Minn Kota and test all motor functions for proper operation 14 18 Genesis Repair Manual 11 07 07 GENESIS To Re Orient Steering Potentiometer to Motor Position It will be necessary to Re Orient the Steering Potentiometer to the Motor Position in the following circumstances Lower unit has been forced to turn steering clutch slipped more than one full turn from its original position LCD will display ER3 ifmotor has been taken apart and the steering potentiometer was turned out of position when the motor lower unit was removed from outer tube possibly while routing transducer ifsteering potentiometer board has been replaced Step 1 If motor is stowed note if motor is stowed in the left or right park position direction of prop and proceed to Step 2 below If motor is deployed turn Master Switch OFF and place the motor lower unit in line with the bowmount base housing with the prop towards you when looking straight at the LCD NOTE you may need to forcefully turn the motor by hand to place it in this position Step 2 With the Master Switch OFF and the control box cover
10. LMA Sows OOO QL 059 38 CMOHS 3 3 Nid 9 Nid QL QL QL OL QL QL OL SZ S53 2 OL S 20 430813 ANOA HUM 104 SHL dob JIMIN CUWICNI SV 1531 LON 5300 FOALNOD 1009 31 SWHO d Nid SSOMOV SINVISISSY 440 0109736 3346 7 Wows MOHS GMOHS WOA 96 14086 MOHS MWOA G6 LYOHS GMOHS 8 Nid Wg 14086 GINOHS WoA cs V OHS MOHS AINOHS 25 V Nid MOHS GINOHS WOA 6 SLINTLLOV 9 ILMLI 9 ALN Loy JLYNL 2 FIV TNL 1 5 077043 SV SNOILLYIJNIdS NOIJONNS JHL SIVOS X FDNVLSISZy NO 486 INOA LMAN 7 1005 403 ASAL JHL AutoPilot Repair Manual 06 13 08 Chapter 9 AutoPilot PD AP Models Corded foot pedal models non Genesis non Terrova This AutoPilot Repair Manual is divided into two parts Part I pertains to both V2 models s n AH and later and Grip Glide models s n AB through AT AutoPilot switch is located on the top of the control box cover pages 9 1 through 9 7 Part pertains to motors manufactured prior to model year 2001 s n AA amp earlier AutoPilot switch is located on the lower speed control cover pages 9 8 through 9 14
11. Minn Kota Service Manual This manual is designed to assist in basic trouble shooting procedures Table of Contents Page Safety Warnings ii Trouble Shooting Tips iii Chapter 1 Lower Unit Motor Assembly 1 1 includes DC motor theory instructions to remove motor from composite shaft and repair information Chapter 2 Depth Finder Interference 2 1 Chapter 3 Universal Sonar US1 amp US2 3 1 Chapter 4 Hand Control Models with a Speed Coil 4 1 5 speed models Chapter 5 Hand Control Models with a Printed Circuit Board 5 1 Variable speed models non 3X Chapter 6 Hand Control Steering 6 1 Chapter 7 Hand Control Vantage 7 1 Chapter 8 Foot Control PowerDrive PD amp PD V2 8 1 Chapter 9 Foot Control AutoPilot PD AP amp PD AP V2 9 1 Chapter 10 Foot Control Cordless PD C amp PD AP C manufactured 1996 1999 10 1 Chapter 11 Foot Control Terrova 11 1 Chapter 12 Foot Control Cable Steer Models with a Speed Coil 12 1 5 speed Maxxum All Terrain amp Edge models Chapter 13 Foot Control Cable Steer Models with a Control Board 13 1 Variable speed Maxxum and All Terrain models Chapter 14 Foot Control Genesis manufactured 2001 2003 14 1 Chapter 15 PowerUp Lifts Trims and Tilts manufactured 1996 2002 15 1 Chapter 16 Engine Mount EM amp Neptune EP EP manufactured 1997 2002 16 1 Chapter 17 DeckHand Electric Anchors 17 1 Chapter 18 CoPilot Wireless Accessory 18 1 Chapter 19
12. Remove the lower wire clamp wire tie and tape spring assembly from the motor wire leads Then remove the two screws p n 2053401 that hold the yoke bearing to the motor shaft Remove the coil spring p n 2990429 and washer from the top end of the lift screw shaft Remove the broken stripped lift screw yoke from the lift screw shaft If necessary turn the lift screw to unscrew the old yoke and bearing race assembly Slide the old parts up and off the motor wire leads Install the required new parts and reassemble the Vantage motor in reverse order of disassembly Take special care not to twist the motor wire leads and to reinstall the wire tie lower wire clamp and the tape spring in the same manner and position they were in prior to disassembly Vantage Repair Manual 02 15 08 205 6700 205 0100 233 2101 a 257 1715 2050210 0 e 205 1712 ne me 290 2100 P ou 07 X9 205 0102 Nees e 205 0200 201 2100 4 4 05 2246 r ine 205 3415 3 1 235 3401 Am 72057200 205 3414 2 205 0220 Figure d 205 0101 201 2100 2 a 205 3700 205 3700 F iquve Vantage Repair Manual 02 15 08 2 205 3107 205 2511 205 Gb 7 3 2550421 995 0156 2 205 1737 215 1730 e 22 ssembly 205 1736 205 6510 t M E 205 0015 oe E 205 4600 o gt 205 6515 gt n SNR 238 3500 205 3407 2 ___
13. Step 4 If remote has been taken apart the keypad and top case may have been installed backwards A Take remote apart see BATTERY REPLACEMENT below and reinstall case halves with the proper orientation Case II Multiple receivers have failed been replaced on a customer s CoPilot trolling motor combination Step 1 Replace the servo motor in the drive housing assembly or complete drive housing assembly on the trolling motor It is suspected that the transient voltage suppressor TVS on the servo motor is faulty or damaged Case III Terrova motor equipped with CoPilot but CoPilot doesn t work Step 1 Remove right motor sideplate and inspect network connection from CoPilot receiver board to main control board Check to ensure that the five plug pins on the main control board side are not missing or bent and that the plug connection is fully engaged and properly seated NOTE when fully engaged no yellow space will be seen between the plug ends and the plug connection will snap twice as they are pushed together Reconnect power to motor or deploy motor to turn on the system ready LED and enable the system Test for motor function using CoPilot remote transmitter If motor does not function proceed to Step 2 Step 2 Test motor with known good corded foot pedal If motor functions properly with test pedal the CoPilot remote transmitter may be faulty Disassemble the transmitter to check battery voltage battery is 3 volt lithium coi
14. check the drive housing B 1 Connect 12 volt power source directly to drive housing leads If drive housing does not steer open drive housing Inspect servo motor and drive gears for binding lack of lubrication Service drive housing to correct malfunction as needed If necessary re lubricate the bushing and sleeve contact surfaces with Schaeffer s 238 Moly Ultra Supreme grease Minn Kota p n 2307720 PART II Case II Motor lower unit fails to run or runs intermittently Step 1 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for any corroded connections Clean rewire if necessary Step 2 Check motor with known good test foot pedal or test the original foot pedal by performing Foot Pedal PCB Test Procedure see page 8 2 Replace as needed B If test pedal does not properly control propeller or if original pedal tests okay as outlined on page 8 2 go to Step 3 Step 3 Check to see if lower unit runs properly A Connect 12 volts directly to the red and black brush leads at the top of the motor shaft in the control box The motor should run If not a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as needed If the motor operates properly go to Step 4 Step
15. 2 Look for this sign U Universal Sonar 2 is available on select Maxxum Pro Maxxum Gow Mount Terrova and PowerDrive Ve trolling motors Look for the Universal Sonar logo on the motor of your choice 20 07 755007 GARMIN LOWRANCE Hand Control w Speed Coil Repair Manual 11 02 07 Chapter 4 Hand Control Models with a Speed Coil Case I Motor fails to operate on any speed Step 1 Check to ensure proper voltage Inspect all battery connection trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Step 2 Check to see if lower unit runs A Connect battery lead wire to battery B Disconnect the black battery leadwire from the switch and connect it directly to the black brush lead C Disconnect the red battery leadwire from the switch and touch it directly to the red brush lead C 1 If motor does run proceed to Step 3 C 2 If motor does not run a problem exists in the lower unit Check the lower unit for voltage at the brushes water damage brushes not making proper contact or an open or shorted armature Repair as needed and test motor for proper operation Step 3 If unit being serviced is not a 12 24 volt model proceed to Step 4 If unit being serviced is a 12 24 volt model check 12 24 switch for continuity Terminal A Terminal 9 Terminal B front side of switch back side of switch A Turn the 12 24 switch to
16. IMPORTANT NOTE The motor may immediately start steering after releasing the buttons described in Step 3A If this happens disengage the steering A S A P by pressing and releasing a momentary steering button A Using the test foot pedal p n 2772040T press and hold both the TrimUp and TrimDown buttons while turning the Master Switch ON then release both trim buttons Disengage steering if motor starts to spin as called out in above IMPORTANT NOTE B LCD display on motor should read LFT B 1 If LCD shows SET PROPELLER turn pedal OFF and perform Master Reset as described on page 14 21 Deploy the motor Then return to Step 2 above B 2 If LCD shows SET STRAIGHT AHEAD then both TrimUp and TrimDown buttons were not pushed simultaneously Turn pedal off and return to Step 3 above C Use the momentary steering buttons to place the motor lower unit in propeller left park position Left park position is motor lower unit at a 90 angle to the Genesis base housing with the prop pointing to the left when viewing the LCD D Press the Momentary ON switch located on heel toe steering pedal once to enter this setting into the main board memory E LCD on motor should now read F NOTE In this step the motor lower unit must be rotated counterclockwise when looking down at the motor lower unit Use the Left Momentary Steering Switch to rotate motor lower unit from left park position to right park positi
17. If Genesis motor has been disassembled for transducer routin procedure and is now assembled and will not steer Step 1 Check to make certain that the anti rattle bushing is in its proper place see below On 45 shaft models the cam profile will extend over the hole in the tube when motor is fully assembled A The anti rattle bushing catch must be in the hole provided in the lift belt channel If it is pushed out of position during reassembly after transducer routing the Genesis motor will not steer or will steer with great difficulty A 1 Disassemble the motor per the transducer routing procedure to correctly position the anti rattle bushing back in its proper place A 2 Reassemble the Genesis motor and test all functions for proper operation Step 2 Visually inspect the primary gear retaining screws for proper installation and tightness see Steering System Module Case I Step I on page 14 3 Step 3 Correct cause of steering problem reassemble and test unit for proper function Case VII Prior to stowing lower unit doesn t steer perpendicular to the mount so that the lower unit lays flat on the motor rests Step 1 Re orient steering potentiometer to the lower unit motor position see page 14 19 As per this procedure it may be necessary to reprogram the left and right park position values into the control board page 14 27 Step 2 Run unit through several stow deploy cycles to test unit for proper function
18. Part I pertains to EM 2006 and later models s n AG and later pages 16 1 through 16 2 Part pertains to EP amp EM motors manufactured prior to model year 2006 s n AF amp earlier pages 16 3 through 16 5 PART I EM motors manufactured for model year 2006 and later s n AG and later Part I Case I Motor does not run Step 1 Check for proper voltage and polarity Check for any corroded connections Step 2 Disconnect motor leads from control module and connect motor leads to 12 volt power source This applies to 12 24 or 36 volt models A If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes bad brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation B If motor ran when motor leads were connected directly to 12vdc the problem is either with the hand controller or control module B 1 Test hand controller Hand Controller Test Procedure Set your VOM to check for continuity With the speed selector knob in the OFF position check to verify that there is no continuity across pins and 3 Rotate speed selector knob clockwise to the forward position pins 1 and 3 should show continuity Rotate speed selector knob counterclockwise to the reverse position Pins 1 and 3 should again show continuity With the speed selector knob in the OFF position an
19. Reattach all wires in their proper locations install potentiometer pulley on potentiometer and reassemble the steering chassis assembly in the control box Reinstall primary gear gear collar and primary gear screws using 603 on the screws Re Orient the new steering potentiometer to motor lower unit see page 14 19 14 24 Genesis Repair Manual 11 07 07 GENESIS Control Board Replacement The Genesis main control board should only be replaced if the control board has failed the control board installed in the motor has been identified as having early or outdated software see page 14 22 Control board replacement on a Genesis motor is a complex procedure and as such should never be done unless the warranty repair center knows for certain that replacement is necessary Main Control Board Replacement Motor may be either stowed or deployed Step 1 Disassembly A B C F G H I Remove the Genesis left and right sideplate retaining screws and then remove the sideplates Remove the center display housing item 33 on the Base Housing parts explosion by pushing in on the retaining tabs to expose the Genesis main control board assembly Remove the 2 screws item 34 on the Base Housing parts explosion to separate the LCD from the center housing Remove the strain relief bracket screw and bracket item 14 and 13 on the Base Housing parts explosion from the base extrusion Disconnect
20. Replace hand controller if it tests faulty If the hand controller tests okay the problem is with the control module Test control module to verify problem B 1 Connect control module to appropriate power source B 2 Plug in known good tested as per above hand controller to control module Check for voltage at module output leads by hooking up test light or V O M probes to control output leads Vary the potentiometer speed control setting Test light or V O M should vary in intensity with the potentiometer setting Replace control module as necessary Part I Case III There is a gap between the propeller and the end bell housing Step 1 On the earliest version of the 2006 EM motors the armatures utilized an E ring behind the commutator to act as an end play spacer Sometimes the E ring would pop off the armature shaft due to the vibration of the outboard The later designs removed the E ring and use a bushing placed on the armature to act as the spacer Replace the armature with a current version Part I Case IV Twin EM motor units only EM160 amp EM202 1 motor runs doesn t Step 1 On the one motor that doesn t run disconnect motor leads from the control module and connect motor leads to 12 volt power source This applies to 12 24 or 36 volt models A If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushe
21. Transom mount 3X Bow mount 3X 3X Disassembly Step 1 Start by removing the extension handle from the inner handle by pressing down on the handle by pressing down on the handle latch detent button located on the top side of the handle near the control box With latch button depressed slide the extension handle off and clear of the inner handle see Fig 3 page 6 2 Step 2 Remove the six Phillips pan head screws 6 20 x 5 8 located on the underside of the control box assembly 2 screws at front middle and rear of control box see Fig 3 page 6 2 6 1 3X Steering Repair Manual 11 06 07 A With the cover screws removed the control box cover can be lifted up and tipped to the side to access the battery meter wires Disconnect the red and black battery meter leads from the speed selector on 5 speed models or the red and black wires exiting the control board on variable speed 3X motors Step 3 Lift up the inner handle assembly along with the handle pivot handle bearing and potentiometer variable speed motors or speed selector switch 5 speed motors Disengage the inner handle assembly from the D shaft on the potentiometer switch remove the inner handle and set it aside for reassembly see Fig 3 Step 4 At this point prior to further disassembly note the routing and positioning of all electrical wiring When reassembling the 3X motor the wires must be placed back in the same position to avoid getting the wires in
22. Using a VOM multi meter measure the voltage of the battery prior to plugging in charger Note this measurement for future reference must be over 8 volts for charger to operate Plug in charger to 110 volt AC power 220 volt for some of the international models only Using a VOM again measure the voltage at the battery The voltage should be slowly increasing as you watch the VOM The battery voltage should continue to rise until the battery reaches the full float voltage of 13 2 This may take several hours depending on the battery state of discharge and the specific model on board charger being used If the battery voltage does not gradually increase when the charger is plugged in the charger is not functioning properly OR the battery is defective 20 1 Battery Chargers 11 19 07 Indicator Lights varies depending upon model MK105P A YELLOW light is lit to indicate the battery is charging A GREEN light is lit for each bank to indicate any of the following A The battery is fully charged and in maintenance mode B There may be a blown fuse in the fuse holder C No battery is connected to an output lead A RED light is lit if any of the following apply A A short circuit B The battery is connected reverse polarity MK110P and MK210P A GREEN power light is lit to indicate AC power is applied A YELLOW light is lit to for each bank to indicate the battery is charging A GREEN light is lit for each bank to indicate the b
23. With motor deployed when the TrimUp foot pedal switch is pressed the lift motor stutter jerks and the Genesis LCD rapidly flickers and appears to read 8 9 and then defaults to ER6 Step 1 Check all battery connections for proper voltage security and corrosion Correct faults and retest Step 2 If all connections are okay the pedal TrimUp switch is faulty The foot pedal assembly p n 2772040 needs replacement A Replace foot pedal with latest pedal from Minn Kota and test all motor functions for proper operation 14 15 Genesis Repair Manual 11 07 07 GENESIS AP PD Base Housing Module Case I Genesis motor operates properly but LCD screen is blank has no display Step 1 Remove motor side plates and center housing to access LCD leads see AP PD Base Housing parts explosion A Examine the five wires connecting the LCD to the main control board 1 of the five wires are cut broken or damaged reconnect or splice back together and retest by turning Master Switch ON and observing display 2 If wires check okay but LCD does not display the LCD 15 faulty and needs to be replaced B Install new LCD p n 2224015 B 1 Cut leads to faulty LCD and solder the leads from the new LCD in its place Wires are color coded Be sure to properly connect solder and seal the wire connections B 2 Reassemble turn Master Switch ON observe LCD for proper function Test all motor operations for prope
24. ________ 205 2208 226 1712 2 e m 231 5105 ec F E T E 205 1705 Figure 3 205 307 205 3414 2 205 1717 2 205 1706 4 205 2000 e Motor screws 831 070 3 Fiquve 4 1 7 Vantage Repair Manual 02 15 08 7 4 205 3413 1 1 T af o A 4 215 1726 e lE 4 205 3103 205 1716 728 4 8 215 1726 4 Ur 299 0429 205 3400 d Te 205 1920 22 520 EE 9 7 7 4252705 2 205 3418 tH 205 2305 205 3200 po 4 Fiauve 5 205 3205 RUN 205 547 0 205 6200 205 1510 _ e 235 3401 205 3400 205 3401 Me re Vantage Repair Manual 02 15 08 cb doe eL fe BEARING USE EXISTINGI STEERING GEAR USE EXISTING FIA USE EX IT Na WASHER EXISTING STEERING SHAFT EXISTINGG DO DISASSEMBLE STEERING SHAFT ASSEMBLY REMOVE BEARING SCREWS AND LIFT ASSEMBLY RECATE NOTE THE ORIENTATION DF THE DRIVLOK PIN IM RELATION TO MOTOR THE UNIT MUST BE REASSEMBLIED IN THE SAME POSITION IT WAS PRIZR T DISASSEMBLY a er Ec 299 6515 LOWER GLAR CAP ASSEM pas EE m nC o BEARING SCREWS USE EXISTING 0 T eo 800 DRIVE BEL BEARING WASHERS USE EXISTING eo SU MOTOR SCREW 3 LIFT GEAR USE EXISTING S an e 205 1103 THRU
25. front post of contactor RED ACTUATOR LEAD PACK ACTUATOR LEAD RED MOTOR LEAD BLUE TILT WIRE from lower unit Switch power GREEN TLT WIRE up position YELLOW TILT WIRE down positon CONTROL BOARD e THROTTLE CABLE PLUG 19 8 E Drive 11 14 07 CONTROL BOARD WIRING for p n 2044006 RED LEAD WIRE from batteries front post contactor CONTACTOR in m ELACK ACTUATOR LEAD to resistor BROWN LEAD RESISTOR Wear pn ORANGE LEAD front pin BLACK LEAD WIRE BLACK TO BLACK batteries B ACTUATOR RESISTOR CONNECTION RED MOTOR LEAD from lower unit M RED JUMPER WIRE rear post of contactor B M GREY CONTACTOR WRE front post of contactor RED ACTUATOR LEAD BLACK MOTOR LEAD from lower unit M BLUE TILT WIRE Switch power GREEN TILT WIRE J up position YELLOW TILT WIRE down position oO THROTTLE CABLE PLUG CONTROL BOARD 19 9 11 14 07 E Drive ee 219 10d 57 Nid 40 1334 ONIM 14002 Q3Q0V 34H1 Nld STONY LY LHOIVHLS 9NI 718 104 Throttle Cable Pin Out Diagram P N 2041401 19 10 11 14 07 E Drive M9IA 9981 JOJOSUUOD e qeo SALIG F Throttle Cable Pin Out Diagram P N 2041401 plugs into main control board 19 11 11 14 07 E Drive 0v1 v0c
26. not all the speed coil wires the speed coil is faulty and needs to be replaced D 2 If the motor runs as you touch the red battery lead to each speed coil wire proceed to Step 3 Step 3 Speed switch is defective Replace Speed switch Test motor for proper operation 4 Hand Control w Speed Coil Repair Manual 01 31 08 Case III Motor works at all speed settings but the customer is complaining that there is no variation between speeds Step 1 Perform an amp draw check while the motor is running in a water test tank A B If the amps step up as the speed setting increases the motor is performing as designed If the amp draw does not increase along with the speed settings check the amp draw of each speed directly through the speed coil B 1 Remove the control box cover Disconnect wires at the switch from the wires to the lower unit B 2 With the lower unit still in a water test tank connect 12 volts to the black motor brush lead B 3 Connect 12 volts to each colored speed coil wire coming up through the motor tube from the lower unit The motor will run on the separate speed designations as you make each connection Note the amp draw as you test the different colored wires a If the amp draw does not vary as you make the different connections with the lower unit still in a water test tank replace the front end bell potted speed coil assembly b If the amp draw does vary as you make the different connections repla
27. serial numbers beginning with MKAA amp serial numbers GNAB0002697 and below need the p n 2222206 gear gt S N between GNAB0002698 to GNAC1002726 amp all GNRW Re worked serial numbers need p n 2222209 gear gt S N GNAC1002727 and above need p n 2222214 coupler gear C 2 The p n is molded on to the end the end of the coupler Identify the correct coupler gear needed by checking the broken part D Reassemble motor in reverse order of disassembly and test all functions for proper operation D 1 Perform Master Reset Emergency Override procedure to reset shaft position counter if motor does not fully stow deploy after lift gear coupler is replaced Case IV If the lift belt has been accidentally cut or damaged but is still routed through the lift housing it can be replaced without disassembling the lift housing If it is not still routed through the housing refer to Case V on page 14 13 for instructions on splitting the lift housing Step 1 With motor in fully stowed position place Quick Grip clamp on lower unit and lift housing see figure below 14 7 Genesis Repair Manual 11 07 07 Step 2 Remove the control box cover screws and cover assembly to expose the Genesis steering system see below Primary Gear Steering Potentiometer Belt Steering Potentiometer Gear Genesis Repair Manual 11 07 07 A Mark and tape the steering potentiometer as shown below Disconnect the red and black motor leads a
28. tension sleeve gt Fun NT 27 207 8700 a a t ni n lensianm sieeve N kn M A 207 5100 7 1225 207 010 ni i i hey tensen block s F 207 2801 M E xi juter Tuae gt racket je MES EM 4 ower collar E Ses ify x ors ri T ES E m 5 E 01 1 LE N e 9 du B 4 y 1 1 pL di i Ey halt call a a 7b 1577 nty 2 eo screw 4 2 777 225 3453 gty 2 Fig 5 3X Steering Repair Manual 11 06 07 Step 9 Remove the collar halves P N 2261622 clamped around the motor inner tube 1 1 8 diameter tube The collar halves are located just below the lower collar P N 2071500 on the outer tube of either the transom mount or bowmount 3X motor A 3 16 allen wrench driver is required see Fig 5 page 6 4 Step 10 With the collar halves removed the motor lower unit and inner tube assembly can be pushed lifted up to expose the 4 hole collar P N 2071560 and four 8 32 x 7 16 Phillips flathead countersunk screws P N 2223468 that hold the pinion gear assembly into the inner tube see Fig 5 page 6 4 A Remove the four screws P N 2223468 to allow removal of the pinion assembl
29. A Disconnect power to motor or stow motor to disable turn off the system ready LED Disconnect the network accessories from the main control board foot pedal AutoPilot and CoPilot if motor is so equipped see Picture 3 page 11 3 Connect known good test foot pedal and reconnect power or deploy motor to enable turn on the system ready LED Test for proper operation A 1 If motor fails to function properly main control board is faulty and needs to be replaced See Case X on page 11 6 for information regarding main board replacement A 2 If motor works properly with test pedal proceed to Step 2B Disconnect power motor or stow motor to disable turn off the system ready LED Disconnect test pedal and connect customer s pedal to motor Reconnect power or deploy motor and retest for proper operation B 1 If motor now malfunctions with customer foot pedal pedal is faulty and needs to be replaced B 2 If motor functions check okay suspect a faulty network accessory AutoPilot or CoPilot depending on how motor is equipped Proceed to Step 2C C Disconnect power to motor or stow motor to disable turn off the system ready LED If the motor is AutoPilot equipped see Case III on page 11 2 to determine or confirm that motor is AutoPilot equipped connect the AutoPilot network accessory plug to the network plug from the main control board NOTE network plug leads from the main control board are common either lead can be con
30. AutoPilot equipped Not all Terrova motors are AutoPilot models but all Terrova motors whether they have AutoPilot or not share the same foot pedal CoPilot remote and main control boards 12 v or 24 36 v This means that all Terrova motors have an AutoPilot button on the foot pedal and CoPilot remote as well as an AutoPilot red LED on the motor base but unless it has the AutoPilot compass control board network accessory installed in the control box at the top of the shaft it is not AutoPilot equipped A All Terrova motors that leave the factory with the AutoPilot feature installed will indicate this on the control box cover decal see Picture 2 Picture 2 digital digital A AutoPilot US us 24 volts 1230 80 B5 lbs thrust Non AutoPilot AutoPilot B Because all Terrova motors are AutoPilot capable with the addition of the AutoPilot compass control board to the network a Terrova motor that originally left the factory as a non AutoPilot model can be converted to AutoPilot at a later date AutoPilot accessory is being sold as an upgrade kit beginning in 2008 A Terrova motor converted to AutoPilot would not have the AutoPilot icon on the cover decal To determine if the motor is AutoPilot equipped remove the control box cover to see if an AutoPilot compass control board is installed Step 2 If it was determined in Step 1A or 1B that the motor is AutoPilot equipped check to ensure that the
31. CON switch Test motor for proper operation Step 6 With battery leads connected to power source and MOM OFF CON switch in the MOM position connect V O M test leads to the battery leadwire and the battery lead terminals at the main control board with ON OFF switch depressed Consult appropriate wiring diagram for the model being diagnosed A If voltage is present replace main control board B If no voltage is present test foot pedal ON OFF switch for continuity with momentary ON OFF switch depressed B 1 If no continuity is noted replace foot pedal ON OFF switch Test for proper operation This Case applies to motors with the magnetic on off reed switch system Case II Motor fails to run in either the continuous CON or the momentary MOM mode Step 1 Check to ensure proper voltage and check polarity at battery red black Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery lead wire Double check position of the MOM OFF CON switch NOTE In the CON position the speed selector must be in the 10 100 setting for the motor to run In the MOM mode the speed selector must be in the 10 100 setting and the momentary ON OFF switch on the foot pedal must be depressed for the motor to run Step 2 Remove the control box cover Disconnect the red and black motor leads and connect 12 volts to these leads This applies to 12 24 or 36 volt models A If motor ru
32. Lift the cable drum pulley off of the drive pinion Remove the barrel end of each cable core from the pulley dad a needle nose pliers pinch the retainer tabs on the cable housing Push the housing and the cable core through the racket Pull cable assembly out through the cable jacket from the motor control box end Push the new assembly through cable jacket Before replacing the cable drum pulley rotate the motor shaft to point the motor straight ahead and adjust the foot pedal 5o the top of the foot pedal is level Install replacement cable assembly in reverse order the oe core tension by tightening cable adjusting screw so the motor is held stationary and the foot pedal has ree play Test for proper 360 steering action and ease of operation Diagram 1 The left cable when viewed from above the control box is a few inches longer because it needs to wrap around the pulley in the foot pedal right side when viewed from underside of pedal 12 4 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 Chapter 13 Foot Control Cable Steer Models with a Control board This Case applies to motors with the older style mechanical on off momentary switch in the foot pedal Case I Motor fails to run Step 1 Check to make sure that the MOM OFF CON switch is not in the OFF position Check to ensure proper voltage and check polarity at battery red black Inspect all battery connections
33. RF interference a ground wire can be connected to the trolling motor lower unit This can be accomplished by means of either an external or internal connection Grounding the motor case in this manner creates a shield between the motor brushes and the transducer trapping shunting the RFI to the ground C 1 To ground the motor case externally drill a small diameter hole 1 8 in the motor skeg Attach one end of the ground wire at this point by using a self tapping stainless steel screw 18 gauge wire may be used for this purpose Run the ground wire up the motor shaft along with the transducer coax cable Connect the other end of the ground wire to the motor negative battery lead or post 2 1 Depth Finder Interference 07 17 08 C 2 To ground the motor case internally it will be necessary to disassemble reseal and reassemble the motor lower unit We recommend this be done only by a Minn Kota authorized repair center with Minn Kota p n 2880310 With the lower unit disassembled connect one end of a light gauge wire to the motor brush plate mounting screw 18 gauge wire may be used for this purpose Run the ground wire up the fiberglass motor shaft along with the red and black motor brush leads Connect the other end of the ground wire to the motor negative battery lead or post Reassemble and reseal the motor lower unit On AutoPilot motors this can go to the brown coil cord wire on Maxxum motors you can connect to the negative si
34. Remove the spool bearing rotate it 1 4 turn and reassemble DeckHand Test unit for proper operation Case VI DeckHand lowers anchor but does not automatically feed out line when anchor hits bottom Step 1 Defective momentary switch Replace as needed 17 2 CoPilot Wireless Accessory 05 29 08 Chapter 18 CoPilot Wireless Accessory Do NOT replace the complete CoPilot as a boxed marine accessory just replace the defective part P N Description LEGACY 2774023 remote transmitter assembly 2774031 receiver assembly white saltwater RipTide 2774033 receiver assembly black freshwater PowerDrive V2 2774023 remote transmitter assembly hand control 2774730 remote foot pedal transmitter assembly 2774088 receiver assembly black freshwater 2774089 receiver assembly white saltwater RipTide Terrova 2774095 remote transmitter assembly 2884090 receiver assembly Case I Remote is not transmitting Step 1 The battery may be discharged Replace battery if needed Step 2 Receiver may not have learned the ID number of the remote A Remote needs to be learned see ADDING REMOVING REMOTES below Step 3 With the foot pedal connected the MOM CON switch is in the CON position An audio response will be heard if a button is pressed with the foot pedal in the CON position A The foot pedal switch must be placed in the MOM position The receiver will not accept any commands from the remote with the switch in the CON position
35. Step 1 This is normal It is designed to prevent the coil cord from wrapping around the shaft of the motor If you steer continuously in one direction until the servo motor stops you can momentarily release the steering and then re engage it in the same or opposite direction PART I Case VI AutoPilot function is erratic and doesn t maintain a heading Step 1 Make sure motor is mounted within 5 degrees of level the compass card with the graduated markings must be floating level and there are no ferrous metal objects near the motor that may be affecting the compass including screws nuts While maintaining a level compass rotate the control box and observe the compass card The card should remain stationary 1 e card should not have lost its magnetic north reference as the control box is turned If the compass card sticks or hangs up it is faulty and the compass assembly needs to be replaced AutoPilot Repair Manual 02 12 08 A Inspect oil level in compass capsule looking for a leaky capsule NOTE Examine the red compass grommets If the compass has leaked fluid the grommets will be swollen almost double their normal size B If any sign of compass fluid leakage is evident replace the compass control board assembly Step 2 Check motor for excessive vibration Inspect propeller and propeller shaft for damage Excessive vibration can cause the AutoPilot compass to oscillate causing erratic operation Step 3 Check for proper v
36. Switch ON Step 3 Continue to hold Mode Switch LCD should be displaying if not then you probably momentarily released the Mode Switch restart procedure until the LCD shows Sto approximately 15 seconds for earlier software versions and approximately 5 seconds for software version 107 Step4 Release Mode Switch Step 5 Important if motor is stowed The motor will be trying to steer you should be able to hear the steering motor running Quickly press either of the momentary steering arrow buttons to disengage the steering system If you do not disengage the steering system within 5 seconds you may overheat and damage the steering motor Also you may get an ER5 code after completing Step 7 below Simply turn off the Master Switch The next time you turn it back on the 5 code will be cleared Important if motor is deployed In some situations the motor may be steering in circles quickly press either of the momentary steering arrow buttons to disengage the steering system Use the momentary steering arrows to orient the lower unit perpendicular to the mount The lower unit can also be rotated by hand ratcheting slipping the steering clutch Step 6 Use the TrimUp Switch to stow the motor Release the TrimUp when the unit is fully stowed Step 7 Press and release Mode Switch to reset the system at this point the LCD display should have switched from Sto to the hour meter reading and then turn the Master
