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Minn Kota Service Manual

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1. QN3 40123NNO2 YOLIINNOD QN3 12 14 02 19 03 Minn Kota Universal Sonar Models Lowrance Eagle Adapter Cable Part No 1852058 MKR US 9 YOLIINNOD JINVYMO 1 YOLIINNOD 32NYHAOT1 J N 19145 8201 829 801238802 VLON NNIW 4 3ONYUMO Nid VLON NNI WHO LO3NNOO VLON NNIW MILA ON3 YOLIINNOD 12 15 Lower Unit Repair 01 27 04 Section 13 Lower Unit Motor Assembly This section refers to the motor assembly only Consult the appropriate section of the Service Repair Manual for more information Instructions to Remove Lower Unit from Composite Shafts Step 1 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 Step 2 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 red LocTite 271 with 7090 primer on motors with black shafts and LocTite 661 7649 primer on white motors NOTE 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 a
2. left park position to right park position Right park position is motor lower unit at a 90 angle to the Genesis base housing with the prop pointing to right when viewing the LCD 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 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 Genesis Repair Manual 12 02 02 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 B
3. With the motor in the DEPLOYED position trim the motor to its highest trim height Torque the lift belt tensioning screw to 6 7 inch pounds Tensioner screw 15 located on the underside of the control box Perform the Master Reset Procedure to reset shaft position counter see page 11 21 Retest motor for proper deploy stow sequence If lift belt is 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 way ER6 may also display the shaft position counter has lost reference and must be reset Step 1 Perform Master Reset see page 11 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 B C Unscrew sideplate screws items 37 and 38 to remove the right sideplate Consult Genesis AP PD Base Housing Parts explosion for reference 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
4. 19195 Nid 2INOSHO3L NN IGI B H YOLIINNOD YOLDINNOD 21 05 231 103 NNIW YWOLOANNOD VLON NNIW YOLOANNOD 7 GHISNIWWOH QN3 YOLIINNOD 12 10 02 19 03 Minn Kota Universal Sonar Models Lowrance Eagle Adapter Cable gray Item No 1852054 MKR US 5 1 YOLD3NNOD 32NVIAO1 JONVUMOT UO123NNO2 VION WO LO3SNNOO VLON NNIW QN3 9UO123NNO2 12 11 02 19 03 Minn Kota Universal Sonar Models Lowrance Eagle Adapter Cable black Item No 1852055 MKR US 6 AJIA QN3 90123NNOO YOLIINNOD JINVYMOT ek ad AV VLOXNNIUI YOOX 401238802 10 NNIN YOLOAINNOD V LOM NNIIA QN3 30123NNO2 12 12 02 19 03 Minn Kota Universal Sonar Models Vexilar Adapter Cable Item No 1852056 MKR US 7 YOLIAINNOD YOLIINNOD UVIIXSA V1ON NNIN 801238 02 e se 2 mE d HV TIX3A V LOX NNI YOLIINNOD VION QN4 YOLIANNOD 12 13 02 19 03 Minn Kota Universal Sonar Models Humminbird Techsonic Adapter Cable Item No 1852057 MKR US 8 0731 10 NNIN 2INOSHO3L V LOX NNIN YO1LIINNOD 931NOSH211 YOLIANNOD VIO NNIW YOLIINNOD JINOSHDIL
5. 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 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 Ifthe motor does run go to Step 3 Units with soft pots only Check soft pot P N 2364005 on control board A Visually check soft pot for collapsed dome switches or a break down of the silver conductive layer for the speed control If necessary solder on replacement soft pot P N 2364005 and test motor for proper operation per the procedure shown in Service Bulletin dated 1 12 99 Case 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 all wires are securely attached to the proper control board terminals Check for corroded
6. Step 3 Step 4 Step 5 Step 6 Step 7 Turn the Master Switch OFF Simultaneously press and hold Mode Switch while turning the Master Switch ON 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 Release Mode Switch 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 ERS code after completing Step 7 below Simply turn off the Master Switch The next time you turn it back on the ERS 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 Use the TrimUp Switch to stow the motor Release the TrimUp when the unit is fully stowed Press and release Mode Switch to reset the system at
7. PART II Case VIII 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 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 shaft 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 PART II Case IX Latch collar on shaft is broken and needs to be replaced Step 1 Remove any remnants of the original collar Step 2 Remove control box cover and control box from the motor composite shaft Loosen drive collar and slide motor lower unit and shaft out of the drive housing Step 3 Using a large blade screwdriver as a wedge pry open the new latch collar by inserting the blade of the screwdriver in the split of the new collar Spread the collar open far enough to allow it to be slid down the shaft from the top to the bottom threaded section of the shaft right above the motor lower unit Step 4 Reassemble the motor in reverse order of disassembly Step 5 Adjust latch collar so that the latch handle firmly engages the collar and the motor lower unit is held tightly in pla
8. 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 automatically display A B C The LCD on motor will display OF0 OF1 or OF2 The display will show last setting selected Press and release the right momentary steering switch to select offset table OF0 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 1 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 11 29 11 28 Genesis Repair Manual 12 02 02 GENESIS Calibrating AutoPilot Compass Software This procedure should only be used gt After replacing the main control board compass assembly gt 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
9. 3 gt ASJ 3 4 PowerDrive Repair Manual 10 31 02 Wiring Gauge Chart The chart below should clarify voltage loss on all of the common wire sizes that we work with The number represents voltage loss per foot In calculating loss the length of wire should be doubled and multiplied to the number in the chart 50 Amps 0125 volis 012 vols 02 voi 032 vols 051 vols O81 vol 20 foot of 10 gauge wire at 40 amps 40 x 0408 1 63 volt drop 3 5 AutoPilot Repair Manual 05 14 03 Section 4 AutoPilot PD AP Models Corded foot pedal models non Genesis This AutoPilot Repair Manual Section 4 is divided into Part I and Part II Part I pertains to motors manufactured prior to model year 2001 prior to S N MKABxxx AutoPilot switch is located on the lower speed control cover pages 4 1 through 4 7 Part Il pertains to 2001 and later models S N MKABxxx and later AutoPilot switch is located on the top control box cover pages 4 8 through 4 13 PARTI Motors manufactured prior to model year 2001 prior to S N MKABxxx PART I Case I Drive Housing will not steer in either direction 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 attache
10. Case II The motor runs but the stow and deplov svstem fails to operate Step 1 Step 2 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 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 10 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 control board B Apply 12 volts directly to the li
11. or 3 5 8 motor assemblies the marking notch should be on the bottom towards the skeg Case IV Motor is noisy Step 1 Possible causes A Water in lower unit B Broken brush plate C Grease or replace armature bearing roller bearing spherical bearing amp flange bearing D Chipped broken brushes new brushes may take a few hours of operation to seat or round to the commutator and quiet down E Ensure rear seal shield 3 1 4 and 3 5 8 motors only is securely in place and not squealing or rubbing against armature shaft F Chipped broken magnets a rule of thumb is if the magnet that chips out is less than 1 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 H Rough worn commutator where brushes ride on armature Smooth with fine sandpaper or emery cloth If scratched too deeply replace armature Case V 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
12. 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 Ifunit 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 Terminal Terminal 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 A terminal 1 If no continuity is noted replace the 12 24 switch and test motor for proper operation 2 If continuity is observed proceed to Step 3B B 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 Motor operates on some speeds not
13. GENESIS Steering System Module see also Foot Pedal Module page 11 17 and or AutoPilot Steering Malfunction page 11 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 1 2 If threads 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
14. If LED operations is 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 5 3 NOTE when using test pedal adapter the MOM CON lever of the corded test foot pedal must be in the CON 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 Non 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 A Verify proper battery voltage to trolling motor 12v or 24v B Make sure that motor on off switch on motor is ON before foot pedal ON OFF switch is turned ON C 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 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 D If batteries and connections in
