Elco Outboard Manual
Elco Outboard Manual
Elco Outboard Manual
operators manual
Thank you for purchasing an Elco Electric Outboard Motor.
Your trust in our company and products is greatly appreciated.
Elco electric outboard motors are powerful, economic, safe and manufactured in the USA with
advanced technology. Please read this manual carefully before operating your outboard motor. A
thorough understanding of the manual will help you to safely operate the product and perform the
required maintenance and care. By following the information contained within this manual, your
outboard motor will operate for many years.
Elco seeks continuous improvement in product quality. Therefore, while this manual contains the
most current product information available at the time of printing, there may be minor discrepancies
between your motor and this manual. If there is any question concerning the manual, please con-
sult your local dealer or Elco directly.
Data, illustrations, or explanations in this Operators Manual do not constitute the basis for any
legal claim against our company. Please read our limited warranty, which is contained in
this manual.
Record your outboard motor serial number in the spaces provided to assist you in
ordering spare parts for your Elco dealer to reference.
Manufacturer’s Declaration
The outboard motor complies with the requirements of Directive 2003/44/EC in relation to noise
emissions. The following installation and maintenance instructions, if applied, will assist in making sure
that the outboard motor will remain in compliance with the noise emissions limits under normal
conditions of use.
Propeller Selection 3
The performance of your outboard motor will be critically affected by your choice of propeller, as an
incorrect choice could adversely affect performance. The outboard motor is fitted with a propeller chosen to
perform well over a range of applications, but there may be uses where a propeller with different pitch would
be more appropriate. Elco dealers stock a range of propellers and can advise you and install a propeller on
your outboard that is best suited to your application.
For a greater boat load and a low motor speed, a smaller-pitch propeller is more suitable. Conversely, a
large-pitch propeller is more suitable for a smaller operating load as it enables the maximum motor speed
to be maintained.
4 Installation and Operation
Mount the outboard motor on the
center line (keel line) of the boat. For
boats without a keel or which are
asymmetrical, consult your dealer.
• Improper mounting of the outboard motor could result in dangerous conditions and injury. For permanently
mounted models, your dealer or other expert experienced in rigging should mount the motor. If you are mounting
the motor yourself you should be trained by an experienced person. For portable models, your dealer or other
expert experienced in proper outboard motor mounting should show you how to mount
your motor.
• The information presented in this section is intended as reference only. Proper mounting depends in part on
experience and the specific boat and motor combination.
Mounting Height Recommendations 5
The mounting height of the outboard motor greatly affects the running efficiency of your boat. If the
mounting height is too high, cavitation tends to occur, thus reducing the propulsion. If the mounting height
is too low the water resistance will increase and thereby reduce motor efficiency. Mount the outboard
motor so that the anti-cavitation plate is between the bottom of the boat and a level 1 inch below it.
NOTE:
The optimum mounting height of the outboard
motor is affected by the boat and motor combination
and the desired use. Test runs at different height can
help determine the optimum mounting height. For
further information, consult your Elco dealer or
boat manufacturer.
6 Clamping the Outboard Motor
1. Tighten the transom clamp screw evenly and securely. Occasionally check the
clamp screws for tightness during operation of the outboard motor because they
could become loose due to the boat’s vibration.
WARNING:
• Loose clamp screws could allow the outboard motor to fall off or move on the
transom. This could cause loss of control. Make sure the clamp screws are tightened
securely. Occasionally check the screws for tightness during operation.
Choose a suitable place on the boat to install the Throttle Control Plank and
punch holes in the boat according to the Throttle Control Plank. Fasten the
Throttle Control Plank and Throttle Control Box to the boat with a bolt.
Stop Switch
Key
Throttle/Remote
8 Starting the Outboard (Tiller Model)
CAUTION
• Do not start the outboard out of water. Overheating of the water pump can occur. Serious injury can occur.
• Check the outboard mounting.
• Look for loose or damaged fasteners.
• Check the propeller for damage.
1. Check to see that the On-Off-Battery switch is in the Off position or the motor will not turn on.
2. Attach the outboard Tether Lanyard to a secure place on your clothing, or on your arm or leg.
Then install the lock plate on the other end of the lanyard into the outboard stop switch.
3. Connect the Blue Power Cable to the outboard.
4. Verify the Forward-Reverse switch is in the neutral position or the motor will not turn on.
5. Move the Throttle Grip to the minimum position.
6. Push the On-Off-Battery switch to On.
7. Carefully and slowly move the Throttle Grip to increase the outboard speed.
8. Check for a steady flow of water from the cooling water pilot hole.
WARNING:
• Do not start the outboard unless the Throttle Grip is in the minimum position.