37. automatically display A B C The LCD on motor will display OFO OFI or OF2 The display will show last setting selected Press and release the right momentary steering switch to select offset table Press Momentary ON switch located on the heel toe pedal once to enter this setting into the main board memory Step 6 After completing Step 5 the LCD on the motor will display A B C Turn Master Switch OFF to lock all steps of this procedure in main board memory and to return motor to normal operating mode If unit is a non AutoPilot model this step completes the Initial Programming Procedure B 1 Test unit for proper operation Service completed If the motor being serviced is an AutoPilot model proceed to the Calibrating AutoPilot Compass Software Procedure page 14 29 14 28 Genesis Repair Manual 11 07 07 GENESIS Calibrating AutoPilot Compass Software This procedure should only be used After replacing the main control board compass assembly When adding the compensating magnet rods and bracket to earlier units without them We recommend that you have and use the specially modified Genesis Test Foot Pedal p n 2772040T when doing this procedure Calibrating AutoPilot Compass Software Steps Motor must be connected to appropriate voltage and be DEPLOYED for the following procedure and test Step 1 Step 2 Calibrating Compass Software No
38. be covered to block any light on the optical sensors 12 volts here volts and black VOM lead here 3 diagram 3 NOTE Compass removed from motor and compass card not covered for clarity Compass card should be covered to block any light on the optical sensors This concludes the trim pot adjustment procedure A small drop of RTV rubber silicone non acidic based sealant over the trim pots will ensure they will not change due to vibration or extreme heat fluctuation The properly adjusted compass control board is now ready to be reinstalled if necessary and the motor put back into use 9 14 Cordless Motors Repair Manual 02 20 08 Chapter 10 Manufactured between 1996 1999 Cordless PowerDrive and AutoPilot Models This does not pertain to CoPilot PD C and PD AP C were series of motors in the late 1990 s Case I Motor fails to operate Step 1 Ensure proper initialization B C Connect motor leadwires to proper voltage and correct polarity Check battery leadwire connections trolling motor plug if one is installed all butt splice connections and leadwire connections at main printed circuit board Turn on receiver sideplate motor ON OFF switch first then turn on the foot pedal transmitter ON OFF switch then send a signal with the foot pedal transmitter Step 2 Check receiver sideplate LED operation Upon initialization first command to receiver the receiver sideplate LED should li
39. by lifting it straight up out of the right lift housing half F Release the tension spring item 38 on the Lift Housing parts explosion from the catch on the latch link pin item 37 of the Lift Housing parts explosion and then lift the upper cam assembly items 39 40 and 41 of the Lift Housing parts explosion up and off the idler pin G Lift the lower cam and locking pin assembly items 34 35 36 and 37 of the Lift Housing parts explosion up slightly to allow removal and inspection of the shaft gear clutch and gear assembly items 28 29 30 31 32 and 33 of the Lift Housing parts explosion H Next remove the gear shaft and sprocket assembly items 25 26 and 27 on the Lift Housing parts explosion If the lift chain and all other gears shafts etc have checked okay then the large gear molded on the shaft of the gear shaft and sprocket assembly is slipping and needs to be replaced This can be verified by clamping the gear in a vise and applying moderate rotational force to the sprocket I Remove the driv lok pin and sprocket from the gear shaft and replace the faulty part Reassemble the sprocket and pin on a new gear shaft J Begin reinstalling the lift housing by reinstalling all gears shafts belts springs washers clutch and lift chain in their proper locations in reverse order of disassembly K Place the left half of the lift housing back onto the right half taking care to properly position t
40. grease pencil or put a piece of tape across the joints of the lower unit front endbell to center housing and center housingl to rear endbell Cut the tape with razor blade Use these marks to assemble the lower unit exactly as it was prior to disassembly When re assembling a motor assembly ensure you evenly tighten the thru bolts Tighten one a little then the other etc Torque specs listed on page 1 3 Case VIII Weedless Wedge 2 motor seems noisy Step 1 The malfunction listed above is most likely due to rough handling and concealed damage that may have occurred while the motor was in shipment to the distributor dealer A B Dis assemble the motor lower unit to remove and inspect the armature thrust support bearing small sealed caged ball bearing on end of the armature shaft To test for bearing smoothness roughness grasp the outer race of the bearing and lift the armature up so that it hangs straight down below the hand grasping the bearing race and supporting the armature With your free hand give the armature a spin The armature should spin freely with no feel of roughness or catching of the bearing B 1 If any roughness or catching is noted inspect the armature Examine the commutator sections for discoloration and arcing caused by the brushes as they make contact with good live commutator sections and bad dead sections Replace armature if arcing is noted B 2 Test armature commutator sections for c
41. handle A Disconnect black and white coil cord wires located behind the extrusion shield p n 2050220 NOTE the coil cord wires are the small gauge wires with bullet connectors B Connect the black and white wires coming from the handle assembly to your V O M C With your V O M set to test continuity press and hold the ON OFF button in the end of the steering handle C 1 If no continuity is noted go to Step 5 C 2 If continuity is observed go to Step 6 Disassemble the steering handle assembly see figure 2 page 7 6 A Remove the gray steering handle grip and unscrew the four handle screws in order to separate the handle halves B Visually inspect wire connections at the ON OFF dome switch the UP DOWN switches and the speed control potentiometer If any corrosion is noted at these points replace the handle control board assembly p n 2994005 C If no corrosion is noted repeat continuity test across black and white coil cord wires Step 4 but press and hold the ON OFF dome switch with your fingertip If continuity 15 now noted but was not observed in Step 4C replace switch plunger p n 2053700 and actuator button p n 2055115 Disconnect the red yellow and green coil cord wires at the main control board A Check resistance across the red and green coil cord wires coming from the handle assembly With your V O M set to test resistance it should indicate Ik ohm or slightly higher B With speed control knob
42. if lift motor works by applying 12 volts directly to lift motor leads bypass all the existing wires and switches A If motor runs fine go to Step 3 B If motor does not run replace lift motor P N 2887800 Test unit for proper operation C If motor can be heard running but the rope spool does not spin remove the gear motor from the side of the base Remove the housing cover gasket so that you can inspect the drive gear P N 350 154 C 1 If the drive gear is cracked broken or the teeth are stripped replace drive gear grease new gear liberally with wheel bearing grease Reassemble unit and test for proper operation NOTE If new gear seems very tight you may need to ream out the center hole of the gear with a 21 64 drill bit C 2 If drive gear looks good remove gear to inspect the armature worm shaft If worm shaft is broken replace entire gear motor Reassemble and test unit for proper operation Step 3 Check for continuity through the automatic reset circuit breaker which is located in the positive lead wire between the battery and the UP DOWN switch The circuit breaker is defective if no continuity is noted Replace circuit breaker and test unit for proper operation Step 4 Disassemble the UP DOWN switch housing and inspect all connections at the switch terminals for security A After going through all the above steps the UP DOWN switch must be defective Replace switch and test unit for proper operation Ca
43. it with a drop of red LocTite on the threads If motor being serviced is an All Terrain motor with a Hinge Door bracket or a RipTide motor with a bowguard 360 assembly that splits vertically left and right casting halves Step 1 Step 2 Step 3 Remove existing defective eyelet from bowmount bracket assembly Drill out the eyelet hole to a 1 2 diameter Slip the new eyelet P N 2772352 into the gt gt eyelet opening and secure it with the 1 2 jam nut provided in the eyelet kit Use a drop of red LocTite on the eyelet threads prior to installing the jam nut 13 3 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 Case IX Customer complaint that the motor slides down in the bracket doesn t maintain consistent depth setting Motors prior to 2004 were subject to this issue Step 1 Install Depth Collar Parts Kit P N 2771550 using Installation Kit P N 2888620 Instructions are included with Kit The Depth Collar Kit includes an additional depth collar and a new bearing race assembly that utilizes a split collar with 4 screws The Installation Kit includes a jig and a drill bit so you can properly align the screw holes Case X LIFT ASSIST WARNING Maxxum Pro WARNING The gas assist lift mechanism in these models are under HIGH SPRING PRESSURE when the motor is in the deployed position DO NOT remove the BowGuard 360 assembly from the mount without disconnecting one end of the gas spring Fai
44. its proper place in the channel of the outer tube The catch on the end of the lift cam needs to prevent the lift cam from sliding in the channel If this is okay a faulty gear shaft or broken chain in the lift housing assembly causes this malfunction To determine which part is at fault the lift housing must be removed from the base housing assembly and disassembled for internal inspection Step 1 Consult the step by step disassembly procedures outlined in the Genesis Transducer Cable Routing Service Bulletin 41400 Part II III and IV Steps 1 and 2 Disassemble the Genesis motor by following the steps as indicated Step 2 Remove the four screws holding the steering chassis assembly item 19 of the Steering Module parts explosion into the lower control box item 13 of the Steering Module parts explosion Disconnect the steering chassis wires as needed A Unscrew the lift belt tension screw item 17 of the Steering Module parts explosion while observing the lift belt tensioner see figure below Note how the lift belt is routed and attached to the tensioner for later reassembly Genesis Repair Manual 11 07 07 Remove the belt tensioner and control box from the outer tube item 8 of the Steering Module parts explosion With the lift belt loose from the top and bottom of the outer tube pull the outer shaft out of the lift housing leaving the lift belt in place through the lift housing assembly ATTENTION For proper reass
45. leads to reverse the actuator direction of travel A If the actuator fails to operate when 12 volts 1s connected to the leads the actuator 1s faulty and needs to be replaced B If the actuator functions properly when connected directly to 12 volts but fails to operate when connected to the main control board assembly the tilt actuator circuit on the control board is faulty and the main control board will need to be replaced Case III Tilt gauge if motor is so equipped does not operate Step 1 Step 2 Step 3 Check battery connections on backside of tilt gauge The tilt gauge must be connected to 12 volts 1n order to function Note power for the trim gauge can be supplied by the boats accessory wiring circuit or one of the series linked 12 volt batteries used to power the E Drive motor If one of the E Drive batteries 1s used to power the tilt gauge we suggest an on off switch be installed in this 12 volt tilt gauge electrical circuit Check connections from sending unit to back of tilt gauge for corrosion and security Clean if needed and test for function Observe the tilt gauge sending unit lever arm as the motor 15 being tilted up or down The lever arm should contact the E Drive motor main extrusion and move rotate as the motor 15 tilted up or down If it fails to rotate check the sending unit spring for proper installation and position A The tilt gauge sending unit is a potentiometer and a simple resistance check can
46. network accessory plugs for the AutoPilot compass control board in the control box at the top of the motor shaft and at the main control board on the motor base plate are clean show no signs of corrosion have no bent pins and are fully engaged and properly seated together see Pictures 3 amp 4 page 11 3 Terrova Manual 11 16 07 Picture 3 a not being used connected to AutoPilot network plug system ready reed switch This picture is showing the 2 network cables coming off control board In this case one is connected to the compass board network plug and the other is not being used No CoPilot attached so yellow cap still on plug NOTE network plug leads from the main control board are common either lead can be connected to either accessory Picture 4 AutoPilot network plug This picture is showing the control box with AutoPilot Compass Control board and network cable plugs Step 3 Reconnect motor to power and or deploy motor to turn on the system ready LED this allows the main board microprocessor to recognize the AutoPilot network accessory Check for AutoPilot function If AutoPilot still fails to operate then replace the AutoPilot compass control board assembly Terrova Manual 11 16 07 Case IV AutoPilot function is erratic and doesn t maintain a heading Step 1 Step 2 Step 3 Step 4 Make sure motor is mounted within 5 degrees of level the compass card with the graduated markings mus
47. normal When the key switch is first turned ON after recharging the microprocessor on the main control board takes a reading of the combined battery voltage and displays the appropriate fuel gauge reading 1 e 51 96 volts equals a full tank reading This information is then used by the microprocessor to establish a battery run time and discharge profile based on the speed setting and amp draw of the motor After running a short period of time if the key switch 1s turned OFF and then turned back ON the microprocessor again checks voltage Now the combined battery voltage has been lowered due to the motor having been operated The new fuel gauge reading will be represented on the LCD and the microprocessor will establish a new battery run time and discharge profile based on the lower battery voltage However this new run time and discharge profile will not be truly accurate as the combined available amperage from the batteries will be greater than is indicated by the batteries float voltage For this reason we would suggest that the key switch not be turned off while the E Drive motor is being used for a boat outing Not turning the key OFF will allow the microprocessor to use the initial voltage profile for more accurate fuel gauge and run time values Case VI Throttle LCD only displays Throttle Fault when key switch is turned ON Step 1 Throttle Assembly is faulty and needs to be replaced Replace with
48. on the extension cable go to Step 4 B If there is not continuity through all the wires the extension cable is defective Step 4 Replace the front end bell transducer assembly on the motor NOTE on 4 diameter motors the transducer cable is held in place in the center section with a metal clip between the magnets For ease of disassembly and reassembly we recommend that the motor be removed from the shaft On 3 5 8 diameter motors you will need to replace the shaft of the motor also Case IV US2 temperature readings are incorrect Step 1 Verify the sonar unit is on the current US2 compatibility list Step 2 Verify the correct adapter cable is being used Step 3 Verify all the plug connections are tight in the control box and at the adapter cable Step 4 To check the temperature sensors A See figure 1 below Measure the resistance from the thermistor pins to the transducer cable connector shield one at a time Pin 2 to shield 5 and then Pin 4 to shield 5 A 1 The shield wire is used as an active ground for the thermistor signals so verify the metallic connectors on the US2 cables are tight NOTE For troubleshooting the transducer cable it may be easier to sacrifice a cable to make a pigtail rather than try to hold your VOM probes on the tiny pins Take either an extension cable female end or any US2 adapter cable and cut the cable approximately 5 inches from the cable end Strip the 4 conductors You now have acces
49. pencil mark Ensure pencil mark stays within the here range of the AP template Turn motor off DO NOT STALL MOTOR FOR MORE THEN 15 SECONDS If pencil mark does not stay within the required range add 1 2 more twistto the main motor wires in the control head re test Step 7 Rotate motor so the prop is facing to the north Repeat steps 5 and 6 If wire adjustments are required atthis step repeat steps 4 5 6 and 7 until steering Is within spec The pencil mark should stay within the template marks in both directions The main motor wires may need to be moved closer to or farther from the compass to fully eliminate the magnetic fields Step 8 Remove stall clamp BETTER UNDERSTANDING As the motor is being stalled a magnetic field is being generated between the main motor wires The more amperage that is drawn will lead to a larger magnetic field This magnetic field causes a magnetic shift between Magnetic TOM lore e North and the compass magnet With proper wire placement and twisting of the main motor wires around each other the magnetic field is interrupted and cancels its effect on the compass magnet 02 12 08 AutoPilot Repair Manual V2 Foot Pedal Test Procedure HN Wwe gt IN COT 04 62 727 2227 242772277 V2 model pedal JLON NOIIVIN3IH ia Bean MI 9 1 igg 19 peaseres
50. polarity to verify drive housing does steer in both directions Step 2 Check for a short between either of the drive housing wires and the metal portion of the drive housing itself To do this use a V O M to check for continuity between the drive housing lead and a screw on the underside of the drive housing A If a short is found disassemble the drive housing and insulate the wire terminals at the drive housing s servo motor to correct the shorted condition Reassemble the drive housing and again check for shorts B If no shorts are found proceed to Step 3 Step 3 The steering logic portion of the main control board is faulty Replace main control board PART Case Drive Housing steers with foot pedal but will not steer in AutoPilot mode Step 1 Check continuity of brown yellow blue orange and white wires in the coil cord with the coil cord stretched out to length If you find a break in continuity in any of these wires the coil cord is defective Replace coil cord if required Step 2 If no break in the continuity of the coil cord perform the Control Board Compass Isolation Test following the procedure provided with the AutoPilot Test Board Minn Kota P N 20 see page 9 11 A If above test indicates sensor board compass assembly is defective the replace compass assembly B If above test indicates main control board is defective check functionality of AutoPilot ON OFF switch check for continuity through switch w
51. power from the receiver by unplugging the receiver from the motor 2 Press and hold the LEARN button and power up the receiver by plugging it back into the motor Hold the learn button down for 10 seconds During this time the receiver audio will emit a warble sound slowly transitioning to a constant beep and then shut off 3 Release the LEARN button and the receiver will reboot The receiver will chirp 4 times followed by a 1 second long beep indicating memory is empty This audio pattern will occur each time the receiver powers up until a remote ID number is learned AUDIO MODES UNIT IS FACTORY PRE SET TO AUDIO MODE 2 There are three receiver audio modes available To switch from one audio mode to another press and hold both the INCREASE and DECREASE speed buttons on the remote down for one second The receiver will respond with 1 2 or 3 audible beeps indicating the corresponding receiver audio mode change Audio Mode 1 All of the normal audible sounds mentioned in this owners manual Audio Mode 2 Same as audio mode plus an audible beep for speed increase decrease and prop on off Audio Mode 3 Same as audio mode 2 plus the prop on audible click every few seconds NOTE when the corded foot pedal is in control and the propeller is on the prop on indicator click will be heard if the receiver is set to audio mode 3 BATTERY REPLACEMENT THE REPLACEMENT BATTERY MUST BE A MODEL CR2032 COIN CELL TYPE 1 Temporarily ground yourself b
52. security Step 2 Test lower unit directly bypass all switches and or control board A Connect the lead wire to battery B Hook the black battery lead directly to the black brush lead that exits the motor assembly C Hook the red battery lead to red brush lead that exits the motor assembly The motor should run If not a problem exists in the lower unit Disassemble lower unit and check for voltage at the brushes water damage brushes not making proper contact and an open armature C 1 An open armature will have some segments on the commutator that are dead If the brushes happen to stop on this open segment it will not run If you can turn the prop a quarter and the motor starts and runs fine the armature may have an open dead spot Replace armature Case II Motor works on high speed but missing some or all of the lower speeds Step 1 Check speed coil functionality Connect battery lead wire to battery B Hook the black battery lead directly to the black brush lead that exits the motor assembly C Touch the red battery lead to each colored speed coil wire one at a time The motor should run as you D make each connection If the motor fails to run as you touch any of the colored speed coil wires the problem is either speed coil is faulty and needs to be replaced or the speed coil jumper wire is not connected to the back of the brush plate in the lower unit D 1 If the motor runs as you touch the red battery lead
53. shaft position counter Case V Genesis motor steers right and left with momentary steering buttons but does not steer with heel toe pedal Step 1 Check foot pedal heel toe potentiometer shaft Foot pedal potentiometer shaft is visible between the left side of the heel toe pedal and top housing A Potentiometer shaft is white approx 1 8 in diameter and should extend from base to pedal If shaft is broken heel toe steering will not function B Replace foot pedal assembly p n 2772040 with latest part from Minn Kota and test for proper operation of all motor functions with new foot pedal Case VI Genesis heel toe pedal is too loose or too tight when attempting to steer the motor right and left Step 1 Locate the tension adjust linkage bar on the underside of the heel toe pedal A If pedal is too tight loosen the steering pedal tension screw item 38 p n 2223412 on Genesis Foot Pedal parts explosion B If pedal is too loose tighten the steering pedal tension screw Step 2 Test for proper operation and feel per customer preference Case VII ON OFF switch on Genesis heel toe steering pedal is inoperative Step 1 Replace foot pedal assembly p n 2772040 with latest part from Minn Kota and test all functions for proper operation with new pedal Case VIII With motor deployed when the TrimUp switch is pressed the lift motor stutter jerks and the Genesis LCD rapidly flickers and appears to read 8 9
54. the circular rack and pinion steering gear mechanism A Disconnect the motor wires battery leads and directional indicator light leads from the speed selector switch 5 speed motors or control board variable speed motors 1 5 speed models the switch can easily be separated from the control box when the wires are disconnected 2 variable speed models loosen the Phillips pan head screw P N 2073414 6 32 x 3 8 holding the P N 2071905 sensor bracket in place Sensor bracket is located in control box along side the potentiometer support Loosening the screw allows removal of the magnetic on off reed switch attached to wires exiting the control box On off reed switch is the small 5 8 long 3 16 diameter black cylinder with 2 small black wires attached Then remove the two P N 2073416 8 32 x gt socket head cap screws located in recessed openings on the underside of the control box using a 9 64 allen wrench driver The control board is then free to be removed see Fig 3 FW MAJ LS ud RT nn 7 Ui A gt 2 99 2 L7 leg inner Leh M rit VN nal b a bs D FN T 7 AE ent blo I A bi gt CUBE i N gt E JF Ske i
55. the coil cord wires lift housing lead wires and battery leads from the control board NOTE if the motor being serviced is a non AutoPilot motor go to Step 1 G Lift the AutoPilot compass assembly up and off the compass mounting bracket Lift the shaft position encoder out of the encoder bracket item 25 on the Base Housing parts explosion Remove the 4 screws that hold the control board into the base extrusion Lift the control board out of the base extrusion Step 2 Reassembly A Place the new control board in the base extrusion Reconnect all wiring refer to wiring diagram with new control board Reinstall the strain relief on the battery lead wire and the control board s plug wire If the motor being serviced is a non AutoPilot go to Step 2 E When replacing the main control board on a Genesis AutoPilot motor install the compensating magnet bracket and magnet rods p n 2881937 which 1s included with the new AutoPilot control board assembly early units did not utilize compensating magnets See figure below Ifyou order the older control board by the old p n 2224011 for 12 volt units or p n 2224013 for 24 volt units it will sub to a kit that has everything needed If you order the control board by the current part numbers p n 2224014 for 12 volt units or p n 2224016 for 24 volt units you will not receive the compensating magnet bracket and magnet rods 14 25 Genesis Repair Manual 11 07 07 C 1 Toinstall the c
56. the four screws holding the steering chassis to the lower control box See Genesis Steering Module parts explosion A 1 Lift steering chassis out of the control box and turn it over to access the steering motor retaining screws p n 2223427 See parts explosion A 2 Remove the three screws that hold the steering motor onto the underside of the steering chassis B Disconnect the leads connecting steering chassis potentiometer board and steering motor to coil cord wires Loosen the potentiometer pulley setscrew item 51 of Steering Module parts explosion and remove the potentiometer gear pulley F Unscrew the nut that holds the steering potentiometer into the steering chassis mounting plate assembly item 19 of the Steering Module parts explosion G Remove the steering potentiometer circuit board from the steering chassis by carefully prying outward on the board retaining fingers 14 23 Genesis Repair Manual 11 07 07 Install the replacement steering potentiometer board and potentiometer NOTE the steering potentiometer must be inserted into the steering chassis with the potentiometer leads toward the outside edge of the chassis and with the small locating pin on the potentiometer inserted into the hole provided in the steering chassis Failure to position the locating pin in this hole will result in damage to the new potentiometer when the potentiometer nut is tightened Reassemble the steering motor and steering chassis
57. then twist the plug collar to secure the connection If the pins are bent or damaged the throttle assembly will need to be replaced Step 4 Step 5 Check the throttle cable along its entire length for damage or cuts We have received reports of throttle cable being damaged chewed cut by rodents or squirrels A Perform a continuity check on both throttle cables p n 2041401 amp 2041402 for pin out connections see pages 19 10 amp 19 12 for pin out diagrams Continuity should be noted from one end of the throttle cable to the opposite end across the pins indicated and ONLY those 2 pins no other should show continuity If continuity 1s not found at all pins as noted in the pin out guide or if continuity 15 noted across more than 2 pins then the throttle cable is defective and needs to be replaced Check for proper voltage and polarity at the contactor and main control board input terminals see wiring diagrams on page 19 8 and 19 9 A B C Remove the E Drive control board shield assembly to expose the main control board and contactor Visually check to see that all wires are securely attached to the proper terminals Inspect main control board for any visual damage replace control board 1f any burned spot evidence of overheating or short circuit is noted 19 2 E Drive 11 14 07 With the E Drive motor connected to a known good throttle assembly or a test throttle assembly and connected to 48 volts chec
58. trim pot 1 so that the voltage displayed on the V O M is as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance Step 2 Test adjust the sensor Z2 voltage see above diagram 1 for component location a ow 29 Tightly cover compass with shop rag to block any light source on the optical sensors With the compass level and pointed southwest connect 12 volts to the orange 12v and brown ground terminals With the digital V O M set to check DC voltage connect the black V O M lead to the brown ground terminal and touch the red probe of the V O M lead to the sensor 2 resistor as shown in diagram 3 Observe the voltage displayed on the V O M while slightly turning the compass a few degrees each side of the original southwest heading Position the compass so that the lowest voltage is displayed on the digital V O M If this voltage is 1 volt 25v no further adjustment is needed If the voltage needs adjustment proceed to Step 2F Using a small non magnetic blade screwdriver adjust trim pot 2 so that the voltage displayed on the V O M is as close as possible to volt 25v Compass is defective if you cannot reach this tolerance 9 13 AutoPilot Repair Manual 02 12 08 3 4 12 volts and black VOM lead here 12 volts here diagram 2 NOTE Compass removed from motor and compass card not covered for clarity Compass card should
59. trolling motor not running prop off at the depth where the problem is Occurring A If the sonar bottom reading 15 correct with the trolling motor off this is interference See Case I above for ideas on addressing this interference issue B If the sonar still has a problem losing the bottom reading even with the trolling motor off suspect faulty transducer Replace endbell transducer assembly as needed Case III Sonar unit not receiving bottom reading with trolling motor ON or OFF Be sure sonar unit is on current list of models compatible with Universal Sonar see page 3 4 amp 3 5 Step 1 Customer should first refer to the sonar unit s owner s manual for its specific trouble shooting guide A Test the sonar with the original transducer that came with the sonar unit to determine if the sonar unit is faulty or if the Universal transducer is at fault A 1 If sonar works properly with original transducer proceed to Step 2 2 sonar still does not receive bottom reading problem lies in sonar unit Step 2 Using your VOM perform a continuity check on the adapter cable This is the short cable that goes from the sonar unit to the extension cable plug end A If the adapter has continuity through all pins go to Step 3 B If the adapter does not have continuity adapter is defective Replace adapter Step 3 Using your VOM perform a continuity test through the extension cable A If there is continuity through all pins
60. 12 volt ON position Check for continuity between the common C terminal and the terminal A 1 If no continuity is noted replace the 12 24 switch and test motor for proper operation A 2 If continuity is observed proceed to Step 3B Turn switch to 24 volt ON Check for continuity between the common terminal C and terminal B B 1 If no continuity is observed replace 12 24 switch and test motor for proper operation B 2 If continuity is observed proceed to Step 4 Step 4 Speed switch is defective Replace the speed switch Test motor for proper operation Case II Motor operates on some speeds not on others Step 1 Check to see if all wires are securely attached to the proper switch terminals Step 2 Check speed coil functionality Connect battery lead wire to battery B Disconnect the black battery lead from the switch and connect it directly to the black brush lead C Disconnect the red battery lead from the switch and touch it to each colored speed coil wire at the D p switch terminals one at a time The motor should run as you make each connection If the motor fails to run as you touch any of the colored speed coil wires the problem is either 1 the speed coil is faulty and needs to be replaced or 2 the speed coil jumper wire is not connected to the back of the brush plate in the lower unit D 1 If the motor runs as you touch the red battery lead to some of the colored speed coil wires but
61. 3 Check for shorted armature commutator to armature shaft should not show continuity B 4 The center section with magnets could be partially demagnetized causing high amp draw Case XI Motor show signs of corrosion electrolysis Step 1 Ensure that this issue is not due to saltwater corrosion on a non RipTide motor A It is a good idea to add the sacrificial anode to all motors that are used in saltwater The anodes would replace the prop nut on the older units p n 2198400 for 3 14 and 3 5 8 motors and p n 2198401 for 4 lower units Step 2 If the motor is a 36 volt model is the crank battery being used as one of the three trolling motor batteries A If no go to Step 3 If yes ensure the crank battery is the first battery in the trolling motor battery system The negative lead of the trolling motor should be connected to the crank battery Step 3 If the motor is a later model Universal Sonar 1 or a USI motor that has had an internal ground bonding wire installed from the brush plate mounting screw to the directional indicator light circuit ensure the ground is connected to the negative side of the indicator light A If you are not sure which wire is the negative side power up the motor and turn it on the light is designed to have voltage applied to it when the propeller is spinning With your VOM multi meter set to check for VDC touch the probes to either wire on both sides of the indictor light If you have
62. 4 Check for control board output by hooking up test light or V O M probes to board output terminals consult appropriate wiring diagram Use known good test pedal Connect battery leads to proper voltage Turn the foot pedal to CON constant ON and vary the speed selector If there is no control board output the main control board is defective Replace main control board 5 1 11 14 07 PowerDrive Repair Manual V2 Foot Pedal Test Procedure V2 model pedal JN enis MI 9 pepdasss 1 tiq 19 veis gor T HOCHST A d IM N 3836 01 IEE aA amme ey vedi V p 831112145 351213810 _ ____ man aw a noun re men MEN GM T opui eros 440 NO 1431 3315 13389 3315 MOTTRA 9 owe 3 usn in 038 Q33d NWOHB IWM NOIIONn4 80109 _ SNHO 028 LNOBY QYiu Q InORS 43137 WHO 721 1Y 03345 HIIM Mid OL Nid 3HOSY3N w4O OF 1 0 QYiu QInOHS 853134 WHO 0 LY 01345 HIIM Nid OL 2 Nid WOW TANSVIN 9 JLON NOIIVIN3IH 5 H313M WHO Nid OL wid ROS 5 E P Nid 9 Hid OL I Nid WOU 1YOHS QINOHS H313M