15. 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 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 CoPilot Wireless Accessory 04 15 03 Section 16 CoPilot Wireless Accessory Although the CoPilot transmitter remote and receiver are not serviceable in the field we have included this Section in the Service Repair Manual to help you understand the product and answer consumer questions regarding the CoPilot Consumers with possible defective CoPilots should be directed to the Minn Kota Customer Service hotline toll free at 800 227 6433 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 pres
16. Step 3 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 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 of adequate wire gauge in boat or any leadwire extension is critical to avoid voltage drop low voltage to the motor as can an inadequate or corroded plug plug receptacle 4 2 AutoPilot Repair Manual 05 14 03 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 SB122099 AutoPilot Compass Control Board Trim Pot Adjustment Procedure page 4 6 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 4 4 If operation is restored replace the sensor board compass assembly If it isn t restored repl
17. 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 4 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 I D 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 17 2 3X Steering Repair Manual 01 21 04 A Reconnect 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 B 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 switc
18. a rubber mallet works well to seat the case halves flush tight Install and tighten case screws 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 Case HI 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 Defective main control board Replace main control board PART II Case IV Motor steers properly but motor lower unit does not run Step 1 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 Step 2 Check motor with known good test foot pedal or test the foot pedal by performing the Foot Pedal Test Procedure see page 3 4 A If test pedal properly controls all motor functions or if the original foot pedal tests bad as outlined on page 3 4 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 3 4 go to Step 3 Step 3 Che
19. belt in the same position and manner it was attached prior to disassembly B Reassemble the Genesis motor in reverse order of disassembly making certain that the anti rattle bushing in the outer shaft stays in its proper place BA 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 to proper voltage Deploy the unit and test for proper function 11 20 Genesis Repair Manual 12 02 02 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 Y v Vv v v 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 Please read this entire procedure prior before performing the Master Reset so that you understand the important notes in Step 5 Master Reset Steps left sideplate should be in place over the counter wheel Step 1 Step 2
20. 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 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 11 18 Genesis Repair Manual 12 02 02 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 gt Lower unit has been forced to turn steering clutch slipped more than one full turn from its original position LCD will display ER3 gt if motor 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 gt if steering potentiometer board has been replaced Step 1 Step 2 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 han
21. 4 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 when ON and no continuity with switch OFF Replace ON OFF switch if defective otherwise replace main control board PART I Case IV AutoPilot changes directions with speed changes Step 1 Step 2 Small direction changes with speed changes are normal If direction changes are more than 4 to 5 degrees perform the Compass Calibration Procedure see page 4 5 PART I Case V Motor won t steer or steers slowly at higher thrust settings Step 1 Step 2 Step 3 Inspect all battery connections trolling motor plug if installed and any butt splice connections in the battery leadwire for corrosion and security 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 See Wiring Gauge chart for recommended minimum wire sizes by amp draw and wire length page 3 4 If after insuring that all wiring and connections are good the steering is still slow at high thrust settings proceed to Step 3 Disassemble motor to separate the drive housing from the motor and tube and bowplate extrusion assembly A Remove the six screws holdi
22. 99 B 1 Ifthere is no control board output motor not running replace control board B 2 there is control board output but the soft pot is worn or either of the dome switches is bad replace the soft pot solder on replacement soft pot P N 2364005 per the procedure shown in Service Bulletin dated 1 12 99 When reassembling the handle pay close attention to ensure that the actuation spring and pin are correctly installed and making contact with the soft pot With the new soft pot and handle reassembled re test motor for proper operation 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 board output the main control board is defective Case III Directional Indicator always stays lit units with magnetic on off reed switch only This reed switch is usually open With the handle bar magnet in close proximity to the reed switch the re
23. Left and Right Park Position values IMPORTANT NOTE The motor may immediately start steering after releasing the buttons described in Step If this happens disengage the steering A S A P by pressing and releasing a momentary steering button A G Using the test foot pedal P N 27720407 press and hold both the TrimUp and TrimDown buttons while turning the Master Switch ON then release both trim buttons Disengage steering 1f motor starts to spin as called out in above IMPORTANT NOTE LCD display on motor should read B 1 If LCD shows SET PROPELLER turn pedal OFF and perform Master Reset as described on page 11 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 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 Press the Momentary ON switch located on heel toe steering pedal once to enter this setting into the main board memory LCD on motor should now read Rt 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
24. ON observe LCD for proper function Test all motor operations for proper 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 Make 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 11 21 11 16 Genesis Repair Manual 12 02 02 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 1 When Master Swi
25. Retest for proper fine adjust function after reassembly to reset the 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
26. 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 control board can be left in the motor control box Be sure to follow the wiring connections as outlined and shown in this procedure 2 Variations of compass boards trim pot A trim pot 12vdc Pin 2 12vdc Diagram 1 A NOTE The diagrams show this procedure being performed with the compass board assembly removed from the AutoPilot control box for clarity This procedure can be done without removing compass assembly Pin 1 Pin 2 trim pot A trim pot B Production Date 12vdc 12vdc Diagram 1 B 4 11 AutoPilot Repair Manual 05 14 03 NOTE The diagrams show this procedure being performed with the compass board assembly removed from the AutoPilot control box for clarity This procedure can be done without removing compass assembly Diagram 2 NOTE Compass removed from motor and not covered for clarification Comp
27. as in above Step 4 C 1 A Because the center section magnet shell and the skeg rudder are electrically isolated from each other due to o rings and or paint you may need to run the ground wire to the center section and the skeg This involves either baring a spot under the transducer clamp stainless steel hose clamp and placing the ground wire in contact with the bare spot under the loose clamp or a piece of aluminum sheet may be used between the motor and transducer ground the aluminum sheet to the motor skeg 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 15 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 2 and 3 and testing with the depth finder 9 2 Vantage Repair Manual 12 04 02 Section 10 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
28. at higher thrust settings See Wiring Gauge chart for recommended minimum wire sizes by amp draw and wire length page 3 5 If after insuring that all wiring and connections are good the steering is still slow at high thrust 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 4 8 AutoPilot Repair Manual 05 14 03 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 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 238 Moly Ultra Supreme grease or a similar lubricant 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
29. 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 A 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 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 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 Depth Finder Interference 10 31 02 Step 5 In certain situations when the above steps do not take care of the interference One additional step may be tried NOTE this is an external ground situation only