• Do not attach the lanyard to clothing that could tear loose.
• Do not route the lanyard where it could become entangled,
preventing it from functioning.
Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of steering
control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the
boat to be thrown forward.
NOTE:
The outboard can also be stopped by pulling the lanyard and removing the lock plate from the
Tether stop switch.
In emergency situations, the main Power Cable connector can also be removed to disconnect
power form the outboard.
To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counter-
clockwise. When constant speed is desired, tighten the adjuster to maintain the desired throttle setting.
WARNING:
Do not over-tighten the friction adjuster. If there is too
much resistance, it could be difficult to move the throttle
lever or grip, which could result in an accident.
Starting the Outboard (Throttle Control Model) 11
WARNING:
• Before changing direction, make sure there are no swimmers or obstacles in the water near you.
• Shifting from forward to reverse or vice versa is possible at any time, but care must be taken to
prevent people and equipment from shifting in the boat.
12 Changing Direction (Throttle Control Model)
1. Place the throttle lever in the
upright position for neutral.
NOTE:
The outboard can also be stopped by pulling the lanyard and removing the lock plate from the Tether
Lanyard switch. In emergency situations, the main Power Cable connector can also be removed to
disconnect power from the outboard.
Tilting Up and Down (Warnings) 13
If the motor will be stopped for some time or if the boat is docked or stopped in shallow
water, the outboard motor should be tilted up to protect the propeller and casing from damage
by collision with obstructions, and also to reduce corrosion.
WARNING:
Be sure all people are clear of the outboard motor when tilting up and down. Also be careful not
to pinch any body parts between the drive unit and outboard bracket.
Remove the Power Cable if the outboard motor will be tilted for more than a few minutes.
Otherwise, an unsafe condition may exist.
NOTE:
• Do not tilt up the outboard by pushing the tiller handle because this could break the handle.
• The outboard motor cannot be tilted when in reverse or when the outboard motor is turned
180 degrees (facing the rear).
14 Tilting Up
1. Place the On-Off-Battery switch in the Off position and face the outboard motor forward.
If this is a Throttle Control Model, turn the Key switch to off and remove the key.
2. Tighten the steering friction screw by turning it clockwise to prevent the motor from turning freely.
4. Hold the rear handle and tilt the outboard up fully until the tilt support bar automatically locks.
Tilting Down
1. Slightly tilt the outboard motor up.
2. Slowly tilt the outboard motor down while pulling the tilt
support bar lever up.
3. Loosen the steering friction screw by turning it counter
clockwise, and adjust the steering friction according to
operator preference.
Cruising in Shallow Water/Salt Water 15
WARNING:
• The outboard motor can be tilted up partially to allow for operation in shallow water.
• The tilt lock mechanism does not work while the shallow water cruising system is being used. Run the boat at
the lowest possible speed to avoid the outboard motor being lifted out of the water, resulting in loss of control.
• Return the outboard motor to its normal position as soon as the boat is back in deep water.
CAUTION:
The cooling water inlet on the lower unit should be not above the surface of the water when setting up for and
cruising in shallow water. Otherwise severe damage from overheating can result.
Maintenance Procedures
While using the outboard motor, periodic maintenance is necessary for you to ensure its performance of the motor.
WARNING:
• Be sure to turn off the outboard when you perform maintenance unless otherwise specified. This work should
always be done by a qualified mechanic or your authorized ELCO dealer.
CAUTION:
If replacement parts are necessary, use only genuine ELCO parts.
16 Removing/Installing the Propeller
1. Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage.
2. Check the propeller shaft for damage.
3. Check the splines/shear pin for wear or damage.
4. Check for fish line tangled around the propeller shaft.
5. Check for the propeller shaft oil seal for damage.
WARNING:
• Before inspecting, removing or installing the propeller, always take actions to ensure
the outboard does not accidentally start, such as removing the Power Cable connector,
placing the On-Off-Battery switch in the Off position, (or remove the Key for the
Throttle Control Model) and removing the lanyard from the outboard Tether stop switch,
etc. Serious injury can occur if the outboard should start and you are standing too close
to the propeller.
• Do not use your hand to hold the propeller when loosening or tightening the propeller
nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the
propeller from turning.
CAUTION:
Inspect the used oil after it has been drained. If the oil is milky, then water is getting into the gear case which
can cause gear damage. Consult your ELCO dealer.