63. 56515 along with the gear housing o ring p n 2054600 See figure 3 page 7 7 Removing the gear housing cap exposes the steering gear and the lift belt flange pulley lift gear assembly of the Vantage motor lift system A If it was determined in Case Step that the drive lock pin p n 2052615 see figure 4 page 7 7 was sheared the broken pin can be replaced at this point Use a 1 8 diameter punch to remove any broken pieces of the pin left in the steering gear steering shaft Install a new pin leaving approximately 14 to 5 16 protruding from the pinion gear on the same side as the D flat on the steering shaft Reassemble the unit in reverse order of disassembly to complete the repair B If it was determined in Case II Step 3B 2 that the lift belt was slipping disassemble the Vantage motor to allow examination of the lift system This will allow determination if the Vantage Lift System Upgrade Kit 1s needed See NOTE on top of page 7 2 for information on how to identify lift system If examination of the lift system indicates that Lift System Upgrade Kit needs to be installed order and install Minn Kota p n 2776517 per instructions on page 7 4 Step 3C 1 B 2 If examination of the lift system indicates that the motor has the newer lift system installed tighten the belt by loosening the 3 screws p n 831 070 that hold the lift motor in place NOTE To access one of these screws you will need to rotate the flang
64. A The steering potentiometer should rotate smoothly without any catching or rough spots until it comes to the rotational stop NOTE the steering potentiometer is a 10 turn pot B If any rough spots or catching occurs replace the potentiometer board as instructed in Step 4 below C If the potentiometer rotates smoothly using a good quality digital multi meter test for the following resistances C 1 The resistance across the potentiometer pot to the pot board should be 5K ohm 5 C 2 With the potentiometer centered 5 turns from either rotational stop the resistance value across the blue and red or blue and green wires should be 2 5K ohm 5 C 3 With the potentiometer shaft turned counter clockwise to the rotational stop the resistance across the red and blue wires should be 0 As the pot shaft is turned clockwise the resistance should gradually increase until at the end of the clockwise rotation 10 turns the resistance should be 5K ohm 5 C 4 Replace the steering potentiometer if the pot does not test to the above specifications D If the steering potentiometer tests fine re orient Steering Potentiometer to Motor Position see page 14 19 E Check the coil cord for continuity replace if necessary To replace the steering potentiometer board disassemble the Genesis motor per Parts I II and III of Transducer Routing Procedure Service Bulletin 41400 stopping at Step 2 of Part III A Remove
65. Case I Step 5 for handle disassembly inspection and control board replacement If continuity is noted replace the handle control board assembly Case III The motor fails to fully extend deploy when the down button is pressed Motor deploys an inch or two and stops NOTE The Vantage control board monitors the current demands of the lift system motor If the board detects higher than normal amp draw or a spike in amp draw the control board shuts off the power to the lift system motor This is how the lift motor stops when fully deployed A Vantage motor lift system that stops prematurely when deploying is binding or 15 restricted in some manner lift motor is drawing higher than normal amperage Step 1 Perform an amp draw check of the lift system motor bypassing the control board A Disconnect the black and white lift motor wires from the main control board Using an in line amp meter apply 12 volts directly to the black and white wires A 1 A 2 a b Observe the amp draw while the motor 1s deploying A properly operating lift system will draw 5 8 amps while deploying Reverse polarity and observe the amp draw while the motor retracting A properly functioning lift system will draw 10 15 amps If the current demands exceed the amperage values listed check the following a Check the tension of the lift system drive belt p n 2050800 If the tension is too tight the amp draw will be higher than normal See Vanta
66. Check to ensure proper voltage Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Step 2 Amp draw is a direct correlation to thrust Test lower unit amp draw directly bypass all switches and or control board while motor is under load in a water test tank A If amp draw meets specifications then the lower unit meets thrust specifications amp specs are listed in the annual Minn Kota product brochures A 1 Possible problem in wiring switches or control boards of motor or in boat s supply voltage A 2 Test amp draw specifications with voltage through complete trolling motor remove any plug the consumer dealer may have installed on the leadwire to determine if a trolling motor problem exists or if there 1s a supply voltage problem to the trolling motor If amp draw is lower than stated specifications B 1 Inspect for water in lower unit B 2 Inspect brushes and armature for discoloration or other signs of overheating smell burnt Replace parts as needed B 3 Suspect low magnetism of motor shell Magnets lose power with time and usage If amp draw is higher than stated specifications C 1 Check for proper even torque of thru bolts C 2 Check for shorted armature commutator to armature shaft should not show continuity C 3 The center section with magnets could be partially demagnetized causing high amp draw Case V Motor s
67. Drive battery leads Inspect all battery leads Inspect all battery connections including the series connection between the four 12 volt batteries for corrosion and security Check for any circuit breakers installed in the E Drive power leads or series connections If push to reset breakers have been installed check to see if they have tripped open and reset 1f needed Step 2 Make sure master key switch 15 in the ON position see Figure 1 page 19 2 A If an icon is displayed on LCD when master key switch is turned ON Throttle control lever is not in neutral position Place throttle control lever in neutral position to reset system B If the Prop Obstruction icon is displayed when the master key switch 15 turned ON B 1 Move throttle control lever to neutral B 2 Tilt motor up B 3 Turn master key switch OFF B 4 Free obstruction B 5 Turn master key switch ON B 6 Lower motor B 7 Re test for proper operation 19 1 E Drive 11 14 07 Figure 1 Step 3 Make sure that the E Drive throttle assembly is properly plugged in Remove the throttle cable plug from the underside of the throttle assembly and examine the throttle cable pins in the throttle assembly for damage straightness Several dealers riggers have bent the pins in the throttle assembly when attempting to connect the throttle cable Be sure to line up the polarizing key in the plug and receptacle before pushing together
68. E Drive 19 1 Chapter 20 Battery Chargers 20 1 Minn Kota Repair Manual 11 07 07 SAFETY WARNINGS To prevent possible eye injury always wear SAFETY GLASSES while servicing motors Remove propeller from motor during test procedures to eliminate chances of being cut by rotating blades Do not run motor out of water for more than a minute at a time The motor assemblies and speed coils are designed to dissipate heat through the motor shell into water The armature seals can also dry out Follow all battery charging precautions to eliminate chances of the escaping fumes exploding Minn Kota Repair Manual 11 07 07 Trouble Shooting Tips With all the new features and models being added to our Minn Kota line motor troubleshooting and repair can be quite complicated However with circuit board costs rising it 15 more important than ever to correctly diagnose the problem before replacing parts Here are a few trouble shooting suggestions If possible locate the failure before replacing any parts Sometimes disassembly fixes the problem pinched wires poor connections etc Look at the wiring as closely as you would the control board There are as many problems with wires and connectors as with defective control boards Check the coil cords on AutoPilot models An open wire here will look like a bad board On control boards with clear sleeves around the quick disconnects be sure the female connector does not slip
69. ECT GAS in front of the pull rope inside of the bowguard with the ends links SPRING BEFORE 4 Lift motor Bowguard assembly straight up on the mount Lower the assembly straight REMOVING MOTOR until bowguard is free from mount down until seated Re install the 5 16 cap FROM MOUNT screw and washer and tighten NOT PULL ROPE UNTIL GAS SPRING IS DISCONNECTED Allen Screw 13 5 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 Motor Control Box Maxxum amp All Terrain Steering Cable Replacement Foot Pedal Base CABLE ASSEMBLY INSTALLATION INSTRUCTIONS Remove the cover from the motor control box On the foot pedal base Remove the two screws from foot pedal boot and slide the boot back Loosen cable adjusting screw to relieve cable tension Remove pulley cover to expose the pulley Lift the pulley off the shaft Remove barrel end of each cable core from cable slots in the foot pedal and from the pulley Using a needle nose pliers pinch retainer tabs on the cable housing Push the housing and the cable core through the conduit adjusting bracket In the motor control box Lit the cable drum pulley off of the drive pinion Remove the barrel end of each cable core from the pulley a needle nose pliers pinch the retainer tabs on the cable housing Push the housing and the cable core through the racket Pull cable assembly out through the cable jacket f
70. N switch is in the Constant On position the right momentary steer button is intermittent delayed or does not respond Step 1 Check for proper right and left steering function with heel toe pedal Step 2 If Genesis motor steers right and left with pedal and with constant momentary switch in the momentary position the left and right steering buttons work A The foot pedal p n 2772040 is faulty and must be replaced B Replace foot pedal assembly with latest part from Minn Kota and test all motor functions for proper operation with new pedal 14 17 Genesis Repair Manual 11 07 07 Case IV Fine adjust knob on foot pedal slips in one or both directions when attempting to make minor speed changes Step 1 Drive belt for fine adjust knob is slipping A Replace fine adjust pulley p n 2222310 item 21 on Genesis Foot Pedal Module parts explosion A 1 Disassemble foot pedal by removing the nine screws holding the pedal base and housing together Note that the housing and base also snap together by means of four catches tangs that extend through the foot pedal base to the underside A 2 Release the four tangs and separate the top and bottom housing and base B Replace the fine adjust pulley item 21 p n 2222310 with the latest part from Minn Kota B 1 Test for proper fine adjust operation and reassemble top and bottom housing and base B 2 Retest for proper fine adjust function after reassembly to reset the
71. OL QL QL OL SZ S53 2 OL S 20 430813 ANOA HUM 104 SHL dob JIMIN ICNI SY 153 LON 5300 delvod 70x LNOO N 3d 1009 ewHo d Nid SSOMOV SINVISISSY 440 0109736 d334S 7 Wows MOHS GMOHS WOA 96 14086 MOHS MWOA G6 LYOHS GMOHS 8 Nid Wg 14086 GINOHS WoA cs V OHS MOHS AINOHS 25 V Nid MOHS GINOHS WOA 6 SLINTLLOV 9 ILMLI 9 ALN Loy JLYNL 2 FIV TNL 1 5 077043 SV SNOILLYIJNIdS NOIJONNS JHL SIVOS X FDNVLSISZy NO 486 INOA LMAN 7 1005 403 ASAL JHL AutoPilot Repair Manual 06 13 08 PART II Motors manufactured PRIOR to model year 2001 prior to s n AB PART II Case I Drive Housing will not steer in one or both directions in manual mode Step 1 Check to ensure proper voltage and polarity at battery Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Visually check to see that all wires are attached to proper control board terminals Consult the appropriate wiring diagram for the model and board being tested Clean rewire if necessary Step 2 Check motor with known good test foot pedal or test t
72. RUSH OR CUT NOT remove the BowGuard assembly from the mount without discon necting one end of the gas spring GAS ASSIST LIFT 1 Place the motor in the deployed posi Rope and latch pin assembly should porte i MER tion NEVER be pulled as the assembly is 3 To reassemble SPRING BEFORE NOTE When the bottom pin is Align the mounting holes for the REMOVING MOTOR removed the stop lever rotates to pre lower pin FROM MOUNT vent the latch pin assembly from travel Install lower pin making sure it pass ing es through the stop lever DO NOT PULL ROPE Align and install upper pin UNTIL GAS SPRING IS DISCONNECTED NOTE NEVER INSTALL UPPER OR LOWER PINS WITH OUT BOWGUARD MOTOR Stop Lever ASSEMBLY Fortrex REMOVAL OF THE BOWGUARD WARNING The gas assist lift mechanism in this unit is under HIGH SPRING PRESSURE when the motor is in the deployed position DO NOT remove the BowGuard assembly from the mount without disconnecting one end of the gas spring MOVING PARTS CAN CRUSH OR CUT 1 Disconnect one end of the gas spring see NOTE Rope and latch bar should never be GAS ASSIST LIFT page 6 for instructions pulled with the motor removed as the MECHANISM IS 2 Place the motor in the deployed position assembly is under HIGH PRESSURE UNDER PRESSURE 3 Remove the 5 16 cap screw and lock washer located on the top of the bowguard 5 To re assemble Align the key ways on DISCONN
73. ST WASHER 205 1705 NYLON WASHER 305 2510 CABLE 205 T302 UPPER BEARING LIFTSCREW 205 8411 BELT TENSIONER 205 3415 SCREW NEUE jj 205 2620 PIN ORIVLOK CET fo EMT S e O3 mess LIFT MOTOR Figure 7 PowerDrive Repair Manual 11 14 07 Chapter PowerDrive PD Models Corded foot pedal non AutoPilot non Genesis non Terrova This PowerDrive Repair Manual Section 3 is divided into 2 parts Part I pertains to V2 models 2007 and later s n AH and later pages 8 1through 8 2 Part pertains to motors prior to 2007 s n prior to AH pages 8 3 through 8 6 PART I V2 motors manufactured for model 2007 and later s n AH and later PART I Case I Drive Housing fails to steer left or right Step 1 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for any corroded connections Clean rewire if necessary Step 2 Check motor with known good test foot pedal or test the original foot pedal by performing Foot Pedal PCB Test Procedure see page 8 2 A If test pedal properly steers motor or if the original pedal tests bad as outlined on page 8 2 then original foot pedal is faulty Replace foot pedal board if necessary If test pedal does not properly steer motor or if original pedal tests okay as outlined on page 8 2 then
74. Switch OFF 14 21 Genesis Repair Manual 11 07 07 GENESIS Identifying Software Version Code Step 1 Check to ensure proper voltage and polarity at battery Genesis 55 12v Genesis 74 24 Step2 Turn the Master Switch located on side of foot pedal ON Step 3 Turn the speed control knob on the foot pedal so that it reads 100 full speed Step 4 While watching the LCD turn Master Switch OFF The software version will flash momentarily on the LCD just before the LCD screen goes blank Step 5 If the software version shown is number 102 or less the main power control board will need to be replaced page 14 25 reprogrammed page 14 27 and recalibrated page 14 29 14 22 Genesis Repair Manual 11 07 07 GENESIS Steering Potentiometer Testing amp Replacement Case If motor LCD defaults to ER4 or steering potentiometer has been damaged turned past its rotational stop Step 1 Remove control box cover and center housing for the LCD Inspect the bullet connections from the coil cord to the potentiometer board and from the coil cord to the main control board Step 2 Step 3 Step 4 A Correct any questionable connections and retest motor operation Check to ensure that the steering potentiometer belt is in place on the primary gear and steering potentiometer If belt is in place make sure Master Switch on foot pedal is OFF Then remove the belt mark the potentiometer pulley and test the potentiometer
75. T THE LOWER UNIT FOR THE FOLLOWING STEPS LOOSENING THE DOOR CLAMP SCREW WILL ALLOW THE MOTOR TO FALL UNTIL THE HANDLE HITS THE MOTOR MOUNT IF NOT SUPPORTED 4 Loosen the door clamp screw align handle parallel with the centerline of the boat Hold the handle and rotate the outer shaft until the steering tension knob is aligned with the handle See pictures below Handle and knob are aligned Steering Tension Knob FOLLOW THE HANDLE ALIGNMENT FOR BOTH MOUNTING OPTIONS 5 With the handle and steering tension knob aligned with the centerline of the boat raise the unit similar to the photo below and retighten the door clamp screw in this position for orientation ring installation door clamp screw 3X Steering Repair Manual 11 06 07 NOTE At this point the handle tension knob outer shaft keyway and lower unit should now be aligned If not repeat steps 2 5 6 Place the orientation ring in the hinge base with the key in the keyslot of the outer shaft Photo below shows mounting option 1 Key slot Orientation ring Mounting screws NOTE THE RING CAN BE TURNED OVER FOR MOUNTING OPTION 2 7 Align two of the seven holes in the ring with two screw holes in the hinge base Note beacuse of the multiple hole options it may be necessary to loosen the door and rotate the shaft slighlty either way to proplerly align the holes for the mounting screws 8 Insert the two supplied socket head ss screws into the holes
76. a 12VDC reading the negative side is the one that your black probe is touching Step 4 The brush shunt wire may be inadvertently touching the inside of the motor case This is more apt to happen on 4 motor assemblies after the lower unit has been opened during field repairs Step 5 Check for shorted armature commutator to armature shaft should not show continuity 1 6 Depth Finder Interference 07 17 08 Chapter 2 Depth Finder Interference Variable speed motors with a PWM speed control Maximizer circuit can sometimes interfere with the operation of a depth finder This can be due to RF radio Frequency or electrical interference NOTE this procedure is for pre Universal Sonar 2 units only For more information regarding Universal Sonar see Chapter 3 Here are a few steps to reduce or eliminate the interference problem If the motor interferes with the depth finder when both are being operated Step 1 Determine if supply voltage for trolling motor and depth finder is provided by the same common battery A If yes disconnect depth finder battery leads from the trolling motor battery and connect them to the engine cranking battery Test depth finder for interference while operating motor Step 2 Inspect for water in the lower unit NOTE Steps 3 5 DO NOT apply to Universal Sonar 2 units Step 3 If interference is still present at Step 1B proceed as follows A Connect a light gauge wire 18 gauge is fine fro
77. all the magnet rods until the procedure instructs you to do so 14 32 Genesis Repair Manual 11 07 07 GENESIS AutoPilot Steering Malfunction Case I AutoPilot turns itself off while operating in AutoPilot mode Step 1 Determine if motor may have been trimmed too high while running in AP mode A The icon will flash if the motor is trimmed too high This indicates that the AP feature has turned itself off due to magnetic interference from lower unit on the AP compass B Trim the motor down and then press the Mode Switch once to reactivate the AP function Step 2 If the AP function turns itself off while in operation A Any interruption in power to the motor will disengage the AP system Check battery leads plug wire connections etc as motor power leads may have an intermittent connection Customer should be informed of the possibility of voltage interruption stemming from power supply in boat breaker kicking off then back on etc Case II Jerky AutoPilot steering If while holding a heading the AP motor steering system seems to jerk back and forth a few degrees it may be due to excessive gear lash or looseness in the steering gear system Step 1 To dampen this oscillation of the motor lower unit make sure that the 2 piece aluminum stop collar on the motor shaft between the lower shaft collar and motor bung is firmly slid up against the lower shaft collar bushing and tightened in place Step 2 If pro
78. and tighten with the supplied hex wrench 9 The motor can be removed without removing the orientation ring To re install the motor line up the key with the key slot and close door End of procedure Vantage Repair Manual 02 15 08 Chapter 7 Vantage Case I Motor fails to operate prop doesn t spin Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Check to ensure proper voltage and polarity at battery red black Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Remove extrusion shield p n 2050220 see figure 1 page 7 6 check to ensure that all wires are connected to the proper control board terminals consult the appropriate Vantage wiring diagram for proper connections Visually inspect the wire terminals and connections for corrosion Clean if needed Check lower unit to see 1f it will run when all switches and circuit board are bypassed A Disconnect black and black red stripe wires from main control board Apply 12 volts directly to these two leads 1 motor does not run a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as needed and test motor for proper operation 2 Ifthe motor does run go to Step 4 Check ON OFF switch and speed control potentiometer in the steering
79. and tighten the collar screws to secure the collar in place Re install the gear carrier bearing P N 2077320 in the pivot yoke A Use care to line up the rib in the pivot yoke with the ends of the split gear carrier see Fig 5 page 6 4 Transom mount motors A Align the motor lower unit with the transom bracket Position the lower unit with the nose of the motor towards the transom bracket clamp screws Block or hold the motor lower unit in this position B Place the gear carrier P N 27702210 into position in the pivot yoke with the tilt detent spring P N 2072705 towards the prop end of the motor lower unit C While looking at the two pinion gear teeth with the raised bumps count five teeth clockwise and you will see a raised rib dash C 1 Thetooth with the raised dash must line up with the timing mark in the gear carrier NOTE The timing mark used for transom mount 3X models is a small raised rib located at the 1 30 o clock position on the inside circumference of the gear carrier see Fig 6 page 6 7 3X Steering Repair Manual 11 06 07 Timing marks Handle and front nose cone of lower unit point this way Propeller on this end Fig 6 Bow mount motors A Align the motor lower unit with the prop end on the same side as the steering tension knob in the pivot yoke Block or hold the motor lower unit in this position B Place the gear carrier P N 27702210 into position in the pivot yoke with the til
80. ansitions into a switch is released a 2 second long beep All steady tone will be heard Pressing the INCREASE SPEED or DECREASE SPEED button ale 1 beep Pressing the PROP ON OFF button to 2 turn the prop on Pressing the PROP ON OFF button to 2 beeps turn the prop off Modes 2 and 3 When the prop is active including when Single tick every 1 5 seconds speed is set to 0 Mode 3 Switching to Audio Mode 1 pressing the INCREASE SPEED and DECREASE SPEED buttons simultaneously for 1 second 1 beep All Switching to Audio Mode 2 pressing the INCREASE SPEED and DECREASE SPEED buttons simultaneously for 1 second 2 beeps All Switching to Audio Mode 3 pressing the INCREASE SPEED and DECREASE SPEED buttons simultaneously for 1 second 3 beeps All Every time the receiver is powered up 1 chirp and there is at least one remote ID All learned OPERATING FREQUENCY The CoPilot system operates on 433 92 MHz frequency It has a 24 bit digital signal totaling 16 million possible combinations 18 2 CoPilot Wireless Accessory 02 08 08 SYSTEM FEATURES CoPilot is a wireless plug and play accessory that allows the angler to control most corded Minn Kota PowerDrive or PowerDrive AutoPilot trolling motors from anywhere on the boat CoPilot may be used with or without the corded foot pedal Legacy CoPilot is compatible with any PowerDrive or AutoPilot motor with the flat fo
81. arts and runs fine the armature may have an open dead spot Replace armature 19 4 E Drive 11 14 07 Case II Tilt system does not operate Step 1 Step 2 Step 3 Check all battery connections plug connections and terminal connections for corrosion and security Clean if needed and test for function The lift motor is a 12 volt motor On some older E Drive motors there are two tilt switches One is located on the throttle assembly and the other on the back of the E Drive motor If one switch operates properly and the other does not check for proper continuity through the malfunctioning switch Replace as needed and test for proper operation If neither tilt switch operates proceed to Step3 Newer E Drive motors have only one trim switch located on the throttle assembly Steps 2A 3A and 3B applies to these motors A If the malfunctioning switch 1s the switch located on the throttle assembly and the switch tested fine for continuity disconnect and remove the throttle cable from the underside of the throttle assembly Inspect the connection on the cable side for bent pins Straighten pins or replace cable as needed and test for proper operation Bent pins are considered accidental damage and are not covered by the warranty Disconnect the tilt actuator leads from the control board assembly Connect the actuator leads directly to 12 volts and observe actuator for extension retraction Reverse polarity at the actuator
82. at the plug connection is fully engaged and properly seated NOTE when fully engaged no yellow space will be seen between the plug ends and the plug connection will snap twice as they are pushed together Reconnect power to motor or deploy motor to turn on the system ready LED and enable the system Test for motor function using CoPilot remote transmitter If motor does not function proceed to Step 2 Test motor with known good corded foot pedal If motor functions properly with test pedal the CoPilot remote transmitter may be faulty Disassemble the transmitter to check battery voltage battery 1s 3 volt lithium coin cell Replace battery if voltage 15 low Inspect the gold plated switch contacts on the transmitter circuit board for corrosion If any corrosion is noted replace the transmitter Clean the conductive rubber contacts on the transmitter switch pads with rubbing alcohol Reassemble and retest If motor still does not respond to the remote transmitter try relearning the receiver to the transmitter If motor still does not respond then reprogram relearn the receiver to a known good remote transmitter If the CoPilot responds properly the customer s transmitter is faulty and needs to be replaced If after learning or programming the receiver to the test transmitter it still does not function the CoPilot receiver board is faulty and needs to be replaced SO gt 11 4 Terrova Manual 11 16 07 Case VII Motor
83. atch collar clamping screw Rotate the latch collar counter clockwise on the shaft when viewed from above to screw the latch collar up away from the motor lower unit The collar and shaft are threaded Check to verify that the catch on the handle or lever firmly engages the latch collar If necessary re adjust latch collar position Tighten the clamping screw to hold the collar in place Step 3 Verify the correct motor rests are used Part numbers are molded on the motor rests 2303933 motor rest right 4 motor assemblies 2303938 motor rest left 4 motor assemblies 2303932 motor rest right 3 5 8 motor assemblies 2303937 motor rest left 3 5 8 motor assemblies 2303930 motor rest right 3 44 motor assemblies 2303935 motor rest left 3 4 motor assemblies Step 4 Replace the pivot pads P N 2305103 Effects of Broken or Intermittent Wires in Coil Cords If either the yellow or green coil cord wires are broken or intermittent the steering with the foot pedal will not function or will be intermittent AP function will not be affected in any way the AP light will be lit when AP is turned on and the motor will track and hold a heading in the normal AP manner If the brown wire in the coil cord is broken or intermittent the AP will not function If the AP function was turned on it will turn off and the AP indicator will not be lit Steering with the foot pedal will be clockwise only regardless if either
84. atrix 77c Matrix 87c Combo Matrix 97 Combo Fishfinder 515 Fishfinder 525 Fishfinder 535 Fishfinder 565 Fishfinder 575 Fishfinder 580 Combo Fishfinder 585c Fishfinder 595c 1412 161 323 343 363 Combo 383c Combo 717 727 737 747c 757c Combo 767 Combo 777c2 787 2 Combo 787c2i Combo 917c Combo 931c 937c Combo 957c Combo MKR US2 9 Eagle Cuda 168 Cuda 168EX 128 Cuda 240 S GP5 Cuda 2401 S GPS Cuda 242 Cuda 250 FishElite 320 FishElite 480 FishElite 500C FishElite 52 OC FishElite 640C FishEli ite 642C FishMark 320 FishMark 480 FishMark 500C FishMark 640C SeaFinder 240DF SeaFinder 24505 SeaFinder SeaFinder 320DF Sea Finder 480DF SeaFinder SOOCDF SeaFinder 640C SeaFinder 642C SeaCharter 320DF SeaCharter 48ODF SeaCharter SOOCDF FishEasy FishEasy 24505 FishEasy 25005 FishEasy 320C Lowrance X 47 X 47EX 5005 X 67C X B6D5 X 96 M 521i M 56 M 56i M 68C M 68i MKR US2 10 Lowrance LCX 20C LCX 17M LCX 25C LCX 26C LCX 27C LCX 28C LCX 37C LCX 38C LCX 110C LCX 11C LCX 2C LCX 113C LMS 330C LMS 332C LMS 334C LMS 335C DF LMS 337 LMS 339C LMS 489 LMS 480 DF LMS 520C LMS 522C LMS 525C LMS 527C 52 59 DF X100 10 X 105C DF X 107C DF 125 126 DF X 135 X 136 DF 510 X 515C MKR US2 11 14 1 2 Universal Sonar 2 extension cable for use with all accessory adapters Manufactured after 2002 m HUMMINBIRD
85. attery is fully charged and in maintenance mode A RED light for each bank is lit if any of the following apply A No battery is connected to an output lead This may also indicate a blown fuse in the fuse holder B The battery voltage is below 8 0 volts C The battery is connected reverse polarity MK106 A GREEN power light is lit to indicate AC power is applied A YELLOW light is lit or each bank to indicate the battery 1s charging A GREEN light is lit for each bank to indicate any of the following A The battery is fully charged and in maintenance mode B There may be a blown fuse in the fuse holder C No battery is connected to an output lead A RED light is lit if any of the following apply A A short circuit B The battery is connected reverse polarity MK110 MK210 MK315 MK220 and MK330 A GREEN power light is lit to indicate AC power is applied A YELLOW light is lit for each bank to indicate the battery is charging A GREEN light is lit for each bank to indicate the battery is fully charged and in maintenance mode A RED light for each bank is lit if any of the following apply A No battery is connected to an output lead This may also indicate a blown fuse in the fuse holder B The battery voltage is below 8 0 volts C The battery is connected reverse polarity RED and GREEN lights are lit simultaneously for each bank if any of the following apply A The battery voltage is below 8 0 volts B A damaged temperatur
86. attery leads from the trolling motor battery and connect them to the engine cranking battery B Test depth finder for interference while operating motor Step 5 If interference is still present proceed as follows A Check the routing of the depth finder and trolling motor battery leads If they run parallel to each other for any length of distance separate the leads as much as possible or run the leads to the trolling motor and depth finder on opposite sides of the boat B Test depth finder for interference while operating the motor Step 6 Check the lower unit A Inspect for water in the lower unit B The brush shunt wire may be inadvertently touching the inside of the motor case This is more apt to happen on 4 motor assemblies after the lower unit has been opened for repairs NOTE Step 7 DOES NOT apply to Universal Sonar 2 units Step 7 If interference is still present at Step 4B proceed as follows A Connect a light gauge wire 18 gauge 1s fine from the negative post of the trolling motor battery to the negative post of the engine s cranking battery We suggest installing a or 2 amp inline fuse in this ground wire Minn Kota P N 2060310 This wire may cause additional interference on US2 models B Test for depth finder interference while operating the motor 3 Minn Kota Universal Sonar Models 09 11 08 Case II Sonar unit losing bottom reading after a certain depth reading Step 1 Customer should test with the
87. be performed to determine if it 1s good or bad Connect a VOM to the 2 leads coming from the sending unit and move the spring loaded sending unit arm A changing resistance value should be noted as the arm 1s moved If not the sending unit is faulty and needs to be replaced B If the sending unit checks ok and proper voltage and polarity 1s provided to the gauge but the gauge fails to function then the gauge 1s faulty and needs to be replaced 19 5 E Drive 11 14 07 Case IV Throttle LCD Fuel Gauge does not show tank Step 1 Check combined battery voltage or the voltage at each battery and sum the total The combined voltage required to show Full 34 4 and Empty are listed below Full 51 96 volts 3 4 50 76 volts 1 2 49 56 volts 1 4 48 36 volts Empty 47 16 volts If after being recharged the combined battery voltage does not reach or exceed 51 96 volts the batteries and or battery charger s are at fault After recharging all four batteries should be at 12 99 13 volts each or slightly higher If one or more batteries are not at this value they will need to be replaced and the charger output for those batteries will need to be checked and replaced if necessary Case V Throttle LCD Fuel Gauge shows full tank when turned on then after running for a short period of time the key switch is turned OFF then back ON the Fuel Gauge only shows full Step 1 Condition described is
88. blem persists install new steering clutch gear system and steering motor output gear p n 2770215 Step 3 Refer to Calibrating AutoPilot Compass Software Step 3 page 14 29 Case III Motor steers fine in manual mode but does not steer in AP mode Step 1 Verify the motor is an AP model and the LCD 2317093 7 icon is displayed Step 2 The sideplate must be in place covering the compass as a bright fluorescent light or sunshine can overpower the compass optical sensors and inhibit AP steering Step 3 Make sure motor is mounted within 5 degrees of level and there is no ferrous metal object near the motor that is affecting normal compass operation Step 4 Ensure the compass assembly is fully snapped in place and seated on the compass bracket compass 1s setting level and able to spin freely Step 5 Spin the base of the motor and ensure the internal compass card is spinning freely Step 6 If all the above steps test okay replace main control board assembly Case IV AutoPilot function is erratic doesn t maintain proper headings Step 1 The sideplate must be in place covering the compass as a bright fluorescent light or sunshine can overpower the compass optical sensors and inhibit AP steering Step 2 Make sure motor is mounted within 5 degrees of level and there is no ferrous metal object near the motor that is affecting normal compass operation including the compass bracket screw Step Ensure th
89. ce the 5 speed switch Hand Control w Control Board Repair Manual 11 06 07 Chapter 5 Hand Control Models with a Printed Circuit Board This does not pertain to 3X models The 3X information is in chapter 6 Case I Motor runs intermittentlv cuts in and out fails to run in either forward or reverse or kicks from forward into reverse Step 1 Step 2 Check to ensure proper voltage and polarity at battery red black Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Check to see if lower unit runs properly A Connect battery lead wire to battery B Disconnect the black battery lead from the control board and connect it directly to the black brush lead C Disconnect the red battery lead from the control board and touch it directly to the red brush lead The motor should run C 1 If motor does not run a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature C 2 If the motor does run replace control board Case II Motor fails to operate Step 1 Step 2 Step 3 Step 4 Check to ensure proper voltage and polarity at battery red black Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Check to see if a