30. be slid out of the transom bracket hinge or BowGuard 360 A On transom mount 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 is 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 17 6 Step 1 Step 2 Step 3 Step 4 Step 5 3X Steering Repair Manual 01 21 04 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 17 4 Re install the 4 hole collar upper bearing and pinion assembly in the inner 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 On transom mount 3X motors the two teeth with th
31. disassemble the Genesis motor per Parts I II and 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 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 Disconnect the leads connecting steering chassis potentiometer board and steering motor to coil cord wires Loosen the potentiometer pulley setscrew item 51 of the Steering Module parts explosion and remove the potentiometer gear pulley Unscrew the nut that holds the steering potentiometer into the steering chassis mounting plate assembly item 19 of the Steering Module parts explosion Remove the steering potentiometer circuit board from the steering chassis by carefully prying outward on the board retaining fingers 11 23 Genesis Repair Manual 12 02 02 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 pi
32. doing this procedure Calibrating AutoPilot Compass Software Steps Motor must be connected to appropriate voltage and be DEPLOYED for the following procedure and test Calibrating Compass Software Note 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 Step 1 Step 2 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 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
33. holding the white plastic continuous actuator in place B Place shim P N 2301731 between actuator and foot pedal base C Reassemble slide control MOM CON switch assembly and test for proper operation 5 2 Cordless Motors Repair Manual 10 31 02 Cordless AutoPilot Test Pedal 7 conductor 7 pin plug from feulty main circuit board of a corded powerdrive motor 44 prop relay must bo energized for the stccring to operate Set the speed control to 0 and set 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 wilt no longer operate CORDLESS AUTOPILOT TEST PEDAL 77 5 3 Foot Control Cable Steer w Speed Coil Repair Manual 01 26 04 Section 6 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 cover 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 nece
34. 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 Disconnect the red battery lead from the switch and touch it to each colored speed coil wire at the D gt 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 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 1 1 Hand Control w Control Board Repair Manual 01 20 04 Section 2 Hand Control Models with a Printed Circuit Board Case I Motor runs intermittently cuts in and out fails to run in either forward or reverse or kicks from forward into reverse Step 1 Step 2 Step 3 Check to ensure proper voltage and polarity at battery red black
35. pedal CoPilot is compatible with any PowerDrive or AutoPilot motor with the flat foot pedal plug 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 16 1 CoPilot Wireless Accessory 02 05 03 MISCELLANEOUS INFORMATION The five buttons are for PROP ON OFF STEER LEFT STEER RIGHT INCREASE SPEED AND DECREASE SPEED Pressing 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 level The speed is adjustable from level 0 10 At level 0 the prop will not turn GENERAL OPERATION Using the CoPilot with the corded foot pedal When the MOM CON switch is in the MOM position the angler may begin using the remote at any time As soon as a
36. properly steers motor or if the original pedal tests bad as outlined on page 3 4 the original foot pedal is faulty Disassemble defective pedal to inspect actuators and dome switches Replace foot pedal if necessary B If test pedal does not properly steer the motor or if the original pedal test okay as outlined on page 3 4 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 housing should reverse the direction of rotation Repair or replace drive housing if required If drive housing test okay proceed to next step C 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 D If above steps test fine the AutoPilot compass control board assembly in the upper control box is faulty Replace compass board assembly PART II 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
37. spin on steering pot shaft without changing pot values gt Steering motor may be overheated the steering motor should draw less than two amps while steering ina 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 gt Steering motor output gear broken internally see page 11 4 Case V gt Set screw mating the worm gear to the steering motor shaft is loose see page 11 4 Case V vy v Vv Vv WV v ER6 Lift system is not responding gt Motor is blocked and cannot trim up or down remove obstructions gt Shaft position counter lost reference possibly due to improper lift belt tension Adjust lift belt tension see page 11 7 Case I gt Coupler gear broken see page 11 7 Case III LP Low power less than 8 volts for 12v units and 16 volts for 24v units under load gt 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 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 11 18 Case VIII Genesis Repair Manual 12 02 02
38. surface of the locking collar See Genesis Transducer Routing 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 Genesis Repair Manual 12 02 02 Case II Steering motor has overheated and smoked due to jammed steering condition see Steering System Malfunction Case D 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 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 Modul
39. the female connector does not slip down beside the male connector It may feel like the connector went on properly but this connection will fail gt For quick troubleshooting use a 12 volt light bulb automotive dome or brake light with wires and alligator clips Clip it 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 gt If you have replaced a board in the same motor more than once this is probably 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 gt 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 is defective On AutoPilot motors seldom do both boards fail at the same time Please double check Hi Hand Control w Speed Coil Repair Manual 10 31 02 Section 1 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
40. 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 2056515 along with the gear housing o ring P N 2054600 See figure 3 page 10 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 III Step 2A that the drive lock pin P N 2052615 see figure 4 page 10 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 4 to 5 16 protruding from the pinion gear on the same side as the 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 is needed See NOTE on top of page 10 2 for information on how to identify lift system 10 3 Vantage Repair Manual 12 04 02 1 Ifexamination
41. 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 E 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 F Initialize and test for motor operation with new switch to verify function 5 Cordless Motors Repair Manual 10 31 02 Case 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 AutoPilot of cordless motor fails to operate Step 1 Consult Section 4 AutoPilot Models Part I Case on page 4 2 for troubleshooting steps and compass isolation test NOTE motor must be initialized properly first Be sure bot
42. the sensor 1 resistor as shown in diagram 2 D Observe the voltage displayed on the V O M while slightly turning the compass a few degrees each side of the original southeast heading E 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 F Using a small non magnetic blade screwdriver adjust trim pot 1 so that the voltage displayed on the V O M 15 as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance Step 2 Test adjust the sensor 2 voltage see above diagram 1 for component location A Tightly cover the compass card with a shop rag to block any light source on the optical sensors B With the compass level and pointed southwest connect 12 volts to the orange 12 and brown ground terminals C 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 D 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 adjustme
43. this point the LCD display should have switched from Sto to the hour meter reading and then turn the Master Switch OFF 11 21 Step 1 Step 2 Step 3 Step 4 Step 5 Genesis Repair Manual 12 02 02 GENESIS Identifying Software Version Code Check to ensure proper voltage and polarity at battery Genesis 55 12v Genesis 74 24v Turn the Master Switch located on side of foot pedal ON Turn the speed control knob on the foot pedal so that it reads 100 full speed While watching the LCD turn Master Switch OFF The software version will flash momentarily on the LCD just before the LCD screen goes blank If the software version shown is number 102 or less the main power control board will need to be replaced page 11 25 reprogrammed page 11 27 and recalibrated page 11 29 11 22 Genesis Repair Manual 12 02 02 GENESIS Steering Potentiometer Testing amp Replacement Case I 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 A Correct any questionable connections and retest motor operation Step 2 Check to ensure that the steering potentiometer belt is in place on the primary gear and steering potentiometer Step 3 If belt is in place make