5. Use a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.
Standard 80-90 gear oil is recommended.
6. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug (If necessary,
change the seal spacer).
7. Insert and tighten the gear oil drain screw (If necessary, change the seal spacer).
CAUTION:
Do not paint anodes, as this would render them ineffective and can cause more
rapid motor corrosion.
Greasing diagram A
The Greasing points are shown in diagram A
Maintenance Table 19
NOTE: When operating in salt water, turbid or muddy water, then engine should be flushed clean after every use.
Transporting and Storing 21
The outboard motor should be trailed and stored in the normal running position. If there
is insufficient road clearance in this position, then trailer the outboard motor in the tilt position
using a motor support device.
CAUTION:
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose
from the tilt support and fall.
WARNING:
• Never get under the lower unit while it is tilted, even if a motor support bar is used.
CAUTION:
• Place a towel or something similar under the outboard motor to protect it from damage.
Storing
When storing your ELCO outboard motor for prolonged periods of time (2 months or longer), several
important procedures must be performed to prevent damage.
It is advisable to have your outboard motor serviced by an authorized ELCO dealer prior to storage.
However, you, the owner, with a minimum of tools, can perform the following procedures.
CAUTION:
• Keep the outboard motor in an upright position when transporting and storing it. If storing or transport-
ing the outboard motor on its side (not upright), put it on a cushion.
• Do not place the outboard motor on its side before the cooling water has drained from it completely.
• Store the outboard motor in a dry, well-ventilated place, not in direct sunlight.
22 Emergency Situations
Impact Damage
If the outboard motor hits an object in the water, follow the procedure below.
1. Stop the outboard immediately.
2. Inspect the control system and all components for damage.
3. Whether damage is found or not, return to the nearest harbor slowly and carefully.
4. Have an ELCO dealer inspect the outboard motor before operating it again.
1. If it is physically impractical to place the circuit breaker or fuse at the source of power, it may be placed within
seven inches of the source of power for each circuit or conductor, measured along the conductor.
2. If it is physically impractical to place the circuit breaker or fuse at or within seven inches of the source of
power, it may be placed within 40 inches of the source of power for each circuit or conductor, measured along
the conductor, if the conductor is contained throughout its entire distance between the source of power and the
required circuit breaker or fuse in a sheath or enclosure such as a junction box, control box, or enclosed panel.
Over current Protection 23
Battery Installation
+ - This diagram is intended for reference only.
Fuse
+ -
24 Troubleshooting: Faults & Warnings
Use the table below to determine the type of fault from the number of LED flashes.
The LED flashes a preset number of times in repetitive sequence (e.g. 3 flashes –
off – 3 flashes – off – and so on). Possible operator action is listed in the right hand
column of the table.
LED indicator
5 PST Fault Fault detected on PST power teer module. Check PST condition.
5 Motor open circuit Unable to establish current in motor. Check motor condition/
wiring.
6 Analog input wire-off Analog input voltage is outside allowable Check analog input
range. wiring
6 Analog output fault(over/ Analog output fault caused by over current Check analog output
under current, failsafe, (>4A), under current if actual current <50% wiring.
short circuit driver) target (current mode only), failsafe circuit
fault, short circuit driver MOSFET.
LED Fault Set Conditions Operator Action
flashes 25
Battery low voltage Battery voltage or capacitor voltage is below Increase battery voltage
7 protection a user definable minimum battery level for a above user defined level
user definable time.
Controller low voltage Battery voltage or capacitor voltage is below Increase battery voltage
7 protection the minimum level allowed for the controller. above minimum level
Controller high voltage Battery voltage or capacitor voltage is below Increase battery voltage
7 protection with line the minimum level allowed for the controller. above minimum level.
contactor closed.
Motor low voltage Capacitor voltage has entered the motor low Reduce battery voltage
7 protection voltage cutback region defined in 4612 below start of motor high
voltage cutback region
7 BDI warning or cutout BDI remaining charge is less than warning Charge battery.
or cutout levels.
26 Troubleshooting: Faults & Warnings
LED Fault Set Conditions Operator Action
flashes
Battery voltage below Battery voltage is below the absolute minimum Increase battery voltage
7 critical level for controller. voltage at which the controller hardware is guar-
anteed to operate.
7 Precharge failure Capacitor voltage is less than 5V after pre- Check controller wiring to
charge operation is complete. ensure there are no short
circuits between B+ and B-.