90. control board can be left in the motor control box Be sure to follow the wiring connections as outlined and shown in this procedure AutoPilot Repair Manual 02 12 08 AutoPilot Compass Control Board Trim Pot Adjustment Procedure MOTORS PRIOR TO 2001 MODELS ONLY for Sensor 1 voltage reading touch red VOM lead here Sensor 1 Trim Pot for Sensor 2 voltage reading touch red VOM lead here Sensor 1 Resistor Sensor 2 Resistor Sensor 2 Trim Pot diagram 1 Step 1 Test adjust the sensor 1 voltage see diagram 1 for component location A B C Tightly cover the compass card with a shop rag to block any light source on the optical sensors With the compass level and pointed southeast connect 12 volts to the orange 12v and brown ground terminals see diagram 2 With your digital V O M set to check DC voltage connect the black V O M lead to the brown ground terminal on the compass control board and firmly touch the red probe of the V O M lead to the sensor 1 resistor as shown in diagram 2 Observe the voltage displayed on the V O M while slightly turning the compass a few degrees each side of the original southeast heading Position the compass so that the lowest voltage is displayed on the digital V O M If this voltage is 1 volt 25v no further adjustment is needed and go to Step 2 If the voltage needs adjustment proceed to Step 1F Using a small non magnetic blade screwdriver adjust
91. d switch Step 1 Step 2 Step 3 Step 4 Step 5 With power to the motor disconnected remove both Terrova motor sideplates and main control board speed control cover Disconnect network plug connections battery leads motor leads system ready and AutoPilot LEDs and push to test battery meter leads from the speed control cover The system ready reed switch is held in the aluminum base extrusion with LocTite Black Max an industrial superglue To remove the reed switch with the least likelihood of damage use a 7 32 punch to drive the reed switch out of the base extrusion Remove the screws holding the main board battery leads and foot pedal plug leads in the reed switch in place Then lift the control board out of the extrusion Install new control board in place of the one removed Reconnect all leads and network plug connections Install system ready and AutoPilot LEDs in their proper locations in the speed control cover system ready LED has green and black leads AutoPilot LED has red and black leads Consult wiring diagram included with new control board for proper wiring schematic Install system ready reed switch in base extrusion Secure in place with a drop or two of commonly available super glue Note that proper placement of reed switch position calls for the tip of reed switch to be flush with outer surface of base extrusion see Picture 5 Picture 5 This illustration shows the magnet in the handle c
92. d to activate the reed switch A If the magnet is missing from the push button assembly replace P N 2993702 and test motor for proper operation B If reed switch and magnet are in place and the magnet is in close proximity to the reed switch when the push button is depressed but the motor still does not run then the reed switch is faulty and the main control board needs to be replaced The reed switch is not available as a replacement part Case IV Motor stops running while in use Motor starts running again after it is pulled up out of the water and is placed back in the water after the control box is struck or after the prop is turned slightly Step 1 The malfunction listed above is most likely due to an intermittent or marginal electrical connection at the armature windings and commutator A Dis assemble the motor lower unit Inspect for water damage If water is present repair and replace parts as necessary B Inspect the armature Examine the commutator sections for discoloration and arcing caused by the brushes as they make contact with good live commutator sections and bad dead sections Test armature commutator sections for continuity from one section to the next going around the circumference of the commutator 13 2 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 B 1 Replace armature if arcing is noted or if no continuity is found when testing commutator sections C Examine commu
93. d your VOM set to measure resistance measure the resistance across pins 2 and 5 The resistance value should be between 950 1050 ohms Measure the resistance across pins 2 and 4 The resistance value should be between 400 600 ohms With your VOM probes across pins 2 and 4 rotate speed selector counterclockwise to full reverse Resistance should gradually decrease to less than 2 ohms Rotate speed selector clockwise to full forward Resistance across pins 2 and 4 should gradually increase to between 990 1000 ohms The hand controller is faulty if any of these steps do not match Plug End Pin End View of Hand Controller 16 1 EM amp EP 01 31 08 B 2 If the hand controller tests okay the problem is with the control module Test control module to verify problem a Connect control module to appropriate power source b Plug in known good tested as per above hand controller directly to control module Check for voltage at module output leads by hooking up test light or motor to control output leads Vary the potentiometer speed control setting Test light or motor should vary with the potentiometer setting Replace control module as necessary Part I Case Motor runs in one direction only Step 1 Check hand controller and control module plug ends pins and connector sleeves for corrosion Clean if needed reconnect and test again for proper operation Step 2 Test hand controller per test procedure on page 16 1 A
94. de of the directional indicator light To determine which wire is the negative side disconnect both the small gauge black and black w orange stripe wires from the directional indicator light Using a digital V O M set to test continuity touch one V O M lead to the trolling motor negative battery lead wire Touch the other V O M lead one wire at a time to the black and the black w orange striped wires in the control box The wire showing continuity with no resistance is the negative wire This is the wire that has continuity to the negative battery lead By following these steps the problem of depth finder interference is usually resolved Oftentimes simply connecting the depth finder to a separate battery will address this issue At other times a separate battery and common negative ground 1s all that is required For other installations all of the steps outlined will be required Keep in mind that the steps should be followed in the order they are written and that the final steps should be attempted only after completing steps 1 5 and testing with the depth finder Minn Kota Universal Sonar Models 07 17 08 Chapter 3 Minn Kota Universal Sonar Minn Kota Universal Sonar motors are serviced in the same manner as their non Universal Sonar counterparts Consult the appropriate section of the Minn Kota Service Manual for the step by step trouble shooting and repair procedures applicable to the motor being serviced This trouble shooting sect
95. does not stow latch properly Step 1 Step 2 Step 3 Step 4 Lubricate the composite shaft with a silicone spray or Armor Inspect release handle and handle follower pin Remove the follower pin and inspect if it is bent you should assume the handle is also bent This condition is usually from forcing the handle down rather that pushing in and then down or stepping on the release handle Inspect the motor ramps Move ramps through an arc between the stowed and deployed positions watching for straight travel Replace parts as necessary Check the release arms both left and right to ensure they are flat They should run parallel with the base extrusion Replace arms if needed Case VIII Terrova motor functions are intermittent work erratically sometimes they work and sometimes they don t Step 1 Step 2 Check all network accessory plug connections foot pedal AutoPilot and or CoPilot depending on how motor is equipped for security and full engagement of the male female plug ends Examine the plug pins and sleeves Pins should be straight and neither pins nor sleeves should show signs of corrosion NOTE be sure to disconnect power to motor or stow motor to interrupt power when disconnecting and reconnecting network accessory plugs Reconnect power or deploy motor after connecting or changing network accessories Test network accessories one at a time to determine which component may be faulty
96. down beside the male connector It may feel like the connector went on properly but this connection will fail For quick troubleshooting use a 12 volt light bulb automotive dome or brake light with wires and alligator clips Clip 1t to the board output and vary the speed to see if the board is working A voltmeter on the output can sometimes be misleading The control board needs some kind of load to work correctly If you have replaced a board in the same motor more than once this 1s probably a symptom of a larger problem Check the wiring in the lower unit Shorts on the motor wires will cause board failures and shorts in PowerDrive drive housings will cause foot pedal board failures We still see control boards replaced under warranty that are NOT defective To help us control costs to all our customers and to ensure that we will honor your warranty reimbursement claim please be certain the board 15 defective On AutoPilot motors seldom do both boards fail at the same time Please double check iii Lower Unit Repair 09 08 08 Chapter 1 Lower Unit Motor Assembly This chapter refers to the motor assembly only Like all motors permanent magnet direct current PM DC motors are used to convert electrical power into mechanical power Unlike other types of motors permanent magnet motors convert power more efficiently This is because a permanent magnet motor does not require electrical energy to create a magnetic field Per
97. e A Observe that the motor now rotates into the park position for proper stowing B If motor is properly aligned at a 90 angle to the bowmount base housing the steering potentiometer is now properly oriented to the motor lower position and is ready for reassembly C If the motor is not properly aligned repeat Step 3B and 3C until motor is rotating into position and properly stowing when the Mode Switch 15 pressed D If after re orienting the steering potentiometer to motor position the motor lower unit rotates more than one full rotation and again displays ER3 it will be necessary to reprogram the left and right park position values into the control board see Control Board Initial Programming Procedure page 14 27 14 19 Genesis Repair Manual 11 07 07 GENESIS Lower Shaft Collar Case I Lower shaft collar has vertical crack or is broken at leading edge pointed end Step 1 Consult Genesis Transducer Routing Procedure Parts I II III and IV of Service Bulletin 41400 A Disassemble Genesis motor as outlined in Transducer Cable Routing Procedure A 1 X After disassembling the motor to the point listed at Part IV Step 1 remove the four screws p n 2221301 that attaches the lower belt clamp and belt to the 2221501 lower outer shaft collar A 2 Replace the broken collar with the new improved part Note Be sure to attach lift belt in the same position and manner it was attached prior to disassembly B Reassemble t
98. e P N 2071512 or 2072513 assembly see Fig 4 page 6 3 A Removing the two P N 2073408 screws these two screws go in to two nyloc nuts located inside the gear carrier will allow the control box assembly pivot knobs and bushings to be separated from the gear carrier and yoke pivot assembly see Fig 4 page 6 3 Step 8 With the control box assembly removed unscrew the 5 16 x socket head shoulder shank cap screw P N 2073400 that is located in the center of the gear carrier P N 2072210 A 5 32 allen wrench driver is required see Fig 4 page 6 3 A Remove the cap screw along with the washers then remove the two P N 2303412 6 20 x 5 8 Phillips head screws and P N 2071714 washers that serve to guide retain the gear carrier on the pivot yoke see Fig 4 page 6 3 B With the cap screw and 2 phillips head screws removed the gear carrier can be removed from the pivot yoke followed by the gear carrier bearing For reassembly note that this bearing is split and that the split ends key onto a rib located on the inside circumference of the pivot yoke pinion assembly upper bearing VL gine T ee HCF a i screw H8 32x7 16 IAA ihe m y ke i k 222 134 aly il d qm felis in primer 7649 amp loctite 603 a __ 4 hole 207 156 25 zl eat
99. e actuators dry or use a dry lubricant to avoid further contamination with sand dirt grit C NOTE If foot pedal sticks while customer is fishing he may simply swish the foot pedal in the water to temporarily flush the sand dirt grit from the actuator surfaces PART II Case IV MOM CON switch lever will not stay down in CON position Step 1 From the underside of footpedal remove the 3 screws holding the slide control and switch lever in place A Remove screw holding the white plastic continuous actuator in place Place washer P N 2301731 between actuator and foot pedal base C Reassemble slide control and MOM CON switch assembly Test for proper operation PART II Case V Motor won t steer or steers slowly at higher thrust settings Step 1 Inspect all battery connections trolling motor plug if installed and any butt splice connections in the battery leadwire for corrosion and security Step 2 Disassemble motor to separate the drive housing from the motor and tube and bowplate extrusion assembly A Remove the six screws holding the top and bottom halves of the drive housing together Note the top and bottom halves of the drive housing are pinned together at the corners with roll pins The two halves will need to be pried apart Inspect the drive housing motor paying special attention to the drive housing motor armature shaft and motor bushings Test run to verify proper high speed operation and RPM C Rem
100. e compass assembly is fully snapped in place and seated on the compass bracket compass 15 setting level and able to spin freely 14 31 PowerUp Repair Manual 11 06 07 Chapter 15 e Manufactured between 1996 2002 PowerUp Lifts Trims and Tilts Case I PowerUp Models MKN 5100 amp MKN 5300 do not lift tilt serial number prefix MKJG and later Step 1 Check for proper voltage and good battery connections at leadwire Step 2 Check connections from UP Down push button switch to replay harness 3 wire plug A Locate relay in relay harness assembly Actuate UP DOWN push button switch you should hear the relay click as this is being done B Isolate and disconnect leads from relay harness to lift motor C With the UP Down push button switch actuated a V O M should show battery voltage across relay harness motor leads If no voltage is noted relay harness needs to be replaced If voltage is noted go to Step 3 Step 3 Apply 12 volts directly to lift motor terminals reverse polarity to reverse motor rotation A If motor fails to run the motor is bad and needs to be replaced Case II PowerUp Models MKN 5400 amp MKN 5500 do not lift trim serial number prefix MKJG and later Step 1 Check for proper voltage and good battery connections at leadwire Step 2 Check connections from UP Down push button switch to replay harness 3 wire plug A Locate relay in relay harness assembly Actuate UP DOWN push button switch you sho
101. e connector plug in the throttle cable Disconnect the plug and examine the eleven 11 pins and sockets for corrosion misalignment or breakage Replace if damage 1s noted With key switch ON use a VOM to check for continuity across pins 7 and 15 on the plug end coming from the throttle assembly see page 19 12 for p n 2041402 throttle cable pin out diagram b l Ifnocontinuity is found this section of the throttle cable is faulty and needs to be replaced b 2 If continuity is found and the female socket plug end appears sound reconnect the throttle cable plug ends and go to Step 5E Ic If you have not already done so remove the p n 2770222 shield assembly black plastic cover from the back of the E Drive main extrusion to expose the control board Locate and remove the throttle cable plug connector from the control board and examine the eleven 11 pins and sockets for corrosion damage misalignment or breakage Replace as needed With key switch ON use VOM to check for continuity across pins 8 and 10 on the plug end coming from the throttle assembly see page 19 10 for p n 2041401 cable pin out diagram cl no continuity is found this throttle cable section is faulty and needs to be replaced c 2 If continuity is found go to Step 5E 1d 19 3 E Drive 11 14 07 d With E Drive motor battery leads connected to 48 volt power source power supply or 4 series linked 12 volt batteries turn key switch ON and check v
102. e customer is complaining that there is no variation between speeds Step 1 Perform an amp draw check while the motor is running in a water test tank A B If the amps step up as the speed setting increases the motor is performing as designed If the amp draw does not increase along with the speed settings check the amp draw of each speed directly through the speed coil B 1 Remove the control box cover Disconnect wires from the foot pedal from the wires to the lower unit B 2 With the lower unit still in a water test tank connect 12 volts to the black motor brush lead B 3 Connect 12 volts to each colored speed coil wire coming up through the motor tube from the lower unit The motor will run on the separate speed designations as you make each connection Note the amp draw as you test the different colored wires a If the amp draw does not vary as you make the different connections with the lower unit still in a water test tank replace the front end bell potted speed coil assembly b If the amp draw does vary as you make the different connections replace the 5 speed switch Case IV Motor runs fine but steering is loose soft or does not function Step 1 Remove control box cover and inspect cable conduit bracket where it attaches to the control box A B If conduit bracket is loose or control box attach point is broken repair replace parts as needed If conduit bracket and control box check out fine inspect st
103. e properly if necessary Step 2 Check motor with known good test foot pedal or test the foot pedal by performing the Foot Pedal Test Procedure found on page 9 7 A If test pedal properly controls all motor functions or if the original foot pedal tests bad as outlined on page 9 7 the original foot pedal is faulty Replace foot pedal B If motor lower unit does not run properly with test pedal or if the original pedal tests okay as outlined on page 9 7 go to Step 3 Step 3 Check to see if lower unit runs properly A Connect 12 volts directly to the red and black brush leads at the top of the motor shaft in the control box The motor should run If not a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as necessary If the motor operates properly proceed to Step 4 Step 4 If Steps 1 2 and 3 test okay the main control board is faulty and needs to be replaced PART II Case VIII All functions dead Step 1 Check for proper battery voltage and polarity at the control board input terminals Visually check for poor or corroded connections Check for proper wiring of control board consult appropriate wiring diagram Step 2 Defective control board Replace main control board PART II Case IX Foot pedal sticks right left when steering Step 1 Inspect actuators on underside of foot pedal for sand dirt grit A D
104. e pulley cluster gear assembly figure 7 on page 7 9 Loosen the setscrew p n 2053420 and then using a 5 32 allen wrench rotate the belt tensioner p n 2058411 Turning the allen wrench CW or CCW will move the motor to adjust the belt tension With the belt tight retighten the 3 motor screws and the belt tensioner setscrew Check motor lift system operation and reassemble in reverse order of disassembly C If it was determined in Case II Step 3B 1that the lift motor needs to be replaced or in Case II 3B 2 that the lift belt is broken examine the lift system to determine if it is the new or older type See NOTE on top of page 7 2 for information on how to identify lift system If examination confirms that the motor has the earlier type lift system order and install p n 2776517 Lift System Upgrade Kit C 1 disassemble the Vantage motor for installation of the Lift System Upgrade Kit lower the motor about 7 to 8 inches down from the fully retracted position If necessary you may connect the lift motor leads to 12 volts to lower the motor unit or you may rotate the lift gear p n 2052208 counter clockwise CCW by hand to lower the motor unit Failure to lower the motor will make further disassembly difficult and may result in damage to the unit Vantage Repair Manual 02 15 08 a Use a 1 8 diameter punch to remove the pin p n 2052620 from the lift gear p n 2052208 and lift screw shaft p n 2053400 b Remove the li
105. e sensor on the output lead The bank will not operate if this occurs MK230 MK345 MK460 MK440 A GREEN power light is lit to indicate AC power is applied A YELLOW light is lit for each bank to indicate the battery is charging A GREEN light is lit for each bank to indicate the battery is fully charged and in maintenance mode A RED light for each bank is lit if any of the following apply A No battery is connected to an output lead This may also indicate a blown fuse in the fuse holder B The battery is connected reverse polarity RED and GREEN lights are lit simultaneously for each bank if any of the following apply A A short circuit B The battery voltage is below 8 0 volts C A damaged temperature sensor on the output lead The bank will stay in maintenance mode if this occurs 20 2 Battery Chargers 11 19 07 Frequently Asked Questions about Minn Kota DC Alternator Chargers Q What is the output of the Minn Kota DC alternator chargers A Each bank of the DC chargers puts out up to 10 amps based on the size of the alternator and how deeply discharged the auxiliary deep cycle batteries are A full battery will take less current outputs operate simultaneously Q When do the Minn Kota DC alternator chargers switch on A The DC chargers will begin to recharge the auxiliary deep cycle batteries when the starting battery reaches 13 6 volts A yellow light will illuminate when the charger is recharging the auxil
106. e to help you find fish o The integrated transducer concealed wiring and plug in compatibility with a variety of fishfinders made the IN original Universal Sonar a home run of an idea So naturally we ve made it even better Universal Sonar 2 features new temperature sensing compatible with all major fishfinder brands and the performance of dual a es beam technology available with all Humminbird DualBeamPLUS models and select Lowrance and Garmin Sua LE models An expanded view and greater bottom detail gives you a totally new perspective of the water below Pa gt Required Accessory Adapter for Universal Sonar 2 MKR UsSe 1 Garmin Fishfinder 100 Fishfinder 160 Fishfinder 240 Fishfinder 250 Fishfinder 5 Fishfinder 320C GPSMAP 168 GPSMAP 178C GPSMAP 188 GPSMAP 198C Fishfinder Fishfinder 120 twih optional Garmin part number 010 10145 00 sold separately MKR US2 4 Humminbird 1005X NS25 LCR W 4055X Legend 1000 Legend 2000 Tracker Pro 160 Boater s World Pro Angler 400 Zercom 2160 MKR US2 7 Vexilar FL 8 FL 8 SE FL 8 SLT FL 10 FL 18 CLC 200 MKR US2 8 Humminbird Piranha amp Piranha 5 PiranhaMAX 10 PiranhaMAX 15 PiranhaMAX 20 PiranhaMAX PT 210 PiranhaMAX 215 PiranhaMA X 220 PiranhaMAX 240 Matrix 10 Matrix 12 Matrix 15 Matrix 17 Matrix 20 Matrix 25 Matrix 27 Matrix 35 Matrix 37 Matrix 55 Matrix 65 Matrix 67 Combo M
107. ed Part II Case Motor runs in one direction only Step 1 Check hand controller and control module plug ends pins and connector sleeves for corrosion Clean if needed reconnect and test again for proper operation Step 2 Test hand controller Forward Off and Reverse switch for proper operation and check continuity through switch per hand controller test procedure on page 16 1 A If faulty switch is found replace hand controller B If switch tests okay problem is with control module Replace module control board or module assembly as needed Part II Case EM 96 EP96 130 twin motor units only 1 motor runs Step 1 On the one motor that doesn t run disconnect motor leads from the control module and connect motor leads to 12 volt power source This applies to 12 or 24 volt models A If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes bad brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation B If motor does run go to Step 2 Step 2 If using four 12vdc batteries to power twin EM or EP models check to make sure that both modules are connected to the same power source For proper operation batteries 1 amp 2 should be connected in parallel next connect batteries 3 amp 4 in parallel Then series connect the two banks of paralleled batteries The ba
108. edal When the MOM CON switch is in the MOM position the angler may begin using the remote at any time 5 soon as any remote button is pressed the initial speed setting will be approximately the same as the foot pedal s speed control position However the prop will not automatically turn on until the remote s prop on off button is pressed Pressing the corded foot pedal switches will override the remote and receiver function and control will automatically go to the corded foot pedal The prop speed will also revert to the current position of the speed control on the foot pedal ADDING REMOVING REMOTES CoPilot kit already has the receiver learned to the ID number of the remote it is packaged with To learn the ID number of additional remotes follow these steps 1 Press and hold the LEARN button located on the side of the receiver receiver will emit a continuous tone 2 Press any button on the remote receiver will beep 4 times confirming that it has learned the ID number of the remote and that the programming is valid and complete Re learning the ID number of the same remote will not overwrite previously learned remotes the receiver has learned the ID number of ten remotes learning an eleventh remote will erase or over write the first learned remote CoPilot allows the angler to erase all stored remote ID numbers fro the receiver do so follow these steps 1 Remove
109. eering cables B 1 Tighten steering cables by turning adjusting screw at foot pedal clockwise Turn counter clockwise to loosen steering cables B 2 If steering cable core s are broken replace steering cable assembly per Diagram 1 page 12 4 Inspect screws at upper bearing race pinion gear assembly Screws may have backed out or sheared off Replace parts as needed LocTite screws in place Later versions utilize an upper bearing race assembly with 4 screws while earlier version just used 2 screws 12 2 Foot Control Cable Steer w Speed Coil Repair Manual 01 31 08 Case V Rope eyelet is worn and quickly wears through pull ropes If motor being serviced is a Maxxum motor or a RipTide motor with a bowguard 360 assembly that splits horizontally upper and lower halves Step 1 Remove existing defective eyelet from bowmount bracket assembly Step 2 Drill out the eyelet hole in the bowguard bracket with a 27 64 drill bit Step 3 Thread the hole with a x 13 tap Step 4 Screw new eyelet p n 2772352 in place and secure it with a drop of red LocTite on the threads If motor being serviced is an All Terrain motor with a Hinge Door bracket or a RipTide motor with a bowguard 360 assembly that splits vertically left and right halves Step 1 Remove existing defective eyelet from bowmount bracket assembly Step 2 Drill out the eyelet hole to a 1 2 diameter Step 3 Slip the new eyelet p n 2772352 into the gt eyele
110. embly you must note the position of the lift housing in the aluminum base assembly i e stowed or deployed position and the position of the outer tube in the lift housing you may want to mark the parts accordingly Also note the top bottom of the outer tube the lift cam in the belt channel of the tube is towards the bottom The lift housing and outer tube should be reassembled so as to place them in the same positions they were in prior to disassembly Failure to do so may disrupt the timing of the lift housing rotation and cause internal gear damage Step 3 Remove the right and left Genesis sideplates from the base housing assembly item 35 and 36 on the Base Housing parts explosion Step 4 A B C If the motor being serviced has a dampener arm shock absorber detach the end of the dampener from the lift housing Remove the three screws item 22 of the Base Housing parts explosion that hold the lift motor in place item 20 of the Base Housing parts explosion Remove the lift motor and lift motor drive gear item 19 on the Base Housing parts explosion Remove the three screws item 17 of the Base Housing parts explosion that attach the motor mount spacer item 16 of the Base Housing parts explosion to the base extrusion On the side opposite the lift motor remove the screw encoder bracket and encoder wheel items 26 25 and 24 of the Base Housing parts explosion Remove the three button head cap scr
111. ering system A Connect the motor battery leads to the appropriate voltage and test run for speed variation and function Test the battery meter for proper function Test the control box tilt adjustment for proper range and travel Check and verify overall motor operation and function This concludes the basic 3X motor re assembly procedures Further step by step repair procedures will be added as needed when field service issues arise 3X Steering Repair Manual 11 06 07 This is a 1 time procedure to initially orient straight ahead on bowmount models with BowGuard 360 3X ALIGNMENT AND COLLAR INSTALLATION 1 Remove the depth collar from bag and review your type of mounting THE DEPTH COLLAR COMES SET FOR STANDARD CONFIGURATION OR OPTION 1 21 Set th depth collar aside until the motor 15 mounted and allgnad 2 DEPLOY THE UNIT MAKING SURE THE MOTOR 15 SUPPORTED BELOW THE MOTOR WILL FALL DOWN UNITL THE HANDLE HITS THE MOTOR MOUNT IF TEL WHEN DEPLOY ING 4 The motor will coma un allgned similar to the picture ta the right 51 Allgn handle parallel with the centerline of the boat Hold the handle and rotate the outer shaft until the steering tension knob Is allgned with the handle See pictures below Handle and knob are Tanesion Knob FOLLOW THE HANDLE ALIGNMENT FOR BOTH MOUNTING OPTIONS B Ralse ina motor and place support under the lo
112. et idler gear idler plate and preload ring P Ns 2070800 2070801 2072215 2071900 and 2073000 see Fig 4 clamp wire coupler socket 226 3201 20 0800 Black 207 0801 White e retaingr light assembly 2 2 n idler plate hit st p brki 207 900 207 2815 j ring prelead detent block 207 3000 207 2810 qty 2 22 Um tus i spring Brem gt 207 2705 serewdta 18x5 8 231 2 100 qty 3 coche Ww 4 Ux FIR 207 3408 qty 2 Am PIVOT 207 0147 FW 207 0118 5 gt pivol kaob 207 0110 SR uet bushing p 207 7346 qty 2 dest Garter 207 2210 hearing gear carrier 207 7320 a La y canitpl hox CUN assembly screw 5 18 x 2 211 3810 washer 5 5 207 1712 a Washer 207 17 l0 vake pivol 207 1512 FW 207 1513 SW screw 4 209 1 8 amm g 207 3410 nui 14 20 207 3100 Screw Hb washer 230 34 12 gly 2 207 1714 qty 2 3X Steering Repair Manual 11 06 07 Step 6 Remove the two P N 2332101 88 32 x V tilt stop bracket detent block retaining screws then remove the P N 2072815 bracket and P N 2072810 detent block see Fig 4 page 6 3 Step 7 Remove the two soft plastic pivot knob covers P N 2070117 or 2070118 to expose the two 14 20 x 7 8 Phillips head screws P N 2073408 that hold the pivot know and control box assembly on the gear carrier P N 2072210 pivot yok
113. ews item 23 on the Base Housing parts explosion that attach the lift housing to the base extrusion NOTE These three screws are secured with Loctite Apply heat as needed to remove them Remove the lift housing from the base extrusion and place on workbench with left side socket head capscrews up A B Remove the eight 1 4 x 20 socket head capscrews item 50 of the Lift Housing parts explosion that hold the left and right halves of the lift housing together With the eight screws removed use a blade screwdriver to carefully pry apart the lift housing halves Lift the left half up and off the right half to expose the internal workings of the lift housing see figure below Lift Belt mw Gear Shaft amp Sprocket Assembly EE Thrust washer in proper location _ dud Input Shaft Visually inspect the lift chain item 42 of the Lift Housing parts explosion for damage If the chain is okay remove the chain connecting link and then remove the chain to allow further disassembly and inspection of the lift housing components 14 14 Genesis Repair Manual 11 07 07 D With the lift chain removed the slip clutch assembly item 23 of the Lift Housing parts explosion can be removed by lifting it up and off the input shaft gear assembly item 22 of the Lift Housing parts explosion E Note how the lift belt is routed 1nside the lift housing around the input shaft gear assembly Remove the input shaft gear assembly
114. exed near the potentiometer end the potentiometer leads are broken and the control board needs to be replaced Case VII Motor runs fine but steering is loose soft or does not function Step 1 Remove control box cover and inspect cable conduit bracket where it attaches to the control box A If conduit bracket is loose or control box attach point is broken repair replace parts as needed B If conduit bracket and control box check out fine inspect steering cables B 1 Tighten steering cables by turning adjusting screw at foot pedal clockwise Turn counter clockwise to loosen steering cables B 2 If steering cable core s are broken replace steering cable assembly per Diagram 2 page 13 6 C Inspect screws at upper bearing race pinion gear assembly Screws may have backed out or sheared off Replace parts as needed LocTite screws in place Later versions utilize an upper bearing race assembly with 4 screws while earlier version just used 2 screws Case VIII Rope eyelet is worn and quickly wears through pull ropes If motor being serviced is a Maxxum motor or a RipTide motor with a bowguard 360 assembly that splits horizontally upper and lower casting halves Step 1 Step 2 Step 3 Step 4 Remove existing defective eyelet from bowmount bracket assembly Drill out the eyelet hole in the bowguard bracket with a 27 64 drill bit Thread the hole with a x 13 tap Screw new eyelet P N 2772352 in place and secure
115. f the control box and turn it over to access the steering motor retaining screws p n 2223427 See parts explosion A 2 Remove the three screws that hold the steering motor onto the underside of the steering chassis B Replace the steering motor assembly with the appropriate part p n 2777805 for 12V model and p n 27777806 for 24V Genesis Reassemble using the original bronze helical gear transmission coupler and motor gear See steering Module parts explosion Step 3 Place reassembled steering motor chassis assembly back into the control box Reassemble in reverse order of disassembly Note be sure to inspect the threads in the primary gear and on the retaining screws Replace if required Use Loctite 603 and primer on retaining screws Tighten screws to the point that they are flush with the aluminum locking collar on the inner shaft tube Step 4 After reassembling Genesis motor connect it to the appropriate voltage and test for proper operation Case III Genesis unit deployed lower unit turned but now will not steer or stow Step 1 Steer system is jammed See Genesis Steering System Module Case I and to correct cause of malfunction Case IV Genesis unit responds to heel toe steering pedal inputs but right momentary steer button is intermittent delayed or not responding Step 1 Replace malfunctioning foot pedal assembly p n 2772040 Step 2 Connect Genesis motor to the appropriate voltage and tes