44. transducer at the extension cable plug end that exits the motor coil cord PD AP and Genesis models or footpedal Maxxum foot control models using your capacitance meter as per Figure 1 Touch the red and black probes from your capacitance meter to the correct pins on the plug transducer and For proper orientation be sure the connector key ridge is at the top of the plug as in Figure 1 page 12 3 just above and between the red and black probes Step 3 Step 4 Step 5 Step 6 Minn Kota Universal Sonar Models 10 31 02 A 1 Ifthe capacitance falls within the minimum and maximum allowable limits per Chart A for the specific Minn Kota Universal Sonar motor being tested go to Step 3 A 2 Ifthe capacitance falls outside the minimum and maximum allowable limits go to Step 4 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 Identify Sonar make then consult pin out diagram for that adapter cable starting on page 12 7 Check continuity from Minn Kota pins to Sonar adapter plug pins A 1 Ifthe adapter has continuity through all three pins the problem lies with the sonar unit not the Minn Kota Universal Sonar motor The customer should refer to his sonar unit owner s manual A 2 Ifthe adapter does not have continuity adapter is defective Replace adapter Procedure is complete Measure the capacitance of the Universal t
45. volt units you will not receive the compensating magnet bracket and magnet rods 11 25 Genesis Repair Manual 12 02 02 C 1 install the compensating 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 11 27 11 26 Genesis Repair Manual 07 23 03 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 Steps Motor must be connected to appropriate voltage Step 1 Readying the motor for Initial Control Board Programming A B Perform the complete Master Re
46. 072810 detent block see Fig 4 page 17 3 Step 7 Remove the two soft plastic pivot knob covers P N 2070117 or 2070118 to expose the two 4 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 yoke P N 2071512 or 2072513 assembly see Fig 4 page 17 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 17 3 Step 8 With the control box assembly removed unscrew the 5 16 x 12 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 17 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 17 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 UN b 207 730 screw 8 eo primer 7649 am
47. 6 25 and 24 of the Base Housing parts explosion Remove the three button head cap screws 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 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 Gear Shaft amp Sprocket Assembly Thrust washer in proper location 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 11 14 Genesis Repair Manual 12 02 02 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 inside the lift housing around
48. 711 lt 205 7200 205 3414 2 205 0220 Figure d 201 2100 T 205 0101 205 3700 205 3412 Ne 205 3700 24 042 3 6 Figure 2 10 6 Vantage Repair Manual 10 31 02 205 0921 003 205 3107 205 2511 2053415 7 i 995 0156 E 205 1737 handle assembly 205 6510 D ir 3115 205 0015 205 3402 205 4600 2056515 e 238 3500 205 3407 2 4 205 2208 226 1712 Q 205 2620 231 5105 s i e 205 1705 Fia NT 205 3407 205 0800 205 2205 Qvo 205 2615 a 2057306 rs aS 205 1706 4 Motor screws 2 5 831 070 3 ee 205 2000 10 7 Vantage Repair Manual 10 31 02 4 205 3413 t how 4 215 1726 4 205 3103 Ke e 4 205 3511 299 0429 205 1920 m ud 205 2610 S 205 2705 205 3418 D 205 2305 qu e Fiquve 5 ES 205 3205 205 3417 205 6200 205 1510 235 3401 205 3400 205 3401 Figu 6 10 8 Vantage Repair Manual 10 31 02 211 6517 VANTAGE UPGRADE KIT BEARING USE EXISTING STEER ING GEAR USE EXISTING PIN DRIVLOK USE EXISTING WASHER USE EXISTING STEERING SHAFT USE EXISTING DO NOT DISASSEMBLE STEERING SHAFT ASSEMBLY REMOVE BEARING SCREWS AND LIFT ASSEMBLY OUT OF TOP PLATE NOTE THE ORIENTATION OF THE DRIVLOK PIN IN RELATION TO MOTOR POSITION THE
49. 87 005 Chart B Minn Kota Universal Sonar Models 01 13 04 With the proper Minn Kota adapter cable the Universal Sonar transducer will be compatible with the following sonar units Bottom Line Tournament NCC 5300 Tournament NCC6500 Minn Kota Adapter MKR US 2 Tournament 1250 Tournament 3310 Tournament 4300 Tournament 3100 Tournament 4100 Tournament 5100 Tournament NCC6300 Tournament 320MAX Tournament 480 Minn Kota Adapter MKR US 3 Eagle FishEasy 2 FishEasy 2P manufactured prior to 2003 FishEasy 2T manufactured prior to 2003 FishMark 160 FishMark 240 TriFinder 2 Minn Kota Adapter MKR US 5 Accura 240 Accura 240FLW Fish Easy Fish Easy ST Fish ID 128 Optima Strata 128 Strata 128 Plus Strataview 128 Trifinder Trifinder FLW Ultra Classic Ultra Classic Plus Minn Kota Adapter MKR US 6 Cuda 128 Cuda 168 Cuda 168EX Cuda 240GPS FishEasy 2 manufactured after 2002 FishEasy 2T manufactured after 2002 FishElite 320 FishElite 480DF FishMark 320 FishMark 480 SeaFinder 240DF SeaFinder 320DF SeaCharter 480DF Minn Kota Adapter MKR US 9 Garmin Fishfinder 100 Fishfinder 160 Fishfinder 240 Fishfinder 250 Fishfinder 250C Fishfinder 320C GPSMAP 168 GPSMAP 178C Fishfinder 80 Fishfinder 120 with optional Garmin part number 010 10145 00 sold separately Minn Kota Adapter MKR US 1 Humminbird 1005 4055 LCRW 525 Tracker Pro 160 Boater s World Pro Angler 400 Legend 1000
50. AP model and the LCD 04107 icon is displayed Step 2 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 is 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 3 Ensure the compass assembly is fully snapped in place and seated on the compass bracket compass is setting level and able to spin freely 11 31 Genesis Repair Manual 12 02 02 Step 4 Spin the base of the motor a complete revolution and ensure the internal compass card is spinning freely not hang
51. ATTERY REPLACEMENT tre REPLACEMENT BATTERY MUST BE A MODEL CR2032 COIN CELL TYPE To replace the battery follow these steps 1 Temporarily ground yourself by 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 16 2 3X Steering Repair Manual 01 21 04 Section 17 3X Steering For step by step motor lower unit procedures refer to Sections 1 2 and 13 of the Minn Kota Service Manual For the one time procedure to initially orient straight ahead on bowmount 3X models go to page 17 9 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 clos
52. IT 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 10 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 Pi lift motor pulley as shown with belt removed for clarity Please note that many of the lift system parts shown on your Vantage parts list will automatically substitute to this kit To avoid duplication simply order P N 2776517 and you will receive the parts you need to retrofit the new lift system components on earlier Vantage motors Install the new upgrade kit as per the disassembly and re assembly procedures outlined later in this section To insure proper operation of the lift system install all of the new parts included with the upgrade kit The kit is shipped assembled for ease of installation 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 any lift system parts for later model Vantage motors
53. Legend 2000 Minn Kota Adapter MKR US 4 Legend 3000 400TX 300TX Piranha 1 Piranha 2 Piranha 3 Piranha 4 Piranha 5 PiranhaMAX 10 PiranhaMAX 15 PiranhaMAX 20 Matrix 10 Matrix 15 Matrix 17 Matrix 20 Matrix 25 Matrix 27 Matrix 35 Matrix 37 Matrix 55 Matrix 65 Matrix 67 Matrix 97 Minn Kota Adapter MKR US 8 Lowrance LCX 15C LCX 15CI LCX 15CT LCX 15MT LCX 16CI LCX 16CT LCX 18C LCX 19C LCX 104C LMS 240 LMS 320 LMS 320DF X51 X 58DF X71 X 87 X 88DF X91 X 97 X 98DF 100C X 105C DF X125 X 126 DF X 135 X 136 DF LMS 480 LMS 480 DF LMS 330C LMS 335C DF Minn Kota Adapter MKR US 5 X24 X28 X29 X38 X48 X49 X58 X65 X75 X85 Minn Kota Adapter MKR US 6 X 47 X 47EX X 67C M 56 M 68C Minn Kota Adapter MKR US 9 Vexilar FL 8 FL 8 SE FL 8 SLT FL 10 FL 18CLC 200 Minn Kota Adapter MKR US 7 Zercom Z160 Minn Kota Adapter MKR US 4 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 12 4 Minn Kota Universal Sonar Models 11 08 02 Minn Kota Universal Sonar Transducer amp Cable Assembly Note Take transducer capacitance readings across the TX and TX pins o 2 lt L J LJ gt e gt me Q2 c 8 2 54 lt gt lu 2 UO uw eo 11 08 02 Minn Kota Un
54. Minn Kota Repair Manual 01 15 04 Minn Kota Service Manual This manual is designed to assist in basic trouble shooting procedures for MinnKota trolling motors Table of Contents Page Safety Warnings ii Trouble Shooting Tips iii Section 1 Hand Control Models with a Speed Coil 1 1 5 speed models Section 2 Hand Control Models with a Printed Circuit Board 2 1 Variable speed models Section 3 PowerDrive PD Models 3 1 Corded foot pedal non AutoPilot non Genesis models Section 4 AutoPilot PD AP Models 4 1 Corded foot pedal non Genesis models Part I motors prior to model year 2001 page 4 1 Part II 2001 and later motors page 4 8 Section 5 Cordless PowerDrives and AutoPilot Models 5 1 Radio frequency controlled models manufactured between 1996 1999 Section 6 Foot Control Cable Steer Models with a Speed Coil 6 1 5 speed Maxxum and Terrain units Section 7 Foot Control Cable Steer Models with a Control Board 7 1 Variable speed Maxxum Terrain units Section 8 PowerUp Lifts Trims and Tilts 8 1 Models manufactured between 1996 2002 Section 9 Depth Finder Interference 9 1 Section 10 Vantage Motors 10 1 Section 11 Genesis Motors 11 1 Section 12 Minn Kota Universal Sonar 12 1 Section 13 Lower Unit Motor Assembly 13 1 includes instructions to remove motor assembly from composite tube Section 14 Engine Mount EM amp Neptune 14 1 Section 15 DeckHand Electric Anchors 15 1