8 Controller too hot Controller has reduced power to motor(s) Remove loading to allow
below maximum specified by user settings controller to cool down.
due to controller over temperature.
8 Controller too cold Controller has reduced power to motor(s) Reduce load to motor to
below maximum specified by user settings allow it to cool down.
due to controller under temperature.
8 Motor over temperature Controller has reduced power to motor(s) Reduce load to motor to
below maximum specified by user settings allow it to cool down.
due to motor over temperature
8 Motor too cold Motor thermistor reports less than -30˙C. Allow motor to warm up.
Check motor thermistor.
11 Current control fault Software is unable to control currents on Check motor load and
PMAC motor. wiring. Check motor
parameters are correct
27
13 DSP Parameter error Motor parameter written to while motor Recycle key switch to
control is operational. allow parameters to be
reloaded correctly.
Limited Warranty
The EPS must be inspected to make sure no damage has occurred during Be sure to save the receipt or invoice you
shipping. Any damage must be reported to Elco immediately in writing at were given when you bought your EPS. It is
the address set forth at the end of this Limited Warranty. In addition, the your proof of purchase and Elco must see it
The Elco Motor Yachts, LLC (“Elco”) Electric Propulsion System (“EPS” allegedly defective EPS must be delivered to the nearest Elco authorized before Elco will honor this Limited Warranty.
or “product”) is warranted to the original retail purchaser to be free from repair facility. The aforementioned notification shall state, (1) that the EPS
defects in material for a period of three years and/or workmanship for a is an Elco product and shall include a copy of the proof of purchase (i.e., Elco makes no warranty other than that
period of two years from the date of purchase, each under normal oper- the receipt or invoice), (2) that warranty consideration is requested and stated above, either express or implied and
ating conditions. Provided that the warranty registration card (located in (3) the name and address of the Elco authorized repair facility holding the expressly disclaims same.
the Owner’s Manual or on the website) is completed and returned to Elco allegedly defective product. Elco will promptly consider all such warranty
within 15 days of purchase, this non-transferable Limited Warranty shall claims. ALL INCIDENTAL AND/OR CONSEQUENTIAL
begin on the date the EPS is sold to the original retail purchaser or the DAMAGES ARE EXCLUDED FROM THIS
date on which the product is first put into service, whichever occurs first. As stated above, Elco’s sole obligation under this Limited Warranty is (at WARRANTY. IMPLIED WARRANTIES ARE
its sole option and discretion) to repair or replace any defective compo- LIMITED TO THE LIFE OF THIS WAR-
This Limited Warranty does not cover product damage due to abuse, ac- nent or product in part or whole. Elco shall be the sole arbiter of such RANTY. SOME STATES DO NOT ALLOW
cidents, modifications, misuse, excessive wear or damage caused by an action. In the event that Elco elects to replace the EPS, Elco shall supply LIMITATIONS ON HOW LONG AN IMPLIED
owner’s failure to provide reasonable and necessary installation and care. such replacement F.O.B. Elco factory or authorized repair facility, as Elco WARRANTY LASTS OR THE EXCLUSION
Purchasing of the unit from anyone other than an Elco authorized Dealer may elect in its sole discretion. OR LIMITATION OF INCIDENTAL OR CON-
and/or having the product serviced or repaired by anyone other than an SEQUENTIAL DAMAGES, SO THE ABOVE
Elco authorized repair facility will void this warranty. Pursuant to the terms Elco will not accept warranty obligations for repair of products by other LIMITATIONS OR EXCLUSIONS MAY NOT
of this Limited Warranty, during the applicable warranty period, Elco will than its authorized repair facility or warranty obligation for materials or APPLY TO YOU. THIS WARRANTY GIVES
repair or replace any defect arising from imperfect material or workman- workmanship employed in making repairs. This Limited Warranty does YOU SPECIFIC LEGAL RIGHTS, AND YOU
ship, without charge, provided that such defective or imperfect part when not cover cost of removal, transportation to and from repair facilities, or MAY ALSO HAVE OTHER LEGAL RIGHTS
discovered shall be immediately reported in writing and returned to an re-installation. WHICH MAY VARY FROM STATE TO STATE.
Elco authorized repair facility.
Elco products requiring service not covered under the terms of this Elco Motor Yachts, LLC 2016
Use of the EPS in any manner other than its intended use (i.e., in marine Limited Warranty may be repaired or replaced by Elco for a fee to be
craft only) will void this warranty. determined by Elco at the time of such repair or replacement. Save this Operators Manual