116. ft gear from the lift screw shaft See figure 5 page 7 8 Remove the 2 screws p n 2053414 that hold the steering shaft p n 2052000 and steering shaft bearing p n 2057306 in place Note the position of the D flat on the steering shaft in relation to the motor lower unit Proper reassembly requires that the D flat be in the same position as it was prior to disassembly relative to the motor lower unit d Lift the steering shaft steering pinion gear and bearing assembly straight up and out of the top plate p n 2051900 e Using a 5 16 nut driver remove the 4 screws p n 2053413 that hold the top plate in place on the housing p n 2056505 See figure 5 page 7 8 f Remove the screw and washer p n 2053415 and 2051716 that hold the motor leadwire in place g Disconnect the motor leads and lift motor wires from the control board Remove the 2 control board mounting screws and insulating washers p n 2053407and 2261712 See figure 3 page 7 7 h Lift the top plate and motor assembly off the housing and install the new top plate lift motor and lift system included with the Lift System Upgrade Kit p n 2776517 i Reassemble the motor in reverse order of disassembly Adjust lift belt tension on the new upgrade kit as outlined in Step 3B 2 above j Test motor for proper operation upon completion of the Lift System Upgrade Kit installation If it was determined in Case II Step 3B 2 that the lift y
117. ft housing In this manner you can push pull the new lift belt into position for reassembly and attachment to the outer shaft collar and lift belt tensioner Step 5 With new lift belt attached at top and bottom tighten the lift belt tension screw to the point that a moderate pull on the belt approx 107 pull will deflect the belt gt to 34 from the outer tube Step 6 Reassemble the steering chassis in the control box and reinstall the primary gear and primary gear retaining screws Note Use Loctite 603 and primer when reassembling Replace primary gear and screws if threads in primary gear are stripped cross threaded or damaged in any way A Reinstall the steering potentiometer belt reconnect the red and black motor wires and reinstall control box cover and directional indicator Step 7 Connect Genesis motor to appropriate power source and test for proper deploy stow as well as all other motor functions If necessary perform Master Reset Emergency Override procedure see page 14 21 to reset the shaft position counter You may also need to re orient the steering potentiometer to the lower unit position page 14 19 if the potentiometer was accidentally moved Case V When the MODE switch is pressed to stow the Genesis motor the motor shaft raises vertically and the motor lower unit contacts the underside of the bowmount Motor does not rotate into the horizontal position for proper stowing NOTE Ensure the lift cam is in
118. ge Disassembly Procedure Step 3 B 2 If the motor has serial number below MKAG2159171 replace the lower cap p n 2996520 On earlier units this cap could shift to the side and bind the lift system causing higher than normal amp draw This lower cap change was discussed in our December 2005 Newsletter Check to make sure that the white plastic lift gear that 1s about 2 diameter p n 2990426 is not rubbing on the cluster gear flange pulley Shim as necessary using thrust and nylatron washers p n 2051703 and p n 2051705 Check lubrication of the lift screw p n 2053400 and lift yoke p n 2051510 Inadequate lubrication will cause higher than normal lift motor amp draw If the air temperature is below freezing the lubricant in the lift system may be thickened and be too viscous for proper operation The lift motor may have been overheated and damaged the lift motor should draw less than two amps while running in a no load or on the bench situation Sometimes just be sniffing the motor you will be able to determine if it has overheated Case IV Vantage motor lower unit does not steer when the handle is turned from side to side Step 1 Disassemble to visually inspect the steering rack and pinion gear See Disassembly Steps 1 amp 2 Step 2 Observe steering pinion gear p n 2052205 and steering shaft p n 2052000 as the steering handle is moved from side to side A If the pinion gear rotates but the steering
119. ght B Torque the lift belt tensioning screw to 6 7 inch pounds Tensioner screw is located on the underside of the control box C Perform the Master Reset Procedure to reset shaft position counter see page 14 21 D Retest motor for proper deploy stow sequence If lift belt 1s still slipping tighten lift belt tension screw one full turn and retest Repeat if necessary until motor stows deploys properly Case II If Genesis displays use trim when in the stowed position or motor does not stow deploy or trim down all of the wav ER6 may also display the shaft position counter has lost reference and must be reset Step 1 Perform Master Reset see page 14 21 Case III Genesis motor displays ER6 and or lift motor can be heard running but motor does not deploy stow Step 1 Inspect lift belt for cuts damage and proper tension If all checks okay proceed to lift motor removal below If lift belt is damaged go to Case IV of this Lift Trim System A Unscrew sideplate screws items 37 and 38 to remove the right sideplate Consult Genesis AP PD Base Housing Parts explosion for reference B Remove the three screws item 22 that attach the lift motor item 20 to the lift motor mount Locate and examine the lift motor drive gear coupler item 19 for damage C 1 If gear is split or if blade across the inside diameter of the gear is broken replace it with new parts from Minn Kota This gear has been changed
120. ght It will stay on for approximately five minutes even if no further commands are received LED should flash when steering and also flash briefly as speed is changed A If LED operates OK then the radio portion of the circuit transmitter receiver is operating correctly Diagnose motor per corded model instructions OR AutoPilot models Use test foot pedal adapter and corded test foot pedal see page 10 3 NOTE when using test pedal adapter the lever of the corded test foot pedal must be in the position and the motor ON OFF switch must be ON If motor operates correctly with this test procedure problem lies in the software transmitter or receiver i e cordless pedal or sideplate If motor does not operate properly with this test procedure diagnose motor per corded model instructions EN on AutoPilot models Non AutoPilot models can be tested with a corded foot pedal do NOT use the corded adapter As with the AutoPilot models the motor ON OFF switch must be ON in order to properly test all motor functions If LED does not come on when initialized B 1 Verify proper battery voltage to trolling motor 12v or 24v B 2 Make sure that motor on off switch on motor is ON before foot pedal ON OFF switch 15 turned ON B 3 Verify transmitter battery condition Signal strength decreases as the AA batteries in the foot pedal get weaker Using a V O M check for voltage across the red and black
121. haft are threaded B Check to verify that the catch on the latch handle now firmly engages the latch collar If necessary re adjust latch collar position Tighten the clamping screw to hold the collar in place PowerDrive Repair Manual 04 29 08 PART Case VII Motor is tight in the cradle and difficult to stow deploy Step 1 Lubricate the composite shaft with a silicone spray or Armor Step 2 Adjust the latch collar A Loosen latch collar clamping screw Rotate the latch collar counter clockwise on the shaft when viewed from above to screw the latch collar up away from the motor lower unit The collar and shaft are threaded B Check to verify that the catch on the latch handle firmly engages the latch collar If necessary re adjust latch collar position Tighten the clamping screw to hold the collar in place Step 3 Verify the correct motor rests are used Part numbers are molded on the motor rests 2303933 motor rest right 4 motor assemblies 2303938 motor rest left 4 motor assemblies 2303932 motor rest right 3 5 8 motor assemblies 2303937 motor rest left 3 5 8 motor assemblies 2303930 motor rest right 3 44 motor assemblies 2303935 motor rest left 3 4 motor assemblies Step 4 Replace the pivot pads P N 2305103 11 14 07 PowerDrive Repair Manual Corded Foot Pedal Test Procedure V2 models have a different pedal SONVLSIS3 I X VW JV 7HOLOST3S 33d XXiassv
122. he Genesis motor in reverse order of disassembly making certain that the anti rattle bushing in the outer shaft stays its proper place Visually confirm this by checking for the anti rattle bushing detent catch in the hole provided in the belt channel of the outer shaft see below On 45 shaft models the cam profile will extend over the hole in the tube when motor is fully assembled After reassembling Genesis motor connect proper voltage Deploy the unit and test for proper function 14 20 Genesis Repair Manual 11 07 07 Genesis Master Reset Emergency Override This Master Reset Emergency Override procedure is required in the following circumstances to reset the shaft position counter especially if the lift belt was loose or slipped to stow the motor in the case the motor becomes stuck in the deployed position the steering motor tries to run when the motor is fully stowed the prop spins when the motor is fully stowed the LCD shows Use Trim when the motor is fully stowed is the first thing to try whenever something peculiar or unexpected occurs WV Please read this entire procedure prior before performing the Master Reset so that you understand the important notes in Step 5 Master Reset Ste DS left sideplate should be in place over the counter wheel Step 1 Turn the Master Switch OFF Step2 Simultaneously press and hold Mode Switch while turning the Master
123. he heel toe steering pedal once to enter this setting into the main board memory Note if the left and right park positions are already set correctly the TrimUp switch may be pressed to skip or toggle through this portion of the procedure Step 3 Setting Shaft Length after completing Step 2 the shaft length setting will automatically display A LCD on motor should read 45 52 or 60 if properly set to match the motor shaft length The memory will default to 45 on a newly installed main board B Use the right momentary steering switch to toggle through the shaft lengths until the correct shaft length for the motor is displayed 45 52 or 60 C Press Momentary ON switch located on the heel toe pedal once to enter this setting into the main board memory NOTE if the shaft length is already set correctly the TrimUp switch may be pressed to skip or toggle through this portion of the procedure Step 4 Setting Lift Motor Condition after completing Step 3 the motor lift condition setting will automatically display 14 27 A Genesis Repair Manual 11 07 07 Display should read either up or dn The display will show last setting selected On a newly installed board the LCD will default to dn Press Momentary ON switch located on the heel toe pedal once to enter this setting into the main board memory Step 5 Selecting the Offset Table after completing Step 4 the Offset Table will
124. he lift belt and tube bearings items 48 and 49 on the Lift Housing parts explosion Be certain that the thrust washer 15 in the proper location it tends to stick to the greased bushing on the opposite half of the housing see figure above L Reinstall and completely tighten the eight 1 4 x 20 socket head capscrews that hold the lift housing halves together M Reinstall the lift housing assembly back into the base assembly Be sure to reinstall the lift housing with the motor mount bushing in place item 51 of the Lift Housing parts explosion Reattach the dampener arm if included on the unit being serviced N Reinstall all fasteners with fresh Loctite where needed and reassemble the motor mount lift motor encoder wheel encoder etc in their proper locations in reverse order of disassembly O Reinstall outer tube in lift housing base housing assembly making sure that the lift cam end of the outer tube is toward the motor lower unit see note of ATTENTION at Step 2 C above regarding reassembly and proper positioning of outer tube and lift housing P Reinstall control box and lower shaft collar back onto the outer tube and reattach the lift belt to the lift belt tensioning device in the control box Q Reassemble the Genesis motor in reverse order of disassembly per the Internal Transducer routing procedure per Service Bulletin 41400 and test for proper operation of stow deploy trim and steering systems Case VI
125. he original pedal by performing Foot Pedal PCB Test Procedure on page 9 7 A If test pedal properly steers motor or if the original pedal tests faulty as outlined on page 9 7 the original foot pedal is defective Disassemble defective pedal to inspect if actuators are properly making contact on foot pedal board Visually inspect foot pedal board for collapsed or burnt dome switches Replace foot pedal if necessary If test pedal does not properly steer motor or if the original pedal tests okay as outlined on page 9 7 then test steering output of main control board Use a test light or V O M probes connected to the main control steering output terminals consult appropriate wiring diagram Connect known good foot pedal to main control board Connect battery leads to proper voltage If there is no board steering output as you try to steer left or right then the main control board is defective and needs to be replaced C If main PCB has output voltage drive housing is faulty Test drive housing by connecting 12 volt power source directly to drive housing leads If drive housing does not steer open drive housing and inspect servo motor drive gears and sleeve bushings for binding lack of lubrication or water damage Repair or replace the drive housing as necessary PART II Case Drive Housing steers one direction only AutoPilot or manual mode Step 1 Test drive housing by applying 12 volts to drive housing leads Reverse
126. hen ON and no continuity with switch OFF Replace ON OFF switch if defective otherwise replace main control board AutoPilot Repair Manual 02 12 08 PART II Case IV AutoPilot changes directions with speed changes Step 1 Small direction changes with speed changes are normal Step 2 If direction changes are more than 4 to 5 degrees perform the AutoPilot Calibration Procedure see page 9 12 PART Case V Motor won t steer or steers slowly at higher thrust settings Step 1 Inspect all battery connections trolling motor plug if installed and any butt splice connections in the battery leadwire for corrosion and security Step 2 Check to insure that wire of adequate gauge has been used in the boat s trolling motor circuit Wiring of inadequate gauge will result in a voltage drop to the motor and steering circuit at higher thrust settings If after insuring that all wiring and connections are good the steering is still slow at high thrust settings proceed to Step 3 Step 3 Disassemble motor to separate the drive housing from the motor and tube and bowplate extrusion assembly A Remove the six screws holding the top and bottom halves of the drive housing together Note the top and bottom halves of the drive housing are pinned together at the corners with roll pins The two halves will need to be pried apart Inspect the drive housing motor paying special attention to the drive housing motor armature shaft and
127. hfinder 80 Fishfinder 120 with optional Garmin part number 010 10145 00 sold separately MKR US 2 Bottom Line Tournament NCC 5300 Tournament NCC 6500 MKR US 3 Bottom Line Tournament 1250 Tournament 3310 Tournament 4300 Tournament 3100 Toumament 4100 Tournament 5100 Tournament NCC 6300 Tournament 320MAX Tournament 480MAX MKR US 4 Humminbird 1009 405SX LCRW 525 Tracker Pro 160 Boater s World Pro Angler 400 Legend 1000 Legend 2000 Zercom 2160 MKR US S Eagle FishEasy2P FishMark 160 FishMark 240 TriFinder 2 Lowrance LOX 15MT LOX 15CT LOX 15Cl LOX 15C LOX 16Cl LOX 16CT LCX 18C LCX 190 LOX 104C LMS 240 LMS 320 LMS 320DF X 51 X 58DF X 71 X 87 X 88DF 91 X 97 X 98DF 1000 X 105C DF X 125 X 126 DF X 135 X 136 DF LMS 480 LMS 480 DF LMS 330C LMS 335C DF MKR US 6 Eagle Accura 240 Accura 240FLW FishEasy FishEasy ST Optima Strata 128 Strata 128 Plus Strataview 128 Trifinder Trifinder FLW UltraClassic Ultra Classic Plus Lowrance X24 X28 X29 X38 X48 X49 X58 X65 X75 X85 MKR US 7 Vexilar FL 8 FL 8 SE FL 8 SLT FL 10 FL 18 CLC 200 MKR US 8 Humminbird Legend 3000 400TX 300TX Piranha 1 Piranha 2 Piranha 3 Piranha 4 Piranha 5 PiranhaM X 10 PiranhaMAX 15 PiranhaMAX 20 Matrix 10 Matrix12 Matrix 15 Matrix 17 Matrix 20 Matrix 25 Matrix 27 Matrix 55 Matrix 37 Matrix 55 Matrix 65 Matrix 67 Matrix 67 Combo Matrix 776 Matrix 87c Combo Matrix 97 Matrix 97 Combo F
128. hile operating the outboard motor 3 The use of one of the trolling motor batteries on 24 volt or 36 volt motors to provide power to start a kicker outboard motor 4 The use of a Perko switch to connect one of the trolling motor batteries 24 36v models to the starting battery 5 The brush shunt wire may be inadvertently touching the inside of the motor case This is more apt to happen on 4 motor assemblies after the lower unit has been opened during field repairs NOTE To address these issues caused by improper boat wiring an internal fuse to the motor bonding grounding wire was added late in the first year of production of the US2 late AH serial numbers If the fuse blows the depth finder may be subject to interference issues A blown fuse also indicates that one of the above conditions exists and must be corrected prior to replacing the fuse Minn Kota Universal Sonar Models 11 14 07 UNIVERSAL SONAR 1 COMPATIBILITY LIST Plug It In Find A Fish Features an integrated and protected transducer No wires ties or clamps Protects sensitive electronics from underwater hazards Universal Sonar is available on selected Maxxum Pro Maxxunf and PowerDrive models REQUIRED ACCESSORY ADAPTER FOR UNIVERSAL SONAR ADAPTER SONAR BRAND COMPATIBLE MODELS MKR US 1 Garmin Fishfinder 100 Fishfinder 160 Fishfinder 240 Fishfinder 250 Fishfinder 2500 Fishfinder 320C GPSMAP 168 GPSMAP 1780 Fis
129. housing itself To do this use a V O M to check for continuity between the drive housing lead and a screw on the underside of the drive housing A 2 If a short is found disassemble the drive housing and insulate the wire terminals at the drive housing s servo motor to correct the shorted condition A 3 Reassemble the drive housing and again check for shorts D If test pedal does not properly steer motor or if original pedal tests okay as outlined on page 8 6 then check the drive housing B 1 Connect 12 volt power source directly to drive housing leads If drive housing does not steer open drive housing Inspect servo motor and drive gears for binding lack of lubrication Service drive housing to correct malfunction as needed If necessary re lubricate the bushing and sleeve contact surfaces with Schaeffer s 238 Moly Ultra Supreme grease Minn Kota p n 2307720 PART II Case Motor lower unit fails to run or runs intermittently Step 1 Step 2 Step 3 Step 4 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for any corroded connections Clean rewire if necessary Check motor with known good test foot pedal or test the original foot pedal by performing Foot Pedal PCB Test Procedure see page 8 6 A If test pedal properly controls propeller speed or if the origi
130. iary deep cycle batteries This ensures the boat engine driven alternator is operating and enough power is available to distribute to the auxiliary deep cycle batteries Q When do the Minn Kota DC alternator chargers turn off A The DC charger will stop charging the auxiliary deep cycle batteries when the starting battery voltage drops below 12 8 volts The yellow light will turn off when the DC alternator charger is not recharging the auxiliary deep cycle batteries This will prevent the DC charger from discharging the starting battery when the boat engine 15 turned off Q How long can the Minn Kota DC alternator chargers stay charging A The DC charger will continue to charge the auxiliary deep cycle batteries as long as the boat engine is running and the engine driven alternator is keeping the starting battery above 12 8 volts It is recommended to disconnect the DC charger if the boat engine is run more than 12 hours Batteries that are charged for an excessive period of time can lose fluid and need to be filled NOTE Minn Kota on board AC battery chargers have a maintenance mode and can be left charging the batteries for long periods of time The fluid levels of flooded lead acid maintenance type batteries should be checked every 30 days if the AC charger is left connected and plugged in Q Can the Minn Kota DC alternator chargers be used with my trolling motor with built in sonar A Yes each output of the DC charge
131. ify problem C Connect control module to appropriate power source 12vdc for 42 EM44 amp EP42 24vdc for EM48 EM54 EM96 EP48 EP96 amp EP130 D Plug in known good tested as per above hand controller directly to control module bypass remove splitter from circuit if motor is an EM96 EP96 or EP130 and check each control module individually E Check for voltage at module output leads by hooking up test light or V O M probes to board output leads Turn hand controller ON to either F or R and vary the potentiometer speed control setting NOTE all EM control modules and early EP modules EPs produced prior to 1999 utilize a motor disconnect relay in the output circuit of the module On modules with the disconnect relay test for output voltage directly at the board output terminals and at the output leads that connect to the motor unit Testing in this manner will determine if the disconnect relay is good or defective E 1 If there is no output voltage at board terminals the control board is defective Replace control board or module as needed 16 3 EM amp EP 01 31 08 E 2 If board terminals have output voltage but there is no output at the leads that connect to the motor the disconnect relay is faulty and needs to be replaced F If motor is an EM96 EP96 or EP130 test second control module If both modules test fine problem is in the splitter cable Replace cable as need
132. ing Service Bulletin 41400 Part II amp III for proper disassembly If screws in primary gear are not loose but steering is binding or jammed the p n 2227324 anti rattle bushing may be out of place This is especially true if the motor has been disassembled for internal routing of the transducer cable B 1 B 2 B 3 To correct this malfunction disassemble the Genesis motor as per the Transducer Routing Procedure See Parts II VI of Service Bulletin 41400 for proper disassembly Replace anti rattle bushing if detent catch on bushing is damaged broken Put anti rattle bushing back in its proper place making sure that the detent catch is secure in the hole provided in the outer shaft lift belt channel see below On 45 shaft models the cam profile will extend over the hole in the tube when motor is fully assembled 14 3 Genesis Repair Manual 11 07 07 Case II Steering motor has overheated and smoked due to jammed steering condition see Steering System Malfunction Case I Steering motor will need to be replaced Step 1 Correct malfunction that is causing the jammed condition as outlined in Case I Step 2 Disassemble unit per Parts I II and III of Transducer Routing Procedure Service Bulletin 41400 stopping at Step 2 of Part III A Remove the four screws holding the steering chassis to the lower control box See Genesis Steering Module parts explosion 1 Lift steering chassis out o
133. ion DOES NOT take the place of the specific sonar unit s trouble shooting guide Consumers should consult their owner s manual for their sonar unit for all depth finder problems USI transducers have a 14 cone and operate at 190 200 kHz US2 features temperature sensing and dual beam technology They have a 20 cone at 200 kHz and a 60 cone at 83 kHz Please note that the transducer is held into the Minn Kota lower unit with tamper resistant torx head screws T 15 These are torqued to 12 15 inch pounds The Minn Kota factory warranty will be voided if the consumer tampers with these screws Case I Sonar display blacks out loses bottom reading or gives erroneous readings while trolling motor is running operates fine with trolling motor off This is an indication of interference not a faulty transducer Step 1 Consumer should refer to the user s manual for the sonar display configuration options Many sonar displays have noise reduction options within their menus Step 2 Reduce gain of sonar display until an adequate display is visible Step 3 If this 1s a US2 model check to make sure the internal fuse in the control box has not blown The first year of US2 AH serial numbers did not have this fuse See Case V of this chapter for an explanation as to why this fuse has blown Step 4 Determine if supply voltage for trolling motor and depth finder is provided by the same common battery A If yes disconnect depth finder b
134. isassemble and clean contaminated actuators Replace components if required B Reassemble foot pedal leave actuators dry or use a dry lubricant to avoid further contamination with sand dirt grit PART II Case X MOM CON switch lever will not stay down in CON position Step 1 From the underside of the footpedal remove the 3 screws holding the slide control and switch lever in place A Remove screw holding the white plastic continuous actuator in place B Place shim P N 2301731 between actuator and pedal base Reassemble slide control and MOM CON switch assembly Test for proper operation PART II Case XI Motor is loose in the cradle Step 1 Check replace the pivot pads P N 2305101 as needed The pads tend to flatten or soften over time AutoPilot Repair Manual 02 12 08 AutoPilot Control Board Sensor Board Isolation Test MOTORS PRIOR TO 2001 MODELS ONLY The AutoPilot test board is to be used to trouble shoot an AutoPilot that is not locking on a heading or 1s failing to properly respond when in the AutoPilot mode Step 1 Use the AutoPilot test board P N 20 provided through the Minn Kota parts department Step 2 Remove the control box cover Step 3 Disconnect the 5 wires from the coil cord to the sensor board Step 4 Connect the 5 wires to the Test Board and turn Switch B to Position 1 Step 5 Turn the AutoPilot ON OFF switch ON and wait 2 seconds Step 6 Flip Switch A to Position 1 and the
135. ishfinder 515 Fishfinder 525 Fishfinder 535 Fishfinder 535 Portable Fishfinder 565 Fishfinder 585c Fishfinder 595c 931c 931c DF 937c 937c DF MKR US 9 Eagle 168EX 168 128 Cuda 240GPS FishElite 320 FishElite 480 FishMark 320 FishMark 480 SeaFinder 3200 SeaFinder 240DF SeaCharter 480DF FishEasy 2 47 X 47EX X 67C M 56 M 68C Lowrance 14 Universal Sonar extension cable for use with all accessory adapters Compatible with most major brands of fish finding equipment requires Accessory Adapter c 5 GARMIN EI an Che ne bee a b rev 2 4 05 For the most current list of sonar units please visit our web site at www minnkotamotors com or call Minn Kota Technical Services at 800 227 6433 3 4 Minn Kota Universal Sonar Models 05 02 08 UNIVERSAL SONAR 2 COMPATIBILITY LIST Choose the Universal Sonar 2 adapter plug that matches your fishfinder Allows you to quickly and conveniently e U 5 connect and disconnect motor from fishfinder New shielded cable connections virtually eliminate the possibility of sonar interference and are waterproof for extra dependability Universal Sonar 2 s state of the art integrated and protected transducer is built into the lower unit of the motor and all wiring runs inside the indestructible composite shaft out of sight and out of harm s way No clamps No ties No exposed wires or connections You get optimal sonar performanc
136. ith 7649 primer If you cannot locate 661 271 is more readily available and substantially less expensive It will suffice for service work in the field Be careful not to heat the shaft itself this is the reason the tube blocks should be slid down directly next to the bung when clamped in the vise While the composite shafts are very strong the combination of heat and the twisting force can break them Step 3 Unscrew the lower unit from the shaft while hot Once you break loose the LocTite do not stop unscrewing or the LocTite may re set Step 4 Clean the residue out of the threads of the lower unit with the hollow tap kit Minn Kota P N 2881021 A Slide the lower unit wires through the hole in the tap B While holding the lower unit upside down gently screw the tap into the motor assembly letting the residue fall out Be careful not to cross thread the motor Thru bolt tightening specifications 3 motors 25 35 inch pounds e 35 8 motors 35 45 inch pounds e 4 motors 40 50 inch pounds e 45 8 motors 40 50 inch pounds End Play specifications e Endplay should be 015 050 if necessary use extra nylatron washers Too much or too little endplay will result in motor running hot or wearing out prematurely Case I Lower unit does not run Step 1 Check to ensure proper voltage Inspect all battery connections trolling motor plug if installed and any butt splice connections in battery leadwire for corrosion and
137. k for motor function If the motor works with the test throttle assembly the customer s throttle assembly is faulty and needs to be replaced If motor does not operate with the test throttle use a VOM to measure the voltage across the B terminal and the front post of the contactor Depending on battery state of charge a voltage of 47 52 volts should be seen If test throttle assembly is not available and the customer s throttle assembly 15 being used turn the E Drive throttle assembly key switch to the position When the switch is turned on an audible click should be heard at the contactor If audible click of contact engaging 1s not heard the cause could be a faulty key switch damaged corroded broken throttle cable wires or connector pins a faulty control board or a faulty contactor Test as follows to determine which part s need to be replaced E 1 a Disconnect throttle cable from throttle assembly and examine the twelve 12 pins and sockets for damage corrosion misalignment and breakage Replace throttle assembly throttle cable if damage is found If no damage found turn the key switch ON and use a VOM to check continuity across pins 11 and 18 on the throttle assembly see page 19 13 for pin out diagram of throttle assembly a l If no continuity is found key switch is faulty and needs to be replaced a 2 If continuity is found reconnect throttle cable and go to Step SE 1b Locate the larg
138. k the UV light interference Install the N S North South compensating magnet rod first positioning the rod with the screwdriver slot outward and slot parallel to the mounting base horizon Install the E W East West compensating magnet rod with the screwdriver slot outward and the slot parallel to the mounting base horizon The E W rod will snap down into place and this will hold the N S rod in place NOTE With the N S and E W screwdriver slots parallel to the base horizon the compensating magnet rods are in the neutral position and the AutoPilot is ready for testing and fine adjustment 14 29 Genesis Repair Manual 11 07 07 Step 3 Testing Adjusting AutoPilot Accuracy NOTE When performing these steps place a shop rag on the compass assembly Sunlight or bright fluorescent lighting can over power the compass optical sensors A B C Turn Master Switch ON With the motor on rotatable stand point motor base extrusion and lower unit to the north LCD to the south Press and release the Mode Switch once to turn AutoPilot ON Note do not hold the Mode Switch down for more than 2 seconds or the motor will stow The icon will display on the LCD above the hours running time If the icon is flashing the motor is trimmed up too high and will not allow the AutoPilot feature to operate Use TrimDown switch to lower motor and reactivate the AutoPilot feature by pressing the mode switch once Rotate the motor base ex
139. ke in relation to the slots grooves in the outer tube Step 13 For further disassembly replacement of the transom bracket or BowGuard 360 assembly the outer tube or outer tube and pivot yoke assembly can be slid out of the transom bracket hinge or BowGuard 360 A transom mount 3X motors note that a tension block P N 2072800 is located between the outer tube and the orientation collar on the transom bracket This block will fall out of place when the outer tube 1s removed from the bracket hinge Be sure to re install this part when reassembling a 3X transom mount model This concludes the basic disassembly procedures for 3X transom and bow mount fresh and saltwater motors 3X motor lower unit trouble shooting disassembly and repair procedures are the same as all other Minn Kota 5 speed or variable speed motor units For re assembly instructions go to page 6 6 Step 1 Step 2 Step 3 Step 4 Step 5 3X Steering Repair Manual 11 06 07 Reassembly With the outer tube and pivot yoke properly positioned and slid into the transom bracket hinge or BowGuard 360 assembly reference Disassembly Procedure Step 12 slide the motor lower unit inner tube assembly and lower collar P N 2071500 back into place in the outer tube with the upper end of the inner tube extending out the top of the pivot yoke see Fig 5 on page 6 4 Re install the 4 hole collar upper bearing and pinion assembly on in the inner
140. king in the CON position go to Step 5 If motor being serviced is not working in the MOM position go to Step 6 With battery leads connected to power source and MOM OFF CON switch in the CON position connect V O M test leads across terminal block and battery lead V O M should read battery voltage A If no voltage is noted remove foot pedal base cover and check connections at MOM OFF CON switch B With switch in CON position check MOM OFF CON switch for continuity across center terminal of switch to terminal connected to wire going to terminal block If there is no continuity replace MOM OFF CON switch Test motor for proper operation With the battery leads connected to power source and MOM OFF CON switch in the MOM position connect V O M test leads to terminal block on under side of foot pedal and to battery leadwire or terminal A of 5 speed switch A With foot pedal momentary ON OFF switch depressed V O M should read battery voltage B If no voltage is present test foot pedal momentary ON OFF switch for continuity with ON OFF switch depressed 12 1 Foot Control Cable Steer w Speed Coil Repair Manual 01 31 08 B 1 If no continuity is noted replace foot pedal ON OFF switch Test motor for proper operation B 2 If continuity is observed go to Step 7 Step 7 Check for voltage across battery lead and white wire from MOM OFF CON switch A B C If no voltage is noted remove foot pedal ba
141. known good new Throttle Assembly and re test for proper operation Step 2 If problem persists check throttle cable cable connections and main control bard as per the procedure outlined in Case 1 Steps 3 4 and 5 Replace parts as needed E Drive 11 14 07 Case VII Throttle LCD only displays Throttle Fault and Prop Obstructed icons when key switch is turned ON Step 1 The main control board is at fault and needs to be replaced Replace board and re test for proper operation Case VIII Throttle LCD flickers on and off Step 1 Check all plug connections for corrosion and security Step 2 Perform a continuity check on both throttle cables p n 2041401 amp 2041402 for pin out connections see pages 19 10 amp 19 12 for pin out diagrams Continuity should be noted from one end of the throttle cable to the opposite end across the pins indicated and ONLY those 2 pins no other should show continuity If continuity 1s not found at all pins as noted in the pin out guide or if continuity is noted across more than 2 pins then the throttle cable 1s defective and needs to be replaced E Drive 11 14 07 CONTROL BOARD WIRING for p n 2044005 RED LEAD WIRE from batteries front post contactor CONTACTOR 7 BLACK LEAD WIRE ape from batteries RED JUMPER WIRE rear post of contactor BROWN LEAD rear pin ORANGE LEAD front pin BLACK MOTOR LEAD from lower unit NA GREY CONTACTOR WIRE