55. Remove extrusion shield P N 2050220 see figure 1 page 10 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 if 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 A 1 Ifthe 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 A 2 Ifthe motor does run go to Step 4 Check ON OFF switch and speed control potentiometer in the steering 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 Ifnocontinuity is noted go to Step 5 C Ifcontinuity is observed go to Step 6 Disassemble the steering handle assembly see figure 2 page 10 6 A Remove the gray steering handle grip and unscrew the four han
56. Section 16 CoPilot Wireless Accessory 16 1 Section 17 Steering 17 1 Minn Kota Repair Manual 10 31 02 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 10 31 02 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 is more important than ever to correctly diagnose the problem before replacing parts Here are a few trouble shooting suggestions gt If possible locate the failure before replacing any parts Sometimes disassembly fixes the problem pinched wires poor connections etc gt 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 gt On control boards with clear sleeves around the quick disconnects be sure
57. UNIT MUST BE REASSEMBL IN THE SAME POSITION IT WAS PRIOR TO DISASSEMBLY 208 3402 SCREW 10 24 53 211 2202 CLUSTER GEAR BEARING SCREWS USE EXISTING 205 0800 DRIVE BELT BEARING WASHERS USE EXISTING RR 0 831 070 MOTOR SCREW 3 OY LIFT GEAR USE EXISTING ho 299 1927 TOP PLATE ASSEM 205 3420 SET SCREW m has 203 1703 THRUST WASHER 299 6515 LOWER GLAR CAP ASSEM 5 205 1705 NYLON WASHER T 205 1302 UPPER BEARING LIFTSCREW 205 8411 T TENSIONER 205 2620 PIN DRIVLOK LIFT SCREW USE EXISTING 205 7801 LIFT MOTOR Figure 7 Genesis Repair Manual 12 02 02 Section 11 Genesis Tools Required for Servicing Genesis motors gt Test Foot Pedal Minn Kota P N 2772040T has trim actuator removed for programming purposes gt 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 Error Codes amp Probable Causes page 11 2 Steering System Module page 11 3 Lift System Trim System Module pag
58. ace the main control board PART I 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 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 found on page 3 4 A If test pedal properly controls all motor functions or if the original foot pedal tests bad as outlined on page 3 4 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 3 4 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 IfSteps 1 2 and 3 test okay the main control board is faulty and needs to be replaced PART I Case VIII All functions dead Step 1 Check for proper battery voltage and polarity at the control board in
59. age situations Use of adequate wire gauge in boat or any leadwire extension is critical to avoid voltage drop low voltage to the motor as can 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 4 9 AutoPilot Repair Manual 05 14 03 Step 5 Check AutoPilot compass control board for proper voltage levels at the optical sensor circuit See Minn Kota Repair Bulletin SB72001 AutoPilot Compass Control Board Trim Pot Adjustment Procedure page 4 11 PART II Case VI 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 II Case 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 C Reassemble slide control and MOM CON switch assembly Test for proper operation
60. aker 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 Case DeckHand does not have enough power to lift anchor you need to help 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 Cas
61. 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 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 B If test pedal does not properly steer motor or if original pedal tests okay as outlined on page 3 4 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 or a similar lubricant 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 3 4 If test pedal properly controls propeller speed or if the ori
62. as shown below Disconnect the red and black motor leads and slip steering potentiometer belt up and off of the primary gear Take care not to rotate the steering potentiometer 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 Primary Gear Retaining Screw Genesis Repair Manual 12 02 02 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 11 10 Genesis Repair Manual 12 02 02 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 11 11 Genesis Repair Manual 12 02 02 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 11 12 Genesis Repair Manual 05 20 03 B With the two belts glued and taped together push the belt into the botto
63. ase 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 6 1 Foot Control Cable Steer w Speed Coil Repair Manual 01 26 04 B If no voltage is present test foot pedal momentary ON OFF switch for continuity with ON OFF switch depressed 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 If no voltage is noted remove foot pedal base cover and check connections at MOM OFF CON switch B Check MOM OFF CON switch for continuity across center terminal to momentary terminal white wire with switch in the MOM position C 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 secure
64. ass card should be covered to block any light on the optical sensors STEP 1 Test adjust the sensor 1 voltage see diagram 1 or 1 B for component location A B 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 red 12v and brown ground terminals see diagram 2 With your digital VOM set to check DC voltage connect the black VOM lead to the brown ground terminal on the compass control board and firmly touch the red probe of the VOM lead to pin 1 of the L C as shown in diagram 2 Observe the voltage displayed on the VOM 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 VOM 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 On compass boards with date of production prior to 11 01 00 using a small non magnetic blade screwdriver adjust trim pot A so that the voltage displayed on the VOM is as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance On compass boards with date of production after 11 01 00 using a small non magnetic blade screwdriver adjust trim pot B so that the voltage displayed on the VOM is as close as possible to 1 volt 25v C
65. bly 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 Screws B With the four retaining screws removed the pinion assembly upper bearing and 4 hole collar can be removed 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 To remove the pivot yoke from the upper end of the outer tube loosen the 4 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 A 1 Ontransom mount 3X motors the steering tension knob is positioned towards the bracket clamp screws A 2 On bow mount 3X 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 yoke in relation to the slots grooves in the outer tube For further disassembly replacement of the transom bracket or BowGuard 360 assembly the outer tube or outer tube and pivot yoke assembly can
66. ce on the motor rest See Case VIII for adjustment procedures Retighten the clamping screw on the collar Effects of Broken or Intermittent Wires in Coil Cords gt 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 15 turned on and the motor will track and hold a heading in the normal AP manner gt Ifthe 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 the left or right side of the steering pedal is pressed gt Ifeither 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 gt Ifthe 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 4 10 AutoPilot Repair Manual 06 04 03 AutoPilot Compass Control Board Trim Pot Adjustment Procedure 2001 AND LATER MODELS ONLY Note
67. ck 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 IfSteps 1 2 and 3 test okay the main control board is faulty and needs to be replaced PART II Case V 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 spin 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 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 voltage to motor while motor is under load AutoPilot steering is susceptible to erratic operation in low volt
68. 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 Ifmotor 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 Remove soft pot from handle assembly and ensure actuator pin and actuator spring are making proper contact on the silver conductor layer of the soft pot Visually inspect soft pot for collapsed dome switches and excess wear on silver conductive layer of soft pot If 2 1 Hand Control w Control Board Repair Manual 01 20 04 necessary solder on replace soft pot P N 2364005 and test motor for proper operation per the procedure shown in Service Bulletin dated 1 12 99 B Operate control board manually without handle assembly actuators With battery and brush leads attached to proper terminals of the control board activate switch in upper right hand corner and run fingertip around silver conductive layer The motor should be varying in speed as you apply pressure to the forward speed portion of the soft pot As per Service Bulletin dated 1 12