142. l present proceed to Step 1B C Armature bent shaft or out of balance armature stack C 1 Remove the prop from the armature shaft C 2 Run the motor never operate the motor for extended periods of time while out of water on medium to high speed and watch the armature shaft for a wobble that may indicate a bent shaft If wobble is noted replace armature You may also put your finger on the armature shaft to feel for a wobble or briefly touch the shaft with a sharp pointed marker while it is spinning A solid mark around the armature indicates a fairly straight shaft while an inconsistent line may represent a bent armature shaft Case X Customer complains the trolling motor is draining battery batteries down too fast Motors with a control board draw a small amount of amps whenever they are hooked to a power supply The relays are engaged Although this is a small amount it will drain batteries down over time if the motor is left plugged in We recommend unplugging the motor when not in use Step 1 Perform amp draw test while motor is under load in a water test tank amp specs are listed in the annual Minn Kota product brochures and on the top of the parts lists on the Service CD A If amp draw meets or is less than stated specs the motor is not the cause of the problem If amp draw is higher than stated specifications B 1 Spin the prop by hand and feel for broken magnets B 2 Check for proper even torque of thru bolts B
143. lats must be aligned with the two ribs along side the hole in the gear carrier for the pivot knob screws P N2073408 With the control box bushing pivot knobs pivot knob screws and nyloc nuts in their proper position securely tighten the two 14 20 x 7 8 phillips head pivot knob screws C 1 two soft plastic pivot knob covers can be re installed at this time Note the flat surfaces on the outer edge of the pivot knob as they serve to key the pivot knob covers to prevent their rotation Step 8 Re install the tilt detent block P N 2072810 in the control box teeth towards the detent spring followed by the tilt stop bracket P N 2072815 and the two 8 32 x gt phillips head screws that are used to attach both parts to the control box Step 9 Re install the preload ring P N 2073000 idler plate P N 2071900 idler gear P N 2072215 and coupler socket P N 2070800 or P N 2070801 White coupler socket for transom mount motors and black coupler socket for bow mount motors A As noted during disassembly position the coupler socket so that any two parallel sides of the hexagon I D of the coupler socket are as close as possible to being parallel to the control box pivot screws Coupler Socket Pivot Screws sides of hexagon are parallel to pivot screws Step 10 Re install the control board or 5 speed switch using the fasteners or parts removed during dis assembly see Fig 3 page 6 2 A Reconnec
144. leaning Procedure Disassemble and remove debris while also inspecting for missing magnets The Terrova foot pedal needs to be cleaned periodically Stones twigs sand and other debris can cause pedal buttons to stick and function abnormally Re assemble pedal and re test steering of motor A 2 If cleaning the customer s pedal doesn t correct steering replace foot pedal if necessary B If test pedal does not properly steer motor check the drive housing B 1 There are 3 different drive housings 12 volt for Terrova 55 24 volt for Terrova 80 and 36 volt for Terrova 101 but you can test the drive housing by connecting a 12 volt power source directly to drive housing leads NOTE with 12 volts applied the 24 and 36 volt drive housing steering speed will be noticeable slow If drive housing does not steer open drive housing Inspect servo motor drive gears and bearings for binding lack of lubrication Service drive housing to correct malfunction as needed If necessary clean and re lubricate the gears If sealed bearings are dry rough or binding replace them with p n 2327308 If above steps test okay the main control board is faulty and needs to be replaced See Case X below for information on Control Board Replacement Case X Instructions to replace main control board NOTE Control board should only be removed or replaced if it has been confirmed to be faulty as removal will in all likelihood damage the System Ready ree
145. ll wires are securely attached to the proper control board terminals Check for corroded connections Check to see if lower unit operates A Connect battery lead wire to battery B Disconnect the black battery lead from the control board and connect it directly to the black brush lead C Disconnect the red battery lead from the control board and touch it directly to the red brush lead The motor should run C 1 If motor does not run a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature C 2 If the motor does run go to Step 4 Check control board MODELS WITH A SOFT POT A The soft pot is no longer available If the soft pot is damaged or intermittent you will need to replace the control board MODELS WITH A MAGNETIC ON OFF REED SWITCH A After rechecking that all wires are securely attached to the proper connections with proper voltage verify the control board is defective A 1 Check for control board output by hooking up a test light or V O M probes to board output terminals consult appropriate wiring diagram Remove handle assembly with handle pivot and magnet rod off potentiometer The magnet rod needs to be away from the on off reed switch Connect battery leads to proper voltage Vary the potentiometer by turning potentiometer s stem The test light should vary in intensity from off to bright If there is no control boa
146. lling motor plug if installed and any butt splice connections in battery leadwire for corrosion and security Visually check to see that all wires are attached proper control board terminals Consult the appropriate wiring diagram for the model and board being tested Clean rewire if necessary Step 3 See Case X on page 11 6 for information on Control Board Replacement Case II System Ready LED is on when the motor is stowed Step 1 Ensure the release handle is fully latched and locked into the stowed position Step 2 Check to ensure the system ready reed switch small plastic cylinder with two wires going to control board is positioned in the side of the base extrusion Remove the right sideplate for viewing see Picture 1 page 11 2 Step 3 Inspect the release handle cover p n 2320215 for the presence of the magnet Replace handle cover if magnet is missing Step 4 If the reed switch and magnet are in place but system ready LED remains lit when the motor is stowed the reed switch is faulty replace main control board See Case X on page 11 6 for information on Control Board Replacement Terrova Manual 10 17 08 Picture 1 This illustration shows the magnet in the handle cover and the system ready reed switch located in the extrusion When the handle is in the deployed position magnet away from reed switch the system ready light will be on Case III AutoPilot is nonfunctional Step 1 Determine if the motor is
147. lure to do this can create a condition where accidental pulling of the rope may cause the mount to spring open rapidly striking anyone or anything in the direct path Maxxum Pro To disconnect one end of the gas spring follow the instructions below Open mount to approximate position as shown and hold there Make sure the yoke assembly roller end does not contact bowplate 2 Remove the e clip and pin attaching the gas spring to the bracket shown 3 Lower the mount back to the deployed position 4 Now it is safe to remove the pins attaching the BowGuard assembly 5 To re assemble attach the BowGuard while mount is in the deployed position Open mount as shown and reattach gas spring to bracket Gas Spring Bracket X j E clip and pin Rollers Bowplate w Maxxum Pro Diagram Fortrex To disconnect one end of the gas spring follow the instructions below 1 With the mount in the stowed position locate the upper cylinder pin 2 Using two Philips screwdrivers remove 1 of the Phillips flat head screws 3 Remove pin from outer arm by sliding thru the arm 4 Now it 1s safe to deploy the motor and remove the motor assembly Fortrex Diagram philips screw 13 4 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 Maxxum Pro REMOVAL OF THE BOWGUARD WARNING The assist lift mechanism in this unit is under HIGH SPRING PRESSURE when the motor is in the deployed position DO MOVING PARTS CAN C
148. m the negative post of the trolling motor battery to the negative post of the engine s cranking battery We suggest installing a 1 or 2 amp inline fuse in this ground wire Minn Kota P N 2060310 is the fused grounding wire B Test for depth finder interference while operating the motor Step 4 If interference is still present after installing the ground wire proceed as follows A Check the routing of the depth finder and trolling motor battery leads If they run parallel to each other for any length of distance separate the leads as much as possible or run the leads to the trolling motor and depth finder on opposite sides of the boat B Test depth finder for interference while operating the motor Step 5 The brush shunt wire may be inadvertently touching the inside of the motor case This is more apt to happen on 4 motor assemblies after the lower unit has been opened during field repairs Step 6 If interference persists after completing the previous steps proceed as follows A Check mounting location of the depth finder transducer If the transducer is mounted externally on the trolling motor s lower unit try temporarily moving it way from the lower unit while operating the motor and observing the depth finder display B If the interference 15 reduced or eliminated when the transducer is moved away from the motor s lower unit the problem is due to the transducers proximity to the lower unit C To reduce eliminate this type of
149. manent magnets have this field already built in thereby reducing the consumption of electrical power by as much as 30 A permanent magnet DC motor consists of three main parts Current carrying conductors wound around a laminated iron core called an armature or rotor 2 A magnetic field provided by permanent magnets or stator 3 Some type of sliding contact arrangement for introducing current to moving conductors usually carbon brushes and a commutator Understanding how an electric motor works is really quite simple but first requires an understanding the basic principle of electromagnetism This principle says simply that when current carrying conductors T in the drawing below are placed within a magnetic field B a force F will act on them Magnetic field Conductor t Now imagine this single wire from the above picture is replaced with a loop of wire Between the magnets poles this looks like two wires with current flowing in opposite directions The forces on the wires cause the loop to rotate The process of switching current direction is called commutation To switch the direction of current brushed DC motors use brushes and commutators The brushes are attached to the motor s two external wires and the commutator segments slide over the brushes so that current through the coils switches at appropriate angles Lower Unit Repair 09 08 08 The following diagrams show how the br
150. motor bushings Test run to verify proper high speed operation and RPM C Remove the drive housing sleeve and bushings Thoroughly clean the bushing and sleeve contact surfaces of all residue and old lubricant Re lubricate the bushing and sleeve contact surfaces with Bel Ray Termalene 699 grease Minn Kota p n 2307720 Reassemble the drive housing taking special care to properly realign the drive housing pins shafts motor and gears Prior to installing and tightening the six drive housing case screws test run the drive housing by applying 12 volts directly to the drive housing wire leads If the drive housing motor runs properly then make sure there are no gaps between the case halves a rubber mallet works well to seat the case halves flush tight Install and tighten case screws D Reassemble the drive housing to the bow plate extrusion assembly Slide the motor and tube through the drive housing Reconnect all wires in the control box and recalibrate AutoPilot compass see page 9 12 Test for proper operation PART Case VI AutoPilot function is erratic and doesn t maintain a heading Step 1 Make sure motor is mounted within 5 degrees of level and there is no ferrous metal object s near the motor that may be affecting the compass including screws and or nuts Step 2 Check motor for excessive vibration Inspect propeller and propeller shaft for damage Excessive vibration can cause the AutoPilot compass to oscillate causing e
151. n cell Replace battery if voltage is low Inspect the gold plated switch contacts on the transmitter circuit board for corrosion If any corrosion is noted replace the transmitter Clean the conductive rubber contacts on the transmitter switch pads with rubbing alcohol Reassemble and retest A If motor still does not respond to the remote transmitter try relearning the receiver to the transmitter B If motor still does not respond then reprogram relearn the receiver to a known good remote transmitter C If the CoPilot responds properly the customer s transmitter is faulty and needs to be replaced D If after learning or programming the receiver to the test transmitter it still does not function the CoPilot receiver board is faulty and needs to be replaced 18 1 CoPilot Wireless Accessory 02 08 08 Audio Pattern What Condition Causes It Occurs in Which Audio When receiver is powered up it sounds a beep pattern 1 long The foot pedal MOM CON Switch is in beep 2 short beeps pause the CON position All repeat second boe Every time the receiver is powered up 9 and there no remote IDs learned Foot pedal speed control is moved after Hear while holding down the learn button A basse After a remote button is pressed while All the receiver learns its ID Heard during the process used to clear all stored remote IDs After the learn A ten second long warbling sound that tr
152. n Position 2 Steering motor should pulse both clockwise and counter clockwise Steering should stop at center position of Switch A Step 7 If no steering is observed in Step 6 check continuity of brown yellow blue orange and white wires in the coil cord with the coil cord stretched out to length If continuity is not observed through each wire replace coil cord If there is continuity through each wire the main control board is defective and needs to be replaced Step 8 Turn AutoPilot ON OFF switch OFF Step 9 Turn Switch B to Position 2 Step 10 Turn the AutoPilot ON OFF switch ON and wait 2 seconds Step 11 Flip Switch A to Position 1 and then Position 2 Steering motor should pulse clockwise and counter clockwise Steering should stop at center position of Switch A Step 12 If Steps 6 7 and 11 work without fault the main control board is functioning properly and the compass sensor board assembly in the control head should be replaced AutoPilot Repair Manual 02 12 08 AutoPilot Calibration PRIOR TO 2001 MODELS ONLY Step 1 Place stall clamp on motor Step 2 Face the control head west Step 3 Turn foot pedal CON constant switch ON advance speed selector between speed 4 5 Watch the compass disc for movement Movement can be minimized by changing cross over point B up or down gradually tighten tie wrap as you calibrate If the compass disc moves clockwise the cross over point must be moved up You may fi
153. nal pedal tested bad then original foot pedal is faulty Disassemble faulty pedal to inspect if actuators are properly making contact on foot pedal board Visually inspect foot pedal control board for collapsed burnt dome switches or bad soft pot Replace foot pedal control board if necessary B If test pedal does not properly control propeller or if original pedal tests okay go to Step 3 Check to see if lower unit runs properly A Connect 12 volts directly to the red and black brush leads at the top of the motor shaft in the control box The motor should run If not a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as needed If the motor operates properly go to Step 4 Check for control board output by hooking up test light or V O M probes to board output terminals consult appropriate wiring diagram Use known good test pedal Connect battery leads to proper voltage Turn the foot pedal to CON constant ON and vary the speed selector If there is no control board output the main control board is defective Replace main control board PowerDrive Repair Manual 11 14 07 PART II Case III Foot pedal sticks right left when steering Step 1 Inspect actuators on underside of foot pedal for sand dirt grit A Disassemble and clean contaminated actuators Replace components as required Reassemble foot pedal leav
154. nd it helpful using a pair of brass needle nose pliers for these adjustments Step 4 Point the motor control head north Repeat the stall test while watching the compass disc usually very little adjustment is needed at this point If necessary adjust while gradually tightening tie wrap If excessive movement is noticed rotate the coil cord in area C the same direction as the movement to minimize magnetic interference from the coil cord Re check in west direction after this adjustment Step 5 Rotate motor to original position Clip end of cable tie Step 6 Remove stall clamp from motor Step 7 Re check AutoPilot function as directed in previous position Step 8 Apply hot glue around pig ring and attach control box cover When rechecking AutoPilot function assure motor finds it direction and doesn t over steer If necessary recalibrate compass Note You must use a non magnetic screwdriver and a good quality digital V O M in order to properly perform this procedure Use a V O M with a sharp probe on the red V O M lead as you will need to pierce through the humiseal coating on the compass control board to obtain accurate voltage readings In addition the compass must be in a level position and away from any ferrous metal steel objects or strong magnetic fields A small fixture such as the one shown in the accompanying diagrams will allow you to perform these adjustments on your bench top or if you wish the compass
155. nd slip steering potentiometer belt up and off of the primary gear Take care not to rotate the steering potentiometer C Remove the two Phillips Flathead countersunk screws that hold the primary gear assembly in the inner shaft Note Heat will be required to remove these screws as they are held in place with LocTite 14 9 Genesis Repair Manual 11 07 07 Step 3 Remove the primary gear and top bearing from the steering chassis Then remove the four screws that attach the steering chassis to the control box This will enable you to access the lift belt tensioner see figures below 14 10 Genesis Repair Manual 11 07 07 A Unscrew lift belt tension screw all the way while observing the lift belt tensioner Note how the tensioner engages the teeth on the upper end of the lift belt see below Step 4 Remove the four screws that attach the lower end of the lift belt to the outer shaft lower collar see below 14 11 Genesis Repair Manual 11 07 07 Butt the ends of the new and old lift belt together add a drop of super glue and securely tape them to each other as shown in the 3 figures below Note Be sure that the length of the new lift belt matches the shaft length of the motor being serviced 14 12 Genesis Repair Manual 11 07 07 B With the two belts glued and taped together push the belt into the bottom of the lift housing while at the same time pulling the lift belt out the opposite side of the li
156. nected to AP or CoPilot accessory Reconnect power or deploy motor to enable turn on the system ready LED and test motor for proper operation C 1 If motor AutoPilot functions do not operate go to Case III page 11 2 pertaining to AutoPilot malfunction C 2 If some other motor function now fails to operate suspect network interference from a faulty AutoPilot network accessory Replace AutoPilot compass control board and retest C 3 If motor functions properly and it is CoPilot equipped proceed to Step 2D D Disconnect power to motor or stow motor to disable turn off the system ready LED Connect the CoPilot network accessory to the network plug from the main control board if motor is so equipped Reconnect power or deploy motor to enable turn on the system ready LED and test motor for proper operation with foot pedal D 1 If motor now fails to respond to foot pedal commands or malfunctions in some other way the CoPilot receiver board is causing network interference and needs to be replaced D 2 If motor functions properly with foot pedal but fails to function or respond to the remote transmitter see Case VI on page 11 4 Terrova Manual 11 26 07 Case IX Foot pedal doesn t steer motor right left Step 1 Step 2 Check motor with known good test foot pedal A If test pedal properly steers motor A 1 On the customer s pedal inspect actuators on underside of foot pedal for sand dirt grit See page 11 7 for Foot Pedal C
157. ns reconnect motor leads and proceed to Step 3 Foot Control Cable Steer w Control Board Repair Manual 11 05 08 B If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes faulty brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation Step 3 If motor ran when the control board was bypassed remove the aluminum foot pedal base plate held in place with screws to expose the main control board Check to ensure that all wires are securely attached to the proper main control board terminals Consult appropriate wiring diagram for the motor being serviced Check for corroded connections A With power applied to the battery leads using a V O M verify appropriate voltage and proper polarity are present at the battery B and B terminals on the main control board Make corrections as needed B If proper voltage and polarity are found at Step 2A remove aluminum cover plate covering the MOM OFF CON switch wire connections Disconnect wire leads to switch and test switch for continuity B 1 If no continuity is found the switch is faulty and needs to be replaced B 2 If continuity is found across the switch reconnect the wires in their proper locations and proceed to Step 3C C With power applied to the battery leads using a V O M test output across main control board motor and m
158. ntrol board B Apply 12 volts directly to the lift motor leads Reverse polarity to reverse the direction of travel If the lift system works while bypassing the UP DOWN switches and control board go to Step 4C Ifthe lift motor fails to run it is faulty and needs to be replaced See Vantage Disassembly Procedure Steps 1 2 3 3C amp 3C 1 and exploded drawings at the end of this section B 2 If lift motor runs audible sound but motor does not deploy or stow the lift belt may be slipping due to improper tension see Vantage Disassembly Procedure Steps 1 2 3 3B 3B 1 amp 3B 2 the lift belt may be broken see Vantage Disassembly Procedure Steps 1 2 3 3C amp 3C 1 or the lift yoke is broken or stripped see Vantage Disassembly Procedure Steps 1 2 3 amp 3D C Check the switches for function and continuity C 1 Disconnect the black blue and orange coil cord wires With your V O M set to test continuity connect the black and orange wires coming from the handle assembly to the V O M probes while depressing the DOWN button a If no continuity is observed go to Case I Step 5 for handle disassembly inspection and control board replacement 7 2 C 2 b Vantage Repair Manual 06 30 08 If continuity is noted proceed to next step Disconnect the orange wire from the V O M and connect the blue wire in its place while depressing the UP button a b If no continuity is observed go to
159. ny lift system parts for later model Vantage motors Case II The motor runs but the stow and deploy system fails to operate Step 1 Check to ensure proper battery connections Consult appropriate wiring diagram for the model being serviced NOTE On the 24 and 36 volt models the black negative and the yellow battery lead must be connected to the negative and positive posts of battery 1 In addition the red positive battery lead must be connected to the positive post of battery 2 24 volt units or battery 3 on 36 volt models If the unit is not connected properly the power stow deploy feature will not operate Step 2 If lower unit is stuck in fully deployed down position press and hold both UP and DOWN switches simultaneously to re set system motor should start to lift immediately This should over ride the current limit circuit and return the motor lift system to normal operation Test unit for proper operation A If lift trim system is not corrected proceed to Step 3 Step 3 Remove extrusion shield p n 2050220 see figure 1 page 7 6 and check to ensure that all wires are connected to the proper control board terminals Consult appropriate Vantage wiring diagram Visually inspect terminals for corrosion clean if needed Step 4 Test lift system motor to see if it will run when the UP DOWN switches and control board are bypassed A Disconnect the black and white lift motor wires from the main co
160. off check resistance across the green and yellow coil cord wires Your V O M should indicate about 1 ohm Observe the V O M reading as the speed control knob is turned The resistance should increase from 1 ohm to ohm as the knob 15 turned to the highest speed setting C If your test resistance values differ greatly from those listed in Step 6A amp 6B or no resistance or continuity is noted go to Step 5 If the resistance values match those indicated here and the motor unit ran at Step 3A replace the main control board 1 1 Vantage Repair Manual 02 15 08 LIFT SYSTEM UPGRADE KIT NOTE If you encounter a lift system problem on any Vantage motor with a serial number MKAA1501460 or below check to see if the Vantage Lift System Upgrade Kit has been installed The upgrade kit consists of the parts shown in figure 7 page 7 9 Many Vantage motors have already been updated in the field with the new Lift System Upgrade Kit so the serial number may not always be a good indicator if the kit is required To determine if the motor being serviced has the upgrade kit examine the lift motor pulley The top of the pulley will be machined away to allow the larger diameter pulley flange to clear lift motor pulley shown with belt removed for clarity Vantage motors with a serial number MKAA1501460 or above will have the improved lift system already installed from the factory Use the upgrade parts list numbers when ordering a
161. oke p n 2051510 see figure 6 page 7 8 is broken or stripped further disassembly is required NOTE the Vantage motor uses a retractable tape spring to hold control the two conductor wire that goes to the motor lower unit The wire control system consists of two parts the wire clamp assembly p n 2053200 2053205 amp 2053417 and the tape spring assembly p n 2051900 2052305 2052610 2052705 amp 2053418 See figure 5 page 7 8 Both of these items are slid onto the raised rib located on the inside surface of the housing p n 2056505 The lower wire clamp is held in place by means of a small plastic finger that catches in a 4 diameter hole in the Vantage motor housing p n 2056505 The hole is located on the transom bracket side of the housing 9 inches down from the top Use a 1 4 diameter pin punch in this hole From the outside push in the end of the finger to release the lower wire clamp and slide it up and lift the tape spring assembly and wire clamp off of the rib Next while supporting the Vantage motor lower unit use the 5 16 nut driver to remove the four screws p n 2053414 that hold the lower support cage p n 2990420 assembly into the housing p n 2056505 After removing these four screws the entire motor lower unit and shaft lift screw p n N 2053400 lift screw yoke p n 2051510 and yoke bearing race p n 2056200 can be lowered out the bottom of the Vantage housing See figures 5 amp 6 page 7 8
162. oltage across the brown and orange wires connected to terminals on left side of contactor 4 1 If voltage equal to voltage of power source is noted but no audible click of the contactor engaging 1s heard then the main control board is good but the contactor 1s faulty and needs to be replaced d 2 If voltage equal to supply voltage of power source is not found the control board is at fault and needs to be replaced If audible click is heard when key switch is turned ON use a VOM to measure the voltage across the B and B board terminals This voltage should equal the voltage across the B terminal and the front post of the contactor If no voltage is measured then the contactor is faulty and needs to be replaced If in Step 5 F proper voltage and polarity was found at the B and B control board terminals when the key switch was turned ON but the throttle assembly LCD does not display the motor does not run when throttle lever is advanced the tilt system does not function and all throttle cable connectors pins and sockets have been examined and continuity checks performed then the main control board is faulty and needs to be replaced If in Step 5 F voltage was noted at the B and B control board terminals when the key switch was turned ON the throttle assembly LCD displays and the tilt system functions but the motor does not run when the throttle lever is advanced then check the main board output to the mo
163. oltage to motor while motor is under load AutoPilot steering is susceptible to erratic operation in low voltage situations Use of inadequate gauge wire in boat or any leadwire extension can result in voltage drop low voltage to the motor as can an inadequate or a corroded plug plug receptacle Step 4 Check continuity of brown red white and black small gauge wires in the coil cord with the coil cord stretched out to length If you find a break in continuity in any of these wires the coil cord is defective Replace coil cord if required See page 9 4 for the specific effects of broken intermittent coil cord wires Step 5 Replace compass control board assembly with latest part Ensure the red and black leads from the lower unit and the leads from the coil cord are twisted as per the following picture PART I Case AutoPilot changes directions with speed changes Step 1 Small direction changes with speed changes are normal Step 2 If direction changes are significant perform the AutoPilot Calibration Procedure see page 9 5 PART I Case VIII Foot pedal sticks right left when steering Step 1 Inspect actuators on underside of foot pedal for sand dirt grit A Disassemble and clean contaminated actuators Replace components if required B Reassemble foot pedal leave actuators dry or use a dry lubricant to avoid further contamination with sand dirt grit PART I Case IX MOM CON switch lever will not sta
164. ompensating magnet bracket remove the compass bracket screw item 32 on the Base Housing parts explosion and position the compensating magnet bracket in place below the AutoPilot compass mounting bracket Reinstall the bracket screw to hold both the compass bracket and the compensating magnet bracket in place Do not install the 2 magnet rods at this time Install the compass assembly on the compass bracket re use the orange grommets from the old compass Install the encoder writing on the encoder to face up and LCD in their places Reinstall the center display housing LCD and right sideplate Proceed to the Initial Board Programming Procedure page 14 27 14 26 Genesis Repair Manual 11 07 07 GENESIS Control Board Initial Programming Procedure We recommend that you have and use the specially modified Genesis Test Foot Pedal p n 2772040T when doing this procedure NOTE These steps should not be done in bright sunlight or under bright fluorescent lighting with the left sideplate covers the encoder removed The bright light can give false information to the encoder Initial Programming Ste DS Motor must be connected to appropriate voltage Step 1 Readying the motor for Initial Control Board Programming A Perform the complete Master Reset Emergency Stow Procedure to set the shaft position counter see page 14 21 B Turn the Master Switch back ON C Deploy the motor by pressing the Mode Switch D Turn the Ma
165. on Right park position is motor lower unit at a 90 9 angle to the Genesis base housing with the prop pointing to right when viewing the LCD G Press Momentary ON switch located on the heel toe steering pedal once to enter this setting into the main board memory Set the Shaft Length after setting the Park Positions the shaft length setting will display A Use the right momentary steering switch to toggle through the shaft lengths until the correct shaft length for the motor is displayed 45 52 or 60 Press the Momentary ON switch located on the heel toe pedal once to enter this correct setting into the main board memory NOTE if the shaft length is already set correctly the TrimUp switch may be pressed to skip or toggle through this portion of the procedure The TrimUp switch may be pressed to toggle through the Lift Motor Condition and Offset Tables After toggling through the Offset Table portion the LCD on the motor will display Turn the Master Switch OFF to lock all steps of this procedure in the main board memory and to return motor to normal operating mode Test motor for proper operation 14 6 Genesis Repair Manual 11 07 07 GENESIS Lift System Trim System Module Case I Motor makes loud ratcheting sound when deploying stowing ER6 may display Step 1 Check lift belt tension for proper adjustment A With the motor in the DEPLOYED position trim the motor to its highest trim hei
166. ontinuity from one section to the next going around the circumference of the commutator Replace armature if no continuity is found B 3 Examine commutator section tangs that connect armature windings to each commutator section Each tang should be pressed down flush to the brush surface of the commutator section If any space is noted between the tang and the commutator the potential for an intermittent electrical connection exists and the armature needs to be replaced If the armature tested fine in Steps B 1 through B 3 then just replace the armature bearing only A bearing puller should be used to remove the rough bearing from the armature when installing new bearing p n 140 010 Press or drive on inner race only when seating new bearing on shaft 1 5 Lower Unit Repair 09 08 08 Case IX Motor vibrating excessively Step 1 Possible causes include A Prop pin bent B Prop damaged or out of balance Due to variables in materials leading edge differences and tolerance variations some vibrations can be attributed to the prop An easy fix is to B 1 Disconnect leads from the battery B 2 Remove the prop nut keeping the prop pin horizontal B 3 Remove the prop B 4 Rotate the prop 180 degrees from the original position B 5 Re install the prop and prop nut B 6 Re test motor in water test tank If vibration is not cured replace with new propeller and re test If excessive vibration is stil
167. operate Step 1 Consult Chapter 9 AutoPilot Model Part II CaseVI on page 9 9 for troubleshooting steps and compass isolation test NOTE motor must be initialized properly first Be sure both switches are turned ON The RF motor switch is the switch with the wires that run closer to the heat transfer bar Case IV Over steer Step 1 Check for old software see Software for Cordless Motors below Case V Delay in speed function prop Step 1 Check for old software See Software for Cordless Motors below Software for Cordless Motors 48PD AP C RT42AP C 2303926 2774709 RT48AP C 2303926 2774709 early units were shipped with 2303923 receiver and 2994705 foot pedal early units were shipped with 2303924 receiver and 2994705 foot pedal the 2774708 new foot pedal has a black label with white letters on the bottom of the pedal versus the 2774705 old pedal which had a white label with black lettering MKA 9 2303925 2774708 Case VI Foot pedal sticks right left when steering Step 1 Inspect actuators on underside of foot pedal for sand dirt grit Disassemble and clean contaminated actuators inspect for repair and replace components if required B Reassemble foot pedal leave actuators dry or use a dry lubricant to avoid further contamination with sand dirt grit NOTE If foot pedal sticks while customer 15 fishing may simply swish the foot pedal in the water to temporarily flush the sand di
168. ot pedal plug There is also a CoPilot system for V2 PowerDrive units and Terrova models CoPilot will not affect AutoPilot operation Up to 10 remotes may be used interchangeably with the same receiver The CoPilot provides finer steering control than the corded foot pedal The receiver and remote are environmentally sealed and will not be affected by rain wind or snow System includes three rod mounts which allows the angler to move the remote from rod to rod MISCELLANEOUS INFORMATION The five buttons are for PROP ON OFF STEER LEFT STEER RIGHT INCREASE SPEED and DECREASE SPEED Terrova CoPilot has two additional buttons HIGH BYPASS and AUTOPILOT ON OFF If the Terrova model does not have AutoPilot the AUTOPILOT ON OFF button will be non functional ePressing the PROP ON OFF button will turn the propeller on or off The button does not need to be held down Press the button once to turn the motor ON press button a second time to turn it OFF Pressing either STEERING button will cause the motor to turn in the desired direction as long as the button is held down If a steering button is held for more than seven seconds the steering will automatically stop Pressing and releasing the INCREASE SPEED or DECREASE SPEED buttons will cause the speed to increase or decrease by one level The speed is adjustable from level 0 10 The prop will not turn at level 0 GENERAL OPERATION using the CoPilot with the corded foot p
169. otor M and M terminals NOTE Place MOM OFF CON switch in the CON mode and the speed selector in the 10 100 range for this test C 1 If no output is noted across the M and M terminals the control board is faulty and needs to be replaced C 2 If output is found across the M and M terminals test for output at the red and black motor leads in the control box If no output is noted at the red and black leads the problem is in the wiring harness from the foot pedal to the control box Repair replace as needed and test motor for proper operation This Case applies to motors with the magnetic on off reed switch system Case III With speed selector in the 10 100 setting motor runs in CON continuous mode but not in MOM momentary mode when the push button is depressed Step 1 Check to ensure the reed switch is properly positioned in the reed switch clip Remove the push button magnet assembly P N 2993702 to visually check this The tip of the reed switch reed switch is a small plastic cylinder with two wires attached should be flush with the recessed area of the reed switch clip Re position reed switch if required See installation instructions that come with P N 2884052 control board kit for clarification and reference Step 2 Check push button magnet assembly to ensure the small magnet rod on the underside of the push button is in place On motors with the new ON OFF magnetic reed switch a small rod magnet is use
170. otor Upon motor deployment with appropriate voltage and polarity applied to the motor battery leads the green System Ready LED will illuminate At this time the microprocessor on the main control board checks for any network accessories foot pedal AutoPilot or CoPilot that could be connected to the main control board If the microprocessor on the main board is getting an incorrect reading at this time or if the AutoPilot or CoPilot network accessory 15 not properly connected the microprocessor will not recognize the accessory and that accessory function will not be enabled A faulty network accessory can also cause Terrova motor malfunctions due to network interference When servicing Terrova motors disassembling removing adding network accessories power to the motor should be disconnected and or the motor should be stowed green system ready LED not lit We recommend having a known good foot pedal and Terrova CoPilot transmitter to aid in troubleshooting Case I Motor is non functional all functions dead Step 1 The motor must be in the deployed position for motor to function The Terrova motor is equipped with a green system ready LED indicator that should only be on when the motor is deployed When the motor is properly stowed this system ready light will be off indicating that the motor is not ready for use and is not operable Step 2 Check to ensure proper voltage and polarity at battery Inspect all battery connections tro
171. ousing should reverse the direction of rotation Repair or replace drive housing if required If drive housing tests Okay proceed to next step Step 4 Check continuity of the individual coil cord wires with the coil cord stretched out to length If you find a break in continuity in any of these wires the coil cord is defective Replace coil cord if required See page 9 4 for the specific effects of broken intermittent coil cord wires Step 5 If above steps test fine the AutoPilot compass control board assembly in the upper control box is faulty Replace compass board assembly PART I Case II Motor steers slowly at higher thrust settings Step 1 Inspect all battery connections trolling motor plug if installed and any butt splice connections in the battery leadwire for corrosion and security Step 2 Check to insure that wire of adequate gauge has been used in the boat s trolling motor circuit Wiring of inadequate gauge will result in a voltage drop to the motor and steering circuit at higher thrust settings If after insuring that all wiring and connections are good the steering is still slow at high thrust proceed to Step 3 9 1 AutoPilot Repair Manual 02 12 08 Step 3 Disassemble motor to separate the drive housing from the motor and tube and bowplate extrusion assembly A Remove the six screws holding the top and bottom halves of the drive housing together Note the top and bottom halves of the drive housing are
172. ove the drive housing sleeve and bushings Thoroughly clean the bushing and sleeve contact surfaces of all residue and old lubricant Re lubricate the bushing and sleeve contact surfaces with Schaeffer s 4238 Moly Ultra Supreme grease Minn Kota p n 2307720 Reassemble the drive housing taking special care to properly realign the drive housing pins shafts motor and gears Prior to installing and tightening the six drive housing case screws test run the drive housing by applying 12 volts directly to the drive housing wire leads If the drive housing motor runs properly then make sure there are no gaps between the case halves case halves a rubber mallet works well to seat the case halves flush tight Install and tighten case screws D Reassemble the drive housing to the bow plate extrusion assembly Slide the motor and tube through the drive housing Reconnect wires in the control box Test operation of reassembled motor to complete the repair PART II Case VI Motor is loose in the cradle Step 1 Check replace the pivot pads P N 2305101 as needed The pads tend to take a set over time Step 2 If unit being serviced is a year 2001 or later Grip Glide unit ensure the Grip Glide latch handle firmly engages the latch collar on the composite shaft A Loosen latch collar clamping screw Rotate the latch collar clockwise on the shaft when viewed from above to screw the latch collar down towards the motor lower unit The collar and s
173. over and the system ready reed switch located in the extrusion 11 6 Terrova Manual 11 16 07 Foot Pedal Cleaning Procedure Step 1 Turn the foot pedal upside down and remove the two screws shown with a 2 Phillips screwdriver peso E Terrova Manual 11 16 07 Step 3 Check for rocks twigs sand or other debris that may be lodged under buttons or button arms The foot pedal is water proof and can be sprayed off or submerged in water to remove any foreign objects such as sand and rocks uti AL 1 uM D ee TET on E UNA j d V g 1 VA 4 E ed i i h E f A A rn T Check for debris stuck between buttons and pedal cover Check for debris under button arms Below are pictures of typical locations debris can reside which may cause undesirable foot pedal operation Rock stuck under button arm Rock stuck between button and cover Step 4 Once the foot pedal is clean the heel toe pedal can be reinstalled with the original springs and Phillips screws Foot Control Cable Steer w Speed Coil Repair Manual 01 31 08 Chapter 12 Foot Control Cable Steer Models with a Speed Coil Case I Motor fails to run Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Check battery connections circuit breakers trolling motor plug if customer has installed a plug and any butt splice connections in the battery leadwire Remove the control box co
174. pinned together at the corners with roll pins The two halves will need to be pried apart B Inspect the drive housing motor paying special attention to the drive housing motor armature shaft and motor bushings Test run to verify proper high speed operation and RPM Remove the drive housing sleeve bushings Thoroughly clean the bushing and sleeve contact surfaces of all residue and old lubricant Re lubricate the bushing and sleeve contact surfaces with Bel Ray Termalene 699 grease Minn Kota p n 2307720 Reassemble the drive housing taking special care to properly realign the drive housing pins shafts motor and gears Prior to installing and tightening the six drive housing case screws test run the drive housing by applying 12 volts directly to the drive housing wire leads If the drive housing motor runs properly then make sure there are no gaps between the case halves a rubber mallet works well to seat the case halves flush tight Install and tighten case screws D Reassemble the drive housing to the bow plate extrusion assembly Slide the motor and tube through the drive housing Reconnect all wires in the control box Test for proper operation PART I Case III All functions are dead Step 1 Check for proper battery voltage and polarity at the control board input terminals Visually check for poor or corroded connections Check for proper wiring of control board consult appropriate wiring diagram Step 2 Defec
175. r function Case II If motor displays ER6 and lift system checks out O K the shaft position counter may be out of place Step 1 Remove left sideplate of Genesis motor by removing the two sideplate screws item 37 and the small screw in front item 38 See the AP PD Base Housing parts explosion A Note location of encoder wheel item 24 and examine encoder wheel counter It is the small U shaped device with two wires attached A 1 certain that the counter is properly snapped in to place and hold in the encoder bracket item 25 If counter is not properly installed it will be unable to count the revolutions of the encoder wheel and the motor will not correctly stow or deploy A 2 Correct any errors noted and retest motor for proper function It may be necessary to perform the Master Reset Emergency Stow Procedure to reset shaft position counter see page 14 21 14 16 Genesis Repair Manual 11 07 07 GENESIS Foot Pedal Module Current Genesis foot pedals have a sticker indicating the manufacture date of the pedal Julian date code It is on a label on the bottom side of the pedal Any foot pedal that does not have this label or has the Julian date code plus INT xxxxxxxINT should automatically be replaced under warranty with a current design This will address most of the foot pedals issues Case I When Master Switch is turned ON the LCD briefly displays 1 2 hour
176. r is isolated from other outputs and the input This means you do not need to connect the grounds of the starting battery to the auxiliary deep cycle batteries like you would on other DC charging systems Connecting the starting battery and deep cycle grounds can cause interference on integrated sonar systems However the Minn Kota DC chargers will still operate correctly if the grounds on your boat are connected Q Can the Minn Kota DC alternator chargers be used on my boat where I have a battery selector switch installed A Yes the DC charger can be used with a battery selector switch The selector switch allows the user to connect a deep cycle battery in parallel with the starting battery The DC charger input and outputs are isolated and will work with the selector switch connecting batteries together 20 3
177. rd output the main control board is defective 3X Steering Repair Manual 11 06 07 Chapter 6 3X Steering For the one time procedure to initially orient straight ahead on bowmount 3X models go to page 6 10 for BowGuard 360 models or page 6 12 for units with latch amp door brackets Case I Directional Indicator always stays lit This reed switch is usually open With the handle bar magnet in close proximity to the reed switch the reed switch contacts will close and disengage power to the PWM circuit Removing the bar magnet from close proximity to the reed switch will open the switch contacts energize the PWM circuit and light the directional indicator Step 1 Check to ensure that the magnet is in place in the handle pivot assembly Step 2 Check to ensure that the sensor bracket and on off reed switch are in the proper position Case II Steering is squeaky Step 1 Replace the gear carrier P N 2072210 and gear carrier bearing P N 2077320 See disassembly reassembly instructions below Disassembly Reassembly Procedures The complete disassembly reassembly procedures listed here will aid the repair center when repairing any 3X Minn Kota motor We suggest that this entire 3X repair section be read prior to starting a 3X repair procedure NOTE The basic disassembly reassembly procedures outlines in this section apply to both transom and bowmount freshwater and saltwater RipTide 3X motors Fig 1 Fig 2
178. removed to expose the Genesis primary gear and potentiometer belt A B C Slip the belt off the primary gear and steering potentiometer gear Turn steering potentiometer counter clockwise to its rotational stop From the rotation stop turn the potentiometer exactly five complete turns clockwise and slip the belt back onto the steering potentiometer and primary gear without turning the steering potentiometer or lower motor assembly out of position Turn Master Switch ON and deploy motor if stowed to test steering function Step 3 Press and hold the Mode Switch down for two seconds to initiate the stow sequence A If motor does not turn and position itself in the park left right position motor MUST be at a 90 angle to the bowmount base housing to properly stow stop the stow sequence by pressing and releasing any foot pedal switch Turn Master Switch OFF Slip the steering potentiometer belt off the primary gear and steering potentiometer With the belt removed physically rotate the lower unit into the proper park position steering clutch will slip Then place the steering potentiometer belt back onto the primary gear and steering potentiometer taking care not to move the potentiometer from its current position Step 4 Turn Master Switch ON and press the TrimDown button to fully deploy the motor When the LCD again displays the hours running time press and hold the Mode Switch for 2 seconds to initiate stow sequenc
179. rom the motor control box end Push the new assembly through cable jacket Before replacing the cable drum pulley rotate the motor shaft to point the motor straight ahead and adjust the foot pedal so the top of the foot pedal is level Install replacement cable assembly in reverse order pis the core tension by tightening cable adjusting screw so the motor is held stationary and the foot pedal has ree play Test for proper 360 steering action and ease of operation Diagram 2 The left cable when viewed from above the control box is a few inches longer because it needs to wrap around the pulley in the foot pedal right side when viewed from underside of pedal 13 6 Genesis Repair Manual 11 07 07 Chapter 14 Genesis Tools Required for Servicing Genesis motors gt Test Foot Pedal Minn Kota p n 2772040T has trim actuator removed for programming purposes Mini Butane Torch Kit can be purchased over the Internet from MicroFlame www microflame com or equivalent gt 360 Rotatable Repair Stand non ferrous material for AutoPilot calibration gt Quick Release Mount Minn Kota p n 2771895 to mount to your rotatable stand gt Loctite 603 gt V O M multi meter gt Allen Wrench 050 Steering System Module page 14 3 Lift System Trim System Module page 14 7 AP PD Housing Module
180. ror of less than 20 Adjust the E W compensating rod as needed with a non magnetic screwdriver to reduce the amount of error H 1 Rotate the motor base extrusion and stand back to the west LCD to the east Observe motor lower unit to confirm that the amount of error when pointing west is less than 20 Repeat Steps 3G amp 3H if needed If AutoPilot functions properly and tests within the limits specified in Steps 3 D through 3 H place a drop of super glue on the E W compensating magnet rod support to lock it in place Install the modified notched sideplate taking care not to bump or move the compensating magnet rods out of position Test the AutoPilot function with the sideplate in place over the compass J 1 If it tests within the limits specified in Steps 3 D through 3 G this procedure is completed J 2 If the motor does not test within these limits adjust the compensating magnet rods until the AutoPilot tests fine i e repeat Step 3 above 14 30 Genesis Repair Manual 11 07 07 Step 4 Spin the base of the motor a complete revolution and ensure the internal compass card 1s spinning freely not hanging up or sticking in any direction Step 5 Early Genesis models did not have compensating magnets under the compass assembly We recommend installation of the compensating magnets and bracket assembly p n 2881937 Step 6 Recalibrate AutoPilot Compass Software as outlined on pages 14 29 and 14 30 Note do not inst
181. rratic operation Step 3 Check for proper voltage to motor while motor is under load AutoPilot steering is susceptible to erratic operation in low voltage situations Use of inadequate gauge wire in boat or any leadwire extension can result in voltage drop low voltage to the motor as can an inadequate or corroded plug plug receptacle Step 4 Check continuity of brown yellow blue orange and white wires in the coil cord with the coil cord stretched out to length If you find a break in continuity in any of these wires the coil cord is defective Replace coil cord if required Step 5 Check AutoPilot compass control board for proper voltage levels at the optical sensor circuit See Minn Kota Service Repair Bulletin 58 122099 AutoPilot Compass Control Board Trim Pot Adjustment Procedure page 9 13 Step 6 Perform the Control Board Compass Isolation Test following the procedure provided with the AutoPilot Test Board Minn Kota P N 20 see page 9 11 If operation is restored replace the sensor board compass assembly If it isn t restored replace the main control board AutoPilot Repair Manual 02 12 08 PART II Case VII Motor lower unit fails to run or runs intermittently Step 1 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for corroded connections Clean rewir
182. rt grit from the actuator surfaces Case IV MOM CON switch lever will not stay down in CON position Step 1 From the underside of the footpedal remove the 3 screws holding the slide control and switch lever in place A Remove screw holding the white plastic continuous actuator in place Place shim P N 2301731 between actuator and foot pedal base C Reassemble slide control MOM CON switch assembly and test for proper operation 10 2 Cordless Motors Repair Manual 02 20 08 Cordless AutoPilot Test Pedal Orange 7 conductor 7 pia plug from faulty main circuit board of a corded powerdrive motor prop relay must bo energized for the steering to Set the speed control 0 and sel the mom con switch to con The steering circuit will be enabled and will steer right or left Once the con switch is turned off the steering will no longer operate 8 conductar 8 pin plug from a faulty 2303923 2303924 2303926 2303927 receiver side plate CORDLESS AUTOPILOT TEST PEDAL 10 3 Terrova Manual 11 16 07 Chapter 11 Terrova Models All Terrova motors rely on a microprocessor based network serving as the communication link between the main control board and network accessories such as the foot pedal AutoPilot compass control board and CoPilot receiver board if the motor is so equipped Any failure in this communication link can cause problems for the Terrova m
183. ry Step 2 Disconnect motor leads from control module and connect motor leads to 12 volt power source This applies to 12 or 24 volt models A If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes bad brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation If motor ran when motor leads were connected directly to 12vdc the problem is either with the hand controller or control module B 1 Test hand controller Hand Controller Test Procedure The test procedure for the hand controller is performed with your V O M set on the Resistance x 1 scale With the speed control zero across the brown and green pins you should have approximately 1 2 ohms As the speed control is turned the resistance will gradually increase to With the F R switch in the Forward position you should see continuity across the black and white wire pins With the F R switch in Reverse you should see continuity across the black and yellow wire pin locations orange brown green 1K ohm potentiometer Black wire Green wire Brown Yellow wire wire White wire Orange wire NI Plug End O O Hand Controller Plug End Pin End View B 2 If the hand controller tests okay the problem is with the control module or splitter Test control module s to ver
184. s then goes blank and motor will not do anything Step 1 Check all battery connections for proper voltage security polarity and corrosion Correct as required Step 2 If all connections check okay test Master Switch by turning it part way on Turn the switch on but do not push the switch rocker to the full extent of its travel A If the LCD now stays on displays LP 1 2 then 99 9 with the speed selector set to off then the Master Switch is faulty and the foot pedal p n 2772040 needs to be replaced B Replace foot pedal assembly with latest part from Minn Kota and test all motor functions for proper operation with new pedal Case II When Master Switch is turned on the LCD briefly displays LP 1 2 hrs then 99 9 hrs with speed selector set to off and stays on 99 9 hrs but goes blank when the mode switch is depressed Step 1 Check all battery connections for proper voltage security polarity and corrosion Correct any faults and retest Step 2 If all connections and voltage check okay retest Master Switch by turning switch part way on and then depressing mode switch to deploy motor A If unit now deploys and LCD stays on the Master Switch is intermittent and the foot pedal p n 2772040 needs to be replaced B Replace foot pedal assembly with latest part from Minn Kota and test all motor functions for proper operation with new pedal Case III When in AutoPilot mode and or when MOM CO
185. s bad brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation B If motor does run go to Step 2 Step 2 Check control module plug end pins for corrosion Clean if needed reconnect and test again for proper operation If both motors still do not run go to Step 3 Step 3 If test was done correctly the control module could be faulty test control module to verify problem A Connect control module to appropriate power source Plug in hand controller to control module Check for voltage at module output leads by hooking up a test light or motor to control module output leads Vary the potentiometer speed control setting Test light or motor should vary in intensity or speed with the potentiometer setting NOTE VOM usage not recommended as it will not show a varying voltage due to pulsed PWM output from control module With PWM output voltage does not vary only the length of time between pulses varies Replace control module as necessary 16 2 EM amp EP 01 31 08 PART II All Neptune EP and EM motors manufactured prior to year 2006 s n AF and earlier Part II Case I Motor does not run Step 1 Check for proper voltage and polarity Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for any corroded connections Clean rewire if necessa
186. s to the following colored wires red pin transducer black pin 3 transducer yellow pin 2 thermistor brown pin 4 thermistor and shield B The resistance at normal room temperature approximately 70 should be between 9K 11K ohms for each of the two temp pins The reading will vary slightly as the ambient room temp varies The transducer is defective and needs to be replaced if the readings do not fall within this range at normal room temperature 3 2 Minn Kota Universal Sonar Models 01 24 08 gt 5 SHIELD figure 1 Case V US2 connector adapter plug getting hot US2 motors have internal bonding grounding wire connections to eliminate depth finder interference This internal bonding grounding wire links the trolling motor negative to depth finder battery negative starting battery negative The combination of US2 motor internal bonding and the external ground connections could cause a shorted condition This could result in damage to the motor that would not be covered by Minn Kota s warranty We have received a few calls regarding the metal US2 connector adapter plug getting hot You can trace this to one of the following situations 1 Depthfinder hooked to trolling motor battery The depthfinder needs to be powered by the crank starting battery 2 The use of DC alternator charger Some of these chargers link the trolling motor battery negative post to the starting battery w
187. se II DeckHand does not have enough power to lift anchor vou need to hel by pulling up and feeding rope into winch as it lifts Step 1 Check to ensure proper voltage Inspect battery connections and any butt splice connections in battery leadwire for corrosion and security Step 2 Check for proper voltage to motor while DeckHand is under load Use of adequate gauge wire in boat or any leadwire extension is critical to avoid voltage drop low voltage to the motor Inadequate wiring or corroded plug plug receptacle connections can result in considerable voltage loss and poor performance Step 3 Possible problem with the drive gear P N 350 154 in the gear motor Remove the gear motor from the side of the base Remove the housing cover gasket so that you can inspect the drive gear P N 350 154 A Ifthe drive gear is cracked broken or stripped replace drive gear grease new gear liberally with wheel bearing grease Reassemble unit and test for proper operation NOTE If new gear seems very tight you may need to ream out the center hole of the gear with a 21 64 drill bit Case III DeckHand lowers anchor then immediately lifts anchor or vice versa Step 1 Possible knot in rope on spool If the rope is caught by a knot or part of the rope is buried in the layered wrappings of the rope the spool will be turning the proper direction but the rope will reverse when it catches the knot A Remove cover from DeckHand base B Feed o
188. se cover and check connections at MOM OFF CON switch Check MOM OFF CON switch for continuity across center terminal to momentary terminal white wire with switch in the MOM position If no continuity replace MOM OFF CON switch Test motor for proper operation Case II Motor operates on some speeds not on others Step 1 Check to see if all wires are securely attached to the proper switch terminals Step 2 Check speed coil functionality A B C D E F Remove the control box cover Disconnect wires from the foot pedal from the wires to the lower unit Connect 12 volts to the black motor brush lead Connect 12 volts to each colored speed coil wire coming up from the motor tube The motor should run on the separate speed designations as you make each connection If the motor fails to run as you touch any of the colored speed coil wires the problem is either 1 the speed coil is faulty and needs to be replaced or 2 the speed coil jumper wire is not connected to the back of the brush plate in the lower unit If the motor runs as you touch the 12 volt lead to some of the colored speed coil wires but not all the speed coil wires the speed coil 1s faulty and needs to be replaced If the motor runs as you touch the 12 volt lead to each speed coil wire proceed to Step 3 Step 3 Speed switch is defective Replace speed switch Test motor for proper operation Case III Motor works at all speed settings but th
189. shaft does not turn with the pinion gear the drive lock pin p n 2052615 is broken and needs to be replaced See Disassembly Steps 1 2 3 amp 3A Step 1 Step 2 Step 3 Vantage Repair Manual 02 15 08 Vantage Disassembly Reassembly Remove extrusion shield p n 2050220 pointer plug p n 2056700 and the pointer knob p n 2050100 Remove the leadwire clamps located on the side of the housing using a long shank phillip s screwdriver Then remove the four screws which hold the control head shroud p n 2050210 in place and disconnect the two indicator lights from the shroud Note the position of the light with black wires and the light with the white wires for proper reassembly black wire light is motor white wire light is power indicator See figure 1 page 7 6 Remove the three phillip s head screws p n 2053415 holding the control head cover assembly p n 2050200 in place Lift the cover off Remove the latch p n 2057500 the latch return spring p n 2052711 and the steering shaft roller p n 2052210 NOTE for reassembly the small end of the steering shaft roller must be pointed down Disconnect the coil cord wires from the main control board Using a 9 16 socket or box end wrench unscrew the top lock nut p n 2053107 Remove the flat and cup washers Lift off the gear housing upper cap p n 2056510 and gear housing ring Unscrew the three screws p n 2053402 and remove the lower gear housing cap p n 20
190. side down B 1 On 4 motors the red brush lead is on the bottom opposite on smaller motors B 2 On 4 Terrova motors the red brush is on the right side when viewing the brush plate from opposite the prop side Magnet shell upside down on 3 14 or 3 5 8 motor assemblies the marking notch should be on the bottom towards the skeg Case VII Motor is noisy Step 1 Possible causes A p K Water in lower unit Broken brush plate Grease or replace spherical or flange bearing Chipped broken brushes new brushes may take a few hours of operation to seat or round to the commutator and quiet down Ensure rear seal shield 3 4 and 3 5 8 motors only is securely in place and not squealing or rubbing against armature shaft Chipped broken magnets a rule of thumb 15 if the magnet that chips out is less than square inch the magnet shell is still functional On 4 motors bung on magnet center section pull up lightly on brush wires to ensure all slack is out of lower area so armature does not rub on the slack from the brush leads Rough worn commutator where brushes ride on armature Smooth with fine sandpaper or emery cloth If scratched too deeply replace armature Ensure the E ring is securely snapped into place behind commutator Engine Mount models utilize a bushing instead of the E ring The motors are timed Before you open a lower unit it is a good idea to use a
191. steers properly but motor lower unit does not run Step 1 Step 2 Step 3 Step 4 Check for proper voltage and polarity at the control board input terminals Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for corroded connections Clean rewire properly if necessary Check motor with known good test foot pedal A If test pedal properly controls all motor functions the original foot pedal is faulty Replace foot pedal B If motor lower unit does not run properly with test pedal proceed to Step 3 Check to see if lower unit runs properly A Connect 12 volts directly to the red and black brush leads at the top of the motor shaft in the control box The motor should run If not a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as necessary If the motor operates properly proceed to Step 4 If Steps 1 2 and 3 test okay the main control board is faulty and needs to be replaced See Case X on page 11 6 for information on Control Board Replacement Case VI Terrova motor equipped with CoPilot but CoPilot doesn t work Step 1 Step 2 Remove right motor sideplate and inspect network connection from CoPilot receiver board to main control board Check to ensure that the plug pins are not bent and th
192. ster Switch OFF Step 2 Setting Left and Right Park Positions A Using the test foot pedal p n 2772040T press and hold both the TrimUp and TrimDown buttons while turning the Master Switch ON then release both trim buttons B LCD display on motor should read LFT B 1 If LCD shows SET PROPELLER turn pedal OFF and return to Step 1 above B 2 If LCD shows SET STRAIGHT AHEAD then both TrimUp and TrimDown buttons were not pushed simultaneously Turn pedal off and return to Step 1 above C Use momentary steering switches to place motor lower unit in propeller left park position Left park position is motor lower unit at a 90 angle to the Genesis base housing with the prop pointing to the left when viewing the LCD D Using care not to adjust the footpedal rocker steering position press the Momentary ON switch located on heel toe steering pedal once to enter this setting into the main board memory E LCD on motor should now read Rt F NOTE In this step the motor lower unit must be rotated counterclockwise when looking down at the motor lower unit Use the Left Momentary Steering Switch to rotate motor lower unit from left park position to right park position Right park position 1s motor lower unit at a 90 angle to the Genesis base housing with the prop pointing to right when viewing the LCD G Using care not to adjust the footpedal rocker steering position press Momentary ON switch located on t
193. t Pedal Module page 14 17 and or AutoPilot Steering Malfunction page 14 31 Case I Steering Motor tries to run audible ticking sound in control box but motor does not steer steering is jammed Step 1 Remove Genesis control box cover and visually inspect the two flathead countersunk screws that hold the primary gear into the inner shaft tube items 49 of the Steering Module parts explosion These two screws must be flush with the aluminum locking collar on the inner shaft tube If they are not flush with the outer surface of the locking collar the steering system will bind and will not steer This will also affect the stow deploy sequence of the Genesis motor as the unit must be able to steer in order to properly deploy and stow If screws are loose remove them one at a time and visually inspect the screw threads and the threads in the primary gear A A 1 A 2 If threads are O K in both parts reassemble with Loctite 603 amp primer on threads of retaining screws and fully tighten to seat screws so they are flush with the outer surface of the aluminum locking collar If threads in primary gear or on retaining screws are stripped or cross threaded replace them with new parts Use Loctite 603 amp primer when reassembling the primary gear locking collar and retaining screws Be sure to fully tighten the retaining screws so that the heads are flush with the surface of the locking collar See Genesis Transducer Rout
194. t be floating level and there are no ferrous metal objects near the motor that may be affecting the compass including screws nuts While maintaining a level compass spin the control box and observe the compass card The card should remain stationary 1 e card should not have lost its system ready north reference as the control box is turned If the compass card sticks or hangs up it is faulty and the compass assembly needs to be replaced A Inspect oil level in compass capsule looking for a leaky capsule NOTE Examine the red compass grommets If the compass has leaked fluid the grommets will be swollen almost double their normal size B If any sign of compass fluid leakage is evident replace the compass control board assembly Check motor for excessive vibration Inspect propeller and propeller shaft for damage Excessive vibration can cause the AutoPilot compass to oscillate causing erratic operation Check for proper voltage to motor while motor is under load AutoPilot steering is susceptible to erratic operation in low voltage situations Use wire of adequate gauge in boat or for any leadwire extension to avoid voltage drop low voltage to the motor Also check for an inadequate or a corroded battery leadwire plug plug receptacle Correct any low voltage issues and retest If in previous steps no problems were noted but AutoPilot still does not function properly then replace the compass control board assembly Case V Motor