69. ct Genesis motor to the appropriate voltage and test 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 A 1 replace broken output shaft gear see Steering System Module Case Steps 1 amp 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 1 Disassemble steering system as per Case II Step 2 Steering System Module Genesis Repair Manual 12 02 02 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
70. ctions are now incorporated into the new compass control board assembly located in the control box head The existing AutoPilot test board P N 20 does not work with the new board The AP ON OFF switch is now in the top control box gt The main control board on the 2001 PD AP serves only two functions It provides power to the compass sensor control board assembly and it controls the Maximizer variable speed function for the motor lower unit gt The same main control board is now used in both AutoPilot and non AutoPilot models gt AutoPilot compass calibration is no longer a big issue due to magnetic interference surrounding the motor leads To lessen the interference the coil cord now enters the front of the control box and the compass is moved further back and higher up than on previous AutoPilot models PART II Case I Drive Housing will not steer in either direction with AP switch turned ON or OFF 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 3 4 A If test pedal
71. d replacement Case III Vantage motor lower unit does not steer when the handle is turned from side to side Step 1 Step 2 Step 1 Step 2 Step 3 Disassemble to visually inspect the steering rack and pinion gear See Disassembly Steps 1 amp 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 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 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 15 motor white wire light is power indicator See figure 1 page 10 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
72. d to place it in this position With the Master Switch OFF and the control box cover removed to expose the Genesis primary gear and potentiometer belt A Slip the belt off the primary gear and steering potentiometer gear Turn steering potentiometer counter clockwise to its rotational stop B 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 C 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 B Turn Master Switch OFF Slip the steering potentiometer belt off the primary gear and steering potentiometer With 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 ho
73. d 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 the original pedal by performing Foot Pedal PCB Test Procedure on page 3 4 A If test pedal properly steers motor or if the original pedal tests faulty as outlined on page 3 4 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 B If test pedal does not properly steer motor or if the original pedal tests okay as outlined on page 3 4 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 d
74. dle 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 is 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 1k ohm or slightly higher B With speed control knob 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 1k ohm as the knob is turned to the highest speed setting 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 10 1 Vantage Repair Manual 12 04 02 LIFT SYSTEM UPGRADE K
75. 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 I page 7 3 C Inspect set 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 set screws while earlier version just used 2 set screws Case IV 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 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 gt 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 assembl
76. e 11 7 AP PD Housing Module page 11 16 Foot Pedal Module page 11 17 To Re Orient Steering Potentiometer to Motor Position page 11 19 Lower Shaft Collar page 11 20 Master Reset Emergency Override page 11 21 Identifying Software Version Code page 11 22 Steering Potentiometer Testing amp Replacement page 11 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 11 25 B Initial Programming Procedure page 11 27 C Calibrating AutoPilot Compass page 11 29 AutoPilot Steering Malfunction page 11 31 Genesis Repair Manual 12 02 02 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 is required see page 11 21 Also check to insure proper li
77. e 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 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 15 1 DeckHand Electric Anchor 12 11 02 Case 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 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
78. e 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 A Check to ensure that the magnet is in place in the handle pivot assembly B Check to ensure that the sensor bracket and on off reed switch are in the proper position 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 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 17 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 17 2 A With the cover screws removed the control box cover can be lifted up and tipped to the s
79. e parts explosion 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 Replace the steering motor assembly with the appropriate part P N 2777805 for 12V model and P N 2777806 for 24V Genesis 1 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 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 II 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 Conne
80. e raised bumps need to be oriented toward the nose of the motor lower unit when installed in the inner tube 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 1 Re apply 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 A 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 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 17 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
81. ed 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 A Check to ensure that the magnet is in place in the handle pivot assembly B Check to ensure that the sensor bracket and on off reed switch are in the proper position 2 2 PowerDrive Repair Manual 10 31 02 Section 3 PowerDrive PD Models Corded foot pedal non AutoPilot amp non Genesis models 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 3 4 A If test pedal properly steers motor or if the original pedal tests bad as outlined on page 3 4 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 1 If dome switches burnt check drive housing for short between either of the drive housing wires
82. ee Case IV regarding noisy motor amp 10 31 02 Section 14 Engine Mount amp Neptune 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 necessary 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 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 The test procedure for the hand controller is performed with your V O M set on the Resistance x 1 scale 1 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 1K 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 yo
83. eplace components as required B Reassemble foot pedal leave 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 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 B Place washer P N 2301731 between actuator and foot pedal base Reassemble slide control MOM CON switch assembly Test for proper operation Case V Motor won t steer or steers slowly at higher thrust settings NOTE this section applies to both PowerDrive and AutoPilot models 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 See Wiring Gauge chart for recommended minimum wire sizes by amp draw and wire length page 3 5 If after insuring that all wiring and connections are good the steering is still slow at high thrust set
84. er for interference while operating motor Step 1 Step 2 Step 3 Step 4 A B If interference is still present at Step 1B proceed as follows Connect a light gauge wire 18 gauge is fine from 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 Test for depth finder interference while operating the motor A B If interference is still present after installing the ground wire proceed as follows 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 Test depth finder for interference while operating the motor A B If interference persists after completing the previous steps proceed as follows Check mounting location of the depth finder transducer If the transducer is 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 If the interference is 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 To reduce eliminate this type of RF interference a ground wire
85. er 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 After removing the retainer light assembly remove the coupler socket idler gear idler plate and preload ring P Ns 2070800 2070801 2072215 2071900 and 2073000 see Fig 4 clamp wire coupler socket 226 3201 207 0800 Black 207 0801 White screw 8 32 1 2 retainer light d idler gear 233 2101 qty 2 207 2215 idler plate 207 1900 ring preload 207 3000 dir 299 hilt stop brkt us detent block 207 2810 qty 2 s spring detent ___ e gt 207 2705 2 screwH8 18x5 8 237 2100 qty 3 screw 1 4 20x7 8 207 3408 qty 2 E y Y Cover ex sed Wig canttol box nc Oe assembly 207 0117 FW Vai 207 0118 SW screw 5 16 1 2 pivol knob tie 207 0110 qty 2 bushin Washer s s 207 73 Baty 2 gear carrier s d 207 1712 207 2210 o gt lt washer bearing gear carrier 7 207 1710 207 7320 yake pivot 207 1512 FW Ss screw 14 20 1 8 207 1513 SW wm 4 207 3410 nut 114 20 as 207 3100 screw 6 20x5 8 wasner y 230 3412 41 2 207 1714 qty 2 3X Steering Repair Manual 01 21 04 Step 6 Remove the two P N 2332101 8 32 x 4 tilt stop bracket detent block retaining screws then remove the P N 2072815 bracket and P N 2
86. est motor for proper operation B If motor does run go to Step 2 Step 2 If using four 12vdc batteries to power twin 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 battery leads from both modules are then connected to the series connected batteries See diagram below Battery 1 Battery 2 Battery 3 Battery 4 Control Module Control Module Step 3 Check all hand controller control module and 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 Y splitter cable Replace Y cable as needed 14 2 amp 10 31 02 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 co
87. f 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 Lift the cable drum pulley off of the drive pinion Remove the barrel end of each cable core from the pulley Using a needle nose pliers pinch the retainer tabs on the cable housing Push the housing and the cable core through the bracket 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 so the top of the foot pedal is level Install replacement cable assembly in reverse order Adjust the cable core tension by tightening cable adjusting screw so the motor is held stationary and the foot pedal has 3 8 free play Test for proper 360 steering action and ease of operation Diagram 1 7 3 PowerUp Repair Manual 10 31 02 Section 8 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 re
88. for proper steering function Case VI 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 15 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 1 on page 11 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 11 19 As per this procedure it may be necessary to reprogram the left and right park position values into the control board page 11 27 Step 2 Run unit through several stow deploy cycle
89. ft belt tension see page 11 7 Case I Foot pedal is not sending information to motor gt Inspect pedal wire for damage gt Water may be in plug assembly gt Test with new foot pedal Test Pedal P N 2772040T ER3 Sensor board in control head is sending invalid information gt Check orange coil cord wire for continuity gt Iforange wire is okay the lower unit may have been rotated more than one full turn Re orient steering potentiometer to motor position see page 11 19 gt Ifmotor spins in circles you may need to re set park position values see page 11 6 4 Sensor board in control head is not sending information gt 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 11 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 11 3 Check coil cord white and blue wires for continuity Anti rattle bushing not in proper place see page 11 3 amp 11 5 If ER5 occurs while motor is stowed it may be due to improper lift belt tension Adjust lift belt tension see page 11 7 Case I Check to ensure setscrew on the steering potentiometer gear is not stripped causing gear to
90. ft 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 3C B 1 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 Iflift 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 10 2 Vantage Repair Manual 12 04 02 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 b If continuity 1s noted proceed to next step C 2 Disconnect the orange wire from the V O M and connect the blue wire in its place while depressing the UP button a If no continuity is observed go to Case I Step 5 for handle disassembly inspection and control boar
91. g 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 1 2 socket head cap screws located 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 Fig 3 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 17 3 Also note how the directional indicator light wires are twisted and wire 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 8 18 x 5 8 holding the retainer light bracket wire clamp assembly P N 2992900 in place 17 2 3X Steering Repair Manual 01 21 04 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 prop
92. gear is broken replace it with new parts from Minn Kota This gear has been changed serial numbers beginning with MKAA amp serial numbers GNAB0002697 and below need the P N 2222208 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 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 11 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 Genesis Repair Manual 12 02 02 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 12 02 02 A Mark and tape the steering potentiometer
93. ginal pedal tested bad as outlined on page 3 4 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 as outlined on page 3 4 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 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 3 1 PowerDrive Repair Manual 10 31 02 Case 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 R
94. h Then place the handle pivot inner handle and handle bearing in their proper location Note that the triangular shaped arrow on the handle bearing is 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 in 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 E Position cover in place on control box and secure with the six 6 20 x 5 8 phillips head screws P N 2303412 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 steering 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 17 8 3X Steering Repair Manual 01 21 04 This is a one
95. h new pedal Case III When in AutoPilot mode and or when MOM CON 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 11 17 Genesis Repair Manual 12 02 02 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
96. h 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 MKA 9 RT42AP C 8 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 Case VI 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 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 is fishing he may simply swish the foot pedal in the water to temporarily flush the sand dirt 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
97. he 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 error 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 41 2 If the motor does not test within these limits adjust the compensating magnet rods until the AutoPilot tests fine 1 e repeat Step 3 above 11 30 Genesis Repair Manual 12 02 02 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 i
98. he Genesis base housing with the prop pointing to right when viewing the LCD Using care not to adjust the footpedal rocker steering position press Momentary ON switch located on the heel toe steering pedal once to enter this setting into the main board memory Note ifthe 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 B C 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 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 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 11 27 B Genesis Repair Manual 07 23 03 Display should read either up dn The display will show last setting selected On a newly installed board the LCD will default to
99. ide 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 17 1 3X Steering Repair Manual 01 21 04 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 the circular rack and pinion steering gear mechanism 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 On 5 speed 3X models the switch can easily be separated from the control box when the wires are disconnected On variable speed 3X 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 exitin
100. ile 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 2053400 lift screw yoke 2051510 and yoke bearing race P N 2056200 can be lowered out the bottom of the Vantage housing See figures 5 amp 6 page 10 8 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 10 5 Vantage Repair Manual 10 31 02 205 0100 2351 22 205 1717 205020 lt 2 A on 5 230 2100 X2 205 0102 205 0200 201 mE 9 205 Rd Mc de 1716 205 3415 3 Hn om 205 2
101. ing 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 11 29 and 11 30 Note do not install the magnet rods until the procedure instructs you to do so 11 32 Minn Kota Universal Sonar Models 02 19 03 Section 12 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 section 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 A capacitance meter and a good quality multi meter VOM are needed to test the transducer and cable installed in the Minn Kota Universal Sonar Motors We recommend using a Waveteck Meterman model CR50 This meter can be purchased at most major electronics suppliers Some better multi meters may also be capable of measuring capacitance 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 M
102. inn Kota factory warranty will be voided if the consumer tampers with these screws Case I Sonar display blacks out while trolling motor is running This case refers to suggestions the customer should try with the sonar unit and with his boat wiring 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 Determine wiring configuration of the boat A If the power leads of the sonar display are routed next to the power leads for the trolling motor for a great distance separate the leads as much as possible Case II Sonar unit not receiving bottom reading Be sure sonar unit is on current list of models compatible with Universal Sonar see page 12 4 Step 1 Customer should first refer to the sonar unit s owner s manual for its specific trouble shooting guide A If customer still has the original transducer that came with the sonar unit he can use this to determine if the sonar unit faulty or if the Universal transducer is at fault A 1 Ifsonar works properly with original transducer proceed to Step 2 A 2 lfsonar still does not receive bottom reading problem lies in sonar unit Step 2 Verify capacitance measures according to the following picture Figure 1 page 12 3 and chart Chart A page 12 3 A Measure the capacitance of the