195. t detent spring P N 2072705 towards the nose of the motor lower unit C Align the two pinion gear teeth with the raised bumps on bow mount 3X models these two teeth will be oriented toward the prop end of the motor lower unit with the timing mark in the gear carrier NOTE The timing mark used for bow mount 3X models is a raised bump on the gear tooth Located in the 12 00 o clock position when the gear carrier is held with the detent spring towards the viewer and viewed from above see Fig 7 Handle and propeller on this end Lower unit motor assembly points this way Fig 7 Step 6 With the gear carrier in its proper location and position relative to the appropriate timing marks re install the socket head cap screw P N 2073400 and washers Blue LocTite is recommended on this screw Tighten screw with a 5 32 allen wrench driver A Re install the two 86 20 x 5 8 phillips head screws P N 2303412 and washers P N 2071714 that retain guide the gear carrier on the pivot yoke Step 7 Re install the control box with bushing and pivot knobs on to the gear carrier pivot yoke assembly see Fig 4 page 6 3 A Position the control box so that the handle end of the box is opposite the tilt detent spring in the gear carrier 6 7 3X Steering Repair Manual 11 06 07 Examine the pivot knobs in the area where they contact the gear carrier Note the two flat surfaces on both edges of the pivot knob shank These two f
196. t for proper operation Case V Genesis steering motor runs can be heard running in the control box but motor lower unit does not turn The output gear on the steering motor item 37 on the Steering Module parts explosion may be broken or the set screw item 33 mating the worm gear item 32 to the steering motor shaft is loose allowing the worm gear to slip Step 1 Remove control box cover and visually inspect all steering clutch gears and output shaft gear A If gears are broken or damaged replace as required 1 To replace broken output shaft gear see Steering System Module Case II Steps 1 2 for steering motor removal and consult your Genesis Steering Module parts explosion for correct steering motor assembly A 2 Replace broken output gear reassemble and test Genesis motor for proper steering functions B If all gears check okay the setscrew in the worm gear is loose Disassemble steering system as per Case II Step 2 Steering System Module 14 4 Genesis Repair Manual 11 07 07 B 2 Remove steering motor from chassis and consult Steering Module parts explosion for location of worm item 32 and setscrew item 33 The transmission housing needs to be removed from the steering motor The setscrew should tighten against the flat side of the shaft Tighten as required using a 050 allen wrench and Loctite the screw in place Reassemble and test Genesis motor for proper steering function Case VI
197. t motor wires battery leads directional indicator light wires and if a variable speed unit place the on off reed switch back in its proper location Tighten the sensor bracket screw to secure reed switch NOTE if connections were sealed with heat shrink tubing prior to disassembly they MUST be resealed with new heat shrink Re install the inner handle assembly Start by engaging the D hole in the handle pivot on the D shaft of the potentiometer or 5 speed switch Then place the handle pivot inner handle and handle bearing in their proper location Note that the triangular shaped arrow on the handle bearing 15 on top Reconnect the red and black battery meter leads to the appropriate wires exiting the control board on variable speed motors or switch on 5 speed motors NOTE the red and black battery meter wires must be routed to the side of the control box cover and pushed in to the slots 1n the cover ribs prior to installing the cover on the control box Also prior to cover re installation line up the directional indicator with the motor lower unit The directional arrow points toward the nose of the motor lower unit Position cover in place on control box and secure with the six 86 20 x 5 8 phillips head screws P N 2303412 3X Steering Repair Manual 11 06 07 Step 11 Re install extension handle and test the motor for proper full range 3X steering function to make sure that nothing is binding or restricting the ste
198. t opening and secure it with the 2 jam nut provided in the eyelet kit Use a drop of red LocTite on the eyelet threads prior to installing the jam nut Case VI Customer complaint that the motor slides down in the bracket doesn t maintain consistent depth setting Motors prior to 2004 were subject to this issue Step 1 Install Depth Collar Parts Kit p n 2771550 using Installation Kit p n 2888620 Instructions are included with Kit The Depth Collar Kit includes an additional depth collar and a new bearing race assembly that utilizes a split collar with 4 screws The Installation Kit includes a jig and a drill bit so you can properly align the screw holes 12 3 Foot Control Cable Steer w Speed Coil Repair Manual 08 25 08 Motor Control Box Maxxum amp All Terrain Steering Cable Replacement Foot Pedal Base CABLE ASSEMBLY INSTALLATION INSTRUCTIONS Remove the cover from the motor control box On the foot pedal base Remove the two screws from foot pedal boot and slide the boot back Loosen cable adjusting screw to relieve cable tension Remove pulley cover to expose the pulley Lift the pulley off the shaft Remove barrel end of each cable core from cable slots the foot pedal and from the pulley Using a needle nose pliers pinch retainer tabs on the cable housing Push the housing and the cable core through the conduit adjusting bracket In the motor control box
199. tage at board terminals the control board is defective Replace control board or module as needed B 2 If board terminals have output voltage but there is no output at the leads that connect to the motor the disconnect relay is faulty and needs to be replaced 16 4 EM amp EP 01 31 08 Part II Case IV EP only Trim Tilt lift system does not operate Step 1 Check all battery connections plug connections and terminal connections for corrosion and security Clean if needed and test for function The lift system must be connected to 12 volts only per EP wiring diagram Step 2 Disconnect lift motor power leads from relay harness Connect 12 volts directly to lift motor and check for function Reverse polarity to reverse direction of travel A B If lift system does not function when relay harness is bypassed the lift motor 1s faulty and needs to be replaced If lift system functions when relay harness is bypassed the problem is with either the relay harness or the Up Down Switch B 1 Test Up Down Switch for continuity B 2 If switch tests okay replace relay harness 16 5 DeckHand Electric Anchor 11 06 07 Chapter 17 DeckHand Electric Anchor models DH1 DH15 DH18 DH20 DH25 amp DH35 Case I DeckHand does not lower or raise anchor Step 1 Check to ensure proper voltage Inspect battery connections and any butt splice connections in battery leadwire for corrosion and security Step 2 Check to see
200. tator section tangs that connect armature windings to each commutator section Each tang should be pressed down flush to the brush surface of the commutator section If any space is noted between the tang and the commutator the potential for an intermittent electrical connection exists and the armature needs to be replaced Case VI If motor runs in MOM and CON modes but customer states that the motor starts stops or changes speed as the foot pedal is rocked forward and backward to steer the potentiometer leads may be at fault Step 1 Step 2 Remove the control board and potentiometer from foot pedal base Connect power leads directly to control board consult appropriate wiring diagram for correct voltage polarity and terminal locations You should hear the relay on the control board click when the power leads are connected to the board A Connect a test light or a known good motor to the control board motor output terminals With potentiometer shaft turned clockwise to its stop the test light or motor should be off As the potentiometer shaft is rotated clockwise the test light or motor should start to light or run and increase in brightness or speed as you continue to turn the potentiometer shaft clockwise to the switch stop C If the test light or motor is intermittent as the potentiometer shaft is turned clockwise OR as the 3 conductor lead connected to the potentiometer is fl
201. te steering functions will be inactivated during this step Using the Genesis Test Pedal p n 2772040T press and hold down the TrimUp TrimDown and the right momentary steering switches while turning the Master Switch ON A B Release TrimUp TrimDown and right momentary switches LCD should only display the icon If the icon is flashing the motor is trimmed up too high and will not allow the AutoPilot feature to operate Use TrimDown switch to lower motor then reactivate the AutoPilot feature by pressing the mode switch once Temporarily place the left sideplate in position to cover the compass unit and to block UV light that could affect the compass sensors Note earlier sideplates must be notched out as shown in the diagram below to clear the compass magnet bracket Na notch out here With the motor on a rotatable stand rotate the entire motor and base extrusion one complete revolution from the starting point and then rotate it back to the starting point 360 CW then 360 CCW Rotate the unit slowly 360 in about 15 seconds Be sure that no large ferrous metal objects are nearby when doing this step Press Momentary ON switch located on the heel toe pedal once to enter this setting into the main board memory should be displayed on the LCD Turn Master Switch OFF Installing the Compensation Magnet Rods A B C Remove the sideplate that was temporarily placed over the compass assembly to bloc
202. the left or right side of the steering pedal is pressed If either the white or small black coil cord wires are broken or intermittent the steering function will be inoperative or intermittent The motor will not respond to the foot pedal and the AP will not track a heading even though the AP indicator light is lit If the small red coil cord wire is broken or intermittent the foot pedal steering will be inoperative or intermittent If the AP function was turned on it will turn off and the AP indicator light will not be lit and the AP system will not function AutoPilot Repair Manual 02 12 08 AutoPilot Calibration PD AP models 2001 models and newer Step 1 Cutout AP template and tape to a piece of cardboard Step 2 Use an amp meter to measure the current draw through the battery lead wires of the trolling motor Step 3 Place stall clamp on prop Step 4 Rotate motor so the prop is facing to the West Step 5 Lay AP template on top of the Drive Housing see figure 2 Make a pencil mark on the depth collar in line with the center mark of the AP template Figure 2 Step 6 Activate AutoPilot with button on control cover during testing leave the control cover on sunlight and other bright lights can affect the operation of the compass While pressing down on the Momentary switch slide the speed selector until an amp draw of atleast 28 and no more than 38 amps has been obtained Tuck wires ree Observe the movement of
203. tive main control board Replace main control board PART I Case IV Motor steers properly but motor lower unit does not run Step 1 Check for proper voltage at the control board input terminals Visually check to see that all wires are attached to proper control board terminals Consult appropriate wiring diagram for the model and board being tested Check for corroded connections Clean rewire properly if necessary Step 2 Check motor with known good test foot pedal or test the foot pedal by performing the Foot Pedal Test Procedure see page 9 6 or 9 7 A If test pedal properly controls all motor functions or if the original foot pedal tests bad the original foot pedal is faulty Replace foot pedal B If motor lower unit does not run properly with test pedal or if the original pedal tests fine go to Step 3 Step 3 Check to see if lower unit runs properly A Connect 12 volts directly to the red and black brush leads at the top of the motor shaft in the control box The motor should run If not a problem exists in the lower unit Check the lower unit for voltage at the brushes water in the lower unit worn brushes or an open or shorted armature Repair as necessary If the motor operates properly proceed to Step 4 Step 4 If Steps 1 2 and 3 test okay the main control board is faulty and needs to be replaced PART I Case V AutoPilot steering stops after approximately 7 seconds of continuous steering in one direction
204. to some of the colored speed coil wires but not all the speed coil wires the speed coil is faulty and needs to be replaced 1 3 Lower Unit Repair 09 08 08 Case III Motor works at all speed settings but the customer is complaining that there is no variation between speeds Step 1 Perform an amp draw check while the motor is running in a water test tank A B If the amps step up as the speed setting increases the motor is performing as designed If the amp draw does not increase along with the speed settings check the amp draw of each speed directly through the speed coil B 1 Remove the control box cover Disconnect wires from the foot pedal if a foot control motor or at the switch in the control box if hand control from the wires to the lower unit B 2 With the lower unit still in a water test tank connect 12 volts to the black motor brush lead B 3 Connect 12 volts to each colored speed coil wire coming up through the motor tube from the lower unit The motor will run on the separate speed designations as you make each connection Note the amp draw as you test the different colored wires a If the amp draw does not vary as you make the different connections with the lower unit still in a water test tank replace the front end bell potted speed coil assembly b If the amp draw does vary as you make the different connections replace the 5 speed switch Case IV Customer complains of low power thrust Step 1
205. tops running while in use Motor starts running again after it is pulled up out of the water and is placed back in the water after the control box is struck or after the prop is turned slightly Step 1 The malfunction listed above is most likely due to an intermittent or marginal electrical connection at the armature windings and commutator A B Dis assemble the motor lower unit Inspect for water damage If water is present repair and replace parts as necessary Inspect the armature Examine the commutator sections for discoloration and arcing caused by the brushes as they make contact with good live commutator sections and bad dead sections Test armature commutator sections for continuity from one section to the next going around the circumference of the commutator B 1 Replace armature if severe arcing is noted or if no continuity is found when testing commutator sections Examine commutator section tangs that connect armature windings to each commutator section Each tang should be pressed down flush to the brush surface of the commutator section If any space is noted between the tang the commutator the potential for an intermittent electrical connection exists and the armature needs to be replaced 1 4 Lower Unit Repair 09 08 08 Case VI Motor runs backwards Step 1 Polarity reversed to armature Possible causes include A B Wired backwards Brush plate in up
206. tor at the M and M board terminals If a voltage is present proceed to Step 6 If no voltage is present then the main control board is faulty and needs to be replaced Step 6 Test lower unit directly bypassing the throttle assembly and control board to determine if it runs A Connect the black and red motor brush leads connected to the M and M terminals shown on control board wiring diagram directly to 12 volts The motor propeller should turn at a relatively low R P M If the motor does not run in Step 6 A a problem exists in the lower unit Disassemble the lower unit and check for loose brush wire leads at the brush plate damaged brushes or brush springs brushes not making contact with the armature commutator or armature commutator sections that are open or dead Replace any parts found to be bad and reassemble reseal motor lower When reassembled resealed re test motor to verify that it runs by connecting to 12 volts as per Step 6 A Hook the red battery lead to red brush lead normally connected to the control board The motor should run If not a problem exists in the lower unit Disassemble lower unit and check for voltage at the brushes water damage brushes not making proper contact and an open armature C 1 An open armature will have some segments on the commutator that are dead If the brushes happen to stop on this open segment it will not run If you can turn the prop a quarter turn and the motor st
207. trolling motor plug if installed and any butt splice connections in battery lead wire Step 2 Check to insure that all wires are securely attached to the proper control board terminals Consult appropriate wiring diagram for the model being diagnosed Check for any corroded connections Step 3 Remove the control box cover Disconnect motor leads and connect 12 volts across red and black motor leads This applies to 12 24 or 36 volt models A If motor runs reconnect motor leads and proceed to Step 4 B If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes faulty brush springs or an open or shorted armature Repair replace parts as necessary Test motor for proper operation Step 4 If motor being serviced is not working in the CON position go to Step 5 If motor being serviced is not working in the MOM position go to Step 6 Step 5 With battery leads connected to power source and MOM OFF CON switch in the CON position connect V O M leads to battery leadwire and the battery lead terminal at main control board Consult appropriate wiring diagram for motor being diagnosed A If voltage is present replace main control board B If no voltage is noted check MOM OFF CON switch for continuity across center terminal to continuous terminal wire going directly to main control board If no continuity replace MOM OFF
208. trusion and stand slowly to the NW LCD to the SE Observe motor lower unit The lower unit should still point north with an error of less than 20 If error is greater than 20 adjust the N S compensating magnet rod as needed with a non magnetic screwdriver to reduce the amount of error Rotate the motor base extrusion and stand to the NE LCD to the SW and observe motor lower unit The lower unit should still point north with an error of less than 20 Adjust the N S compensating rod as needed with a non magnetic screwdriver to reduce the amount of error E 1 Rotate the motor base extrusion and stand back to the north LCD to the south Observe motor lower unit to confirm that the amount of error when pointing north is less than 20 Repeat Steps 3D amp 3E if needed Rotate the motor base extrusion and stand to the west LCD to the east Steer the lower unit so it points to the west using the left right momentary steering buttons AP function still engaged Rotate the motor base extrusion and stand slowly to the SW LCD to the NE Observe motor lower unit The lower unit should still point west with an error of less than 20 If error is greater than 20 adjust the E W compensating magnet rod as needed with a non magnetic screwdriver to reduce the amount of error Rotate the motor base extrusion and stand to the NW LCD to the SE and observe motor lower unit The lower unit should still point west with an er
209. ttery leads from both modules are then connected to the series connected batteries See diagram below Battery 1 Battery 2 Battery 3 Battery 4 A Series link 1 Control Module Control Module Step 3 Check all hand controller control module and Y splitter plug end pins and sleeves for corrosion Clean if needed reconnect and test again for proper operation If both motors still do not run go to Step 4 Step 4 Disconnect Y splitter cable from hand controller and control modules Connect hand controller directly to the control module for the motor that is not operating Test motor function A If the motor that is connected to this control module operates okay this control module is good The problem is in the splitter cable Replace cable as needed B If the motor that is connected to this control module does not operate something is faulty with this control module assembly Test the control module to determine if just the disconnect relay is defective or the control board is bad NOTE all EM control modules and early EP modules EPs produced prior to 1999 utilize a motor disconnect relay in the output circuit of the module On modules with the disconnect relay test for output voltage right at the board output terminals and at the output leads that connect to the motor unit Testing in this manner will determine if the disconnect relay is good or defective B 1 If there is no output vol
210. tube A Prior to installing the pinion assembly examine the upper top end of the pinion gear teeth Two of the gear teeth will have small raised bumps A 1 transom mount motors when looking straight down at the control box area and lower unit assembly rotate the nose of the lower unit into the 12 o clock position prop in the 6 o clock position On the pinion assembly the two teeth with the raised bumps need to be oriented towards approximately the 9 o clock position A 2 On bow mount 3X motors the two teeth with the raised bumps need to be oriented toward the prop end of the motor lower unit when installed in the inner tube B Examine the four pinion assembly retaining screws P N 2223468 for any damage Replace them with new screws as needed B 1 LocTite primer and LocTite 603 compound then insert and tighten the screws securely into the 4 hole collar inner tube and pinion gear assembly Place the outer tube pivot yoke assembly and inner tube upper bearing and pinion gear assembly back into their normal assembled positions Normal assembled position is with the upper bearing supported in its recessed area of the pivot yoke A Slip the lower collar P N 2071500 up into place on the lower end of the outer tube 1 Re install the collar halves P N 2261622 on the inner tube using the two 4 20 x 1 socket head cap screws A 2 Slide the collar halves up against the bottom of the lower collar
211. uld hear the relay click as this is being done B Isolate and disconnect leads from relay harness to lift motor C With the UP Down push button switch actuated a V O M should show battery voltage across relay harness motor leads If no voltage is noted relay harness needs to be replaced If voltage is noted go to Step 3 Step 3 Apply 12 volts directly to hydraulic pump motor reverse polarity to reverse pump motor rotation A If pump motor fails to run pump motor assembly needs to be replaced For units with MKJG serial number prefix contact Minn Kota for assistance Case III PowerUp Models MKN 5400 amp MKN 5500 with serial number prefix MKJG slowly leak down won t stay up or won t trim outboard when engine is in use Step 1 Contact Minn Kota for assistance Case IV PowerUp Models MKN 5400 amp MKN 5500 with serial number prefix MKJH and later will not fully lift tilt or jerks while lifting tilting Step 1 Check fluid level in pump reservoir A Remove dipstick located in pump body between hydraulic hoses with slotted screw driver dipstick 15 marked to show proper fluid level B Fill with ATF automatic transmission fluid as required Do not overfill Test unit for proper operation For PowerUp models not listed here contact Minn Kota for assistance 15 1 EM amp EP 01 31 08 Chapter 16 Engine Mount EM amp Neptune EP This Repair Manual Chapter is divided into Part I and Part II
212. ushes and commutator works together Commutator sarbon brush Motor current Li Segment i Segment 2 Short circuit current Armature coils Coil f zh 6 te m Sip bd Current in A Curreni out gt 9 i 3 Current flow is in at brush A and out at brush B The small radially oriented arrows show current direction in the individual coil sides If the rotation is clockwise it can be seen that 1 6 of a revolution after the instant shown above the current in coils 3 3 and 6 6 will have changed directions As each successive commutator segments pass under the brushes their current directions will also change As a result of this switching or commutation current flow in the armature occupies a fixed position in space independent of rotation and a steady unidirectional force will result Lower Unit Repair 09 08 08 Instructions to Remove Lower Unit from Composite Shafts Tighten the shaft and lower unit assembly in a bench vise Utilize the Tube Holding Block Set Minn Kota P N 2001022 to lessen chances of scarring the shaft The motor assembly should be slid directly next to the block set Heat the bung area with a commercial heat gun to loosen the LocTite If you use a propane torch as a heat source you risk blistering the paint The heat needed to break down the LocTite is 450 degrees Fahrenheit for 5 minutes We use LocTite 661 w
213. ut rope from spool while watching for knots and or the rope being buried underneath other layers B 1 Re adjust rope on spool as needed 17 1 DeckHand Electric Anchor 11 06 07 Case IV DeckHand lifts anchor when you push DOWN switch and lowers when you push UP Step 1 Check to ensure proper polarity at the battery and at the Up Down switch polarity may be reversed Step 2 Possible knot in rope on spool If the rope is caught by a knot or part of the rope is buried in the layered wrappings of the rope the spool will be turning the proper direction but the rope will reverse when it catches the knot A Remove cover from DeckHand base B Feed out rope from spool while watching for knots and or the rope being buried underneath other layers B 1 Re adjust rope on spool as needed Case V Deckhand will lift anchor but not deploy the anchor NOTE When the UP DOWN switch is in the Down position the anchor rope must have tension applied in order for the motor to run play out rope as the rope tension actuates the momentary switch P N 2374010 Step 1 Possible defective momentary switch P N 2374010 A Remove spool and test with finger by actuating button Step 2 Spool bearing P N 2370000 may be installed incorrectly The spool bearing must be free to move forward and back to actuate the momentary switch A If the spool bearing cannot move back and forth remove rope spool and rope guide from DeckHand base
214. values Steering motor may be overheated the steering motor should draw less than two amps while steering in a no load or on the bench situation Check the next 2 circumstances particularly if you can hear the steering motor running in the control box for a few seconds but the lower unit does not steer prior to ER5 being displayed Steering motor output gear broken internally see page 14 4 Case V gt Set screw mating the worm gear to the steering motor shaft is loose see page 14 4 Case V WV ERO Lift system is not responding Motor is blocked and cannot trim up or down remove obstructions Shaft position counter lost reference possibly due to improper lift belt tension Adjust lift belt tension see page 14 7 Case I gt Coupler gear broken see page 14 7 Case III LP Low power less than 8 volts for 12v units and 16 volts for 24v units under load Check power source all connections and external plugs for loose or faulty contacts most LP error codes are traced back to faulty loose connections at battery or plug CL Propeller is blocked gt Clear propeller obstructions Propeller OFF MOM CON switch is in CON Constant On position turn to MOM momentary position Multiple Error Codes Simultaneously LCD flickers many codes gt Defective foot pedal replace pedal see page 14 18 Case VIII 14 2 Genesis Repair Manual 11 07 07 GENESIS Steering System Module see also Foo
215. ver Disconnect motor leads and connect 12 volts across red and black motor leads This applies to 12 or 24 volt models A If motor does not run the problem is in the motor lower unit Disassemble and check lower unit for voltage at the brushes water in lower unit worn brushes bad brush springs or an open or shorted armature Repair replace parts as necessary If motor does run check speed selector switch connections and test speed selector switch for continuity across terminal to terminals 2 3 etc If switch tests okay proceed to Step 3 C Replace speed switch Test motor for proper operation If unit being serviced 1s not a 12 24 volt model proceed to Step 4 If unit being serviced is a 12 24 volt model check the 12 24 switch for continuity Terminal Terminal Terminal B front side of switch back side of switch A Turn the 12 24 switch to 12 volt ON position Check for continuity between the common C terminal and the terminal A 1 If no continuity is noted replace the 12 24 switch Test motor for proper operation A 2 If continuity is observed proceed to Step 3B B Turn the 12 24 switch to 24 volt ON position Check for continuity between the common C terminal and the B terminal B 1 If no continuity is noted replace the 12 24 switch Test motor for proper operation B 2 If continuity is observed proceed to Step 4 If motor being serviced is not wor
216. wer unl NOTE Atthis point the handle tension knob auler shart keyway and lower unit Should now be allgnad If repeat staps 2 5 3X Steering Repair Manual 11 06 07 71 If mounting configuration or option 2 15 preferred the orlentation block must be rotated 180 Tha orlentatlon block must be ramoved and rotated so the retaining key Is an the right hand side of the screw The picture below shows orkentatlon block configuration or option 1 Orientation Block 8 Open the depth collar and allgn the packet the collar with the tab tha Bowguard unit Alignment Pocket Alignment Tab 81 Leaving the depth collar open place tt on the shat as shown with tab angaged In pocket 19 Loosen onentation Block screw so Key can freely silds Push on screw and silde the onentation block until Key falls Into the siot shart ornenltallan Block Screw shat Slat 11 Once key Is clearly In slot on shall and collar half E into place clase and tighten depth collar 12 Tighten onentation black screw End of procedure 3X Steering Repair Manual 11 06 07 This is a 1 time procedure to initially orient straight ahead on bowmount 3X models with latch amp door mounts 3X ALIGNMENT AND RING INSTALLATION 1 Review your type of mounting OPTION 1 OPTION 2 2 Deploy the motor 3 The handle will come unaligned with steering tension knob similar to photo 7 NOTE SUPPOR
217. wires of the foot pedal battery holder with 4 good AA batteries you should see about 6 volts Check AA battery contacts Replace bad batteries as necessary B 4 If batteries and connections in the foot pedal check out okay test receiver sideplate motor ON OFF switch to insure that the switch is functional This can be accomplished by testing across the switch leads with a V O M for continuity or by testing across pins and E for voltage with the ON OFF switch turned ON Plug end from main control board B 5 If no voltage or continuity is noted inspect the receiver sideplate motor ON OFF switch and replace with switch kit p n 2880230 if necessary B 6 Initialize and test for motor operation with new switch to verify function 10 1 Cordless Motors Repair Manual 02 20 08 Case II Motor operates fine but while in use shuts down and requires re initialization Step 1 Check all battery connections trolling motor leadwire plug and plug receptacle connections if plug has been installed all butt splice connections leadwire connections at main control board and any circuit breakers that may be installed in the boats trolling motor electrical system A Malfunctions of this nature are almost always due to a momentary interruption in power to the trolling motor and RF receiver sideplate B Correct any faulty wiring connections re initialize and test motor under load Case III AutoPilot of cordless motor fails to
218. y P N 2992205 upper bearing P N 2077305 and 4 hole collar see Fig 5 page 6 4 NOTE The four pinion assembly retaining screws are held in place with LocTiteTM during assembly Removal may require heat application to the screw head When reassembling a 3X motor LocTiteTM primer and 603 compound MUST be reapplied to these four retaining SCIeWS B With the four retaining screws removed the pinion assembly upper bearing and 4 hole collar can be removed Step 11 With the pinion assembly bearing and 4 hole collar removed the motor lower unit inner tube assembly along with the lower collar P N 2071500 can be slid down and out the bottom of the outer tube Step 12 To remove the pivot yoke from the upper end of the outer tube loosen the 14 20 socket head cap screw and nyloc nut that serves to clamp the pivot yoke on to the outer tube Loosen the steering tension knob P N 2070105 A With the screw and nut loose the pivot yoke P N 2071512 or P N 2071513 can be lifted up and off the outer tube NOTE When removing the pivot yoke note its position orientation on the outer tube 1 Ontransom mount 3X motors the steering tension knob 15 positioned towards the bracket clamp screws 2 bow mount motors the steering tension know is toward the boat when mounted and positioned for installation of the bow mount orientation collar A 3 Also note that a tube key P N 2076700 is used to properly position the pivot yo
219. y down in CON position or on V2 models motor does not stay running For Grip Glide Motors Step 1 From the underside of the footpedal remove the 3 screws holding the slide control and switch lever in place A Remove screw holding the white plastic continuous actuator in place B Place shim P N 2301731 between actuator and pedal base C Reassemble slide control and MOM CON switch assembly Test for proper operation For V2 Motors Step 1 From the underside of the footpedal tighten screws beneath MOM CON switch 9 3 AutoPilot Repair Manual 02 12 08 PART I Case X Motor is loose in the cradle Step 1 Check replace the pivot pads P N 2305103 as needed The pads tend to flatten or soften over time Step 2 Ensure the latch on the Grip Glide handle or Deploy Assist lever firmly engages the latch collar on the composite shaft A Loosen latch collar clamping screw Rotate the latch collar clockwise on the shaft when viewed from above to screw the latch collar down towards the motor lower unit The collar and shaft are threaded B Check to verify that the catch on the handle or lever now firmly engages the latch collar If necessary re adjust latch collar position Tighten the clamping screw to hold the collar in place PART I Case XI Motor is tight in the cradle and difficult to stow deploy Step 1 Lubricate the composite shaft with a silicone spray or Armor Step 2 Adjust the latch collar A Loosen l
220. y touching a grounded metal object in order to discharge any static electricity in your body 2 Remove the four screws on the bottom of the remote case 3 Separate the case halves to access the circuit board 4 Pull back the retaining fingers of the battery holder to remove the battery underside of circuit board 5 Install the new battery with the positive side of the battery facing up away from the circuit board Ensure battery is snapped securely in place 6 Reassemble the remote Note that the alignment peg in the remote case must line up with the corresponding alignment hole in the circuit board Also note that the keypad must be positioned so that the buttons are over the end of the circuit board opposite from the alignment peg and hole Reinstall the four case screws and tighten them as required 18 3 E Drive 11 14 07 Chapter 19 E Drive Electric Outboard In order to properly diagnose and service E Drive electric outboard motors we would advise that you have the following on hand Dog 48 volt power supply or 4 series linked 12 volt batteries A test p n 2770216 E Drive throttle assembly Test throttle cables p ns 2041401 and 2041402 A good quality VOM Ordinary hand tools such as Phillips screwdrivers pliers wire crimpers wrenches etc Case I Motor does not run does not respond to throttle commands Step 1 Check to ensure proper polarity and voltage 48 volts at the E

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