103. iversal Sonar Models Minn Kota Cable Extension Part No 2211400 and 2211405 e quo 1oydepe puo 6141 SNId AIAVO OL ATAVO YOLOANNOOD V LOM NNIW Sn d 1959npsuun puo sL 51432065 1 OL ATAVO YOLOANNOD VLON NNIMW 12 02 19 03 Minn Kota Universal Sonar Models Garmin Adapter Cable Item No 1852050 MKR US 1 QN3 YOLIINNOD 7 2 YOLIINNOD NINUV9 YO LOANNOD NIWAY PI IUS 820 894 YOLIINNOD VION NNIW On j x ON JIN e et 7 ON3 YOLIINNOD 12 02 19 03 Minn Kota Universal Sonar Models Bottom Line 9 Pin Adapter Cable Item No 1852051 MKR US 2 M3IA QN3 YOLIINNOD YOLIINNOD IN 1N01108 YOLIANNOD Nid 6 INTI WOLLOS L1 FN MEN MONI SNFNOLLOG YOLOANNOD VLON NNIW M3IA 483 801238802 12 02 19 03 Minn Kota Universal Sonar Models Bottom Line 7 Pin Adapter Cable Item No 1852052 MKR US 3 YOLIINNOD INT IWO1 LOG YOLOANNOD NId L ANTI WOLLOS PIelys 24 YOLIINNOD VIO Nid 3 401108 Wid VLON NNIIN M3IA QN3 YOLIINNOD 12 02 19 03 Minn Kota Universal Sonar Models Humminbird Zercom Techsonic Adapter Cable Item No 1852053 MKR US 4 M3l QN3 90123NNOO MESE NENNEN t NEM NEN i MN 06 POE 2
104. lay 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 should hear the relay click as this is being done B Isolate and disconnect leads from relay harness to lift motor 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
105. ll non magnetic blade screwdriver adjust trim pot A so that the voltage displayed on the VOM is as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance 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 4 13 Cordless Motors Repair Manual 12 17 02 Section 5 Manufactured between 1996 1999 Cordless Powerdrives and AutoPilot Models Case I Motor fails to operate Step 1 Step 2 Step 2 Ensure proper initialization 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 Check receiver sideplate LED operation Upon initialization first command to receiver the receiver sideplate LED should light It will stay on for approximately five minutes even if no further commands are received LED will flash when steering and also flash briefly as speed is changed
106. ly attached to the proper switch terminals Step 2 oo speed coil functionality 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 E 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 is faulty and needs to be replaced F 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 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 cl
107. m of the lift housing while at the same time pulling the lift belt out the opposite side of the lift 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 10 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 11 21 to reset the shaft position counter You may also need to re orient the steering potentiometer to the lower unit position page 11 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 no
108. n 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 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 problem 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 11 30 Case III Motor steers fine in manual mode but does not steer in AP mode Step 1 Verify the motor is an
109. n in this hole will result in damage to the new potentiometer when the potentiometer nut is tightened Reassemble the steering motor and steering chassis 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 Loctite 603 on the screws Re Orient the new steering potentiometer to motor lower unit see page 11 19 11 24 Genesis Repair Manual 12 02 02 GENESIS Control Board Replacement The Genesis main control board should only be replaced if gt the control board has failed gt the control board installed in the motor has been identified as having early or outdated software see page 11 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 G H 1 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 ho
110. nd 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 e 34 motors 25 35 inch pounds 35 8 motors 35 40 inch pounds e 4 motors 40 50 inch pounds e 45 8 motors 40 50 inch pounds End Play specifications e 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 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 exist
111. ng 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 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 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 Schaeffer s 238 Moly Ultra Supreme grease or a similar lubricant 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 4 5 Test for proper operation PART I Case VI AutoPilot function is erratic and doesn t maintain a heading Step 1 Step 2
112. ning 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 extrusion 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 t
113. nt proceed to Step 2F F Using a small non magnetic blade screwdriver adjust trim pot 2 so that the voltage displayed on the V O M 15 as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance 4 6 m AutoPilot Repair Manual 05 14 03 i 3 J2 volts and black VOM lead here 2 volts here diagram 2 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 12 volts here 12 volts and black VOM lead here 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 AutoPilot Repair Manual 05 14 03 PART II Motors manufactured for model year 2001 S N MKABxxx and later This series of motor incorporates the Grip Glide mount system NOTE Many of the test procedures for the AutoPilot motors manufactured prior to the 2001 model year do not apply to this series of motors due to several product changes gt AutoPilot and steering steering logic fun
114. ntrol 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 voltage 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 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 is 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 rela
115. number prefix contact Minn Kota for assistance Case III PowerUp Models 5400 amp 5500 with serial number prefix MKJG slowly leak down won t stay up or won t trim outboard when engine is 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 is marked to show proper fluid level B Fill with ATF automatic transmission fluid as required Do not overfill C Test unit for proper operation For PowerUp models not listed here contact Minn Kota for assistance Section 9 Depth Finder Interference 10 31 02 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 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 Determine if supply voltage for trolling motor and depth finder is provided by the same common battery If yes disconnect depth finder battery leads from the trolling motor battery and connect them to the engine cranking battery Test depth find
116. ny 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 Using the CoPilot without the corded foot pedal Some anglers will prefer to have the deck completely clear of any unnecessary cables and foot pedals When using the Copilot in this manner the receiver will always react to any commands from the remote ADDING REMOVING REMOTES The CoPilot receiver in this kit has already learned 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 elf the receiver has learned the ID number of ten remotes learning an eleventh remote will erase or over write the first learned remote The CoPilot all
117. oceed 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 bad 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 C If no continuity replace MOM OFF 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
118. ockwise Turn counter clockwise to loosen steering cables B 2 If steering cable core s are broken replace steering cable assembly per Diagram I page 6 4 C Inspect set 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 set screws while earlier version just used 2 set screws Case IV 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 gt x 13 tap Step 4 Screw new eyelet P N 2772352 in place and secure it with a drop of red LocTite 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 6 2 Foot Control Cable Steer w Speed Coil Repair Manual 01 26 04 Step 3 Slip the new eyelet P N 2772352 into the gt eyelet opening and secure it with the jam nut provided in the eyele
119. 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 10 4 Step 3 1 B 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 flange pulley cluster gear assembly figure 7 on page 10 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 Whth 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 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 10 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 To 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
120. ompass is defective if you cannot reach this tolerance 4 12 AutoPilot Repair Manual 05 14 03 Diagram 3 NOTE Compass removed from motor and compass card not covered for clarifity Compass card should be covered to block any light on the optical sensors STEP 2 Test adjust the sensor 2 voltage see diagram I on prior page for component location A B m Tightly cover the compass card with a shop rag to block any light source on the optical sensors With the compass level and pointed southwest connect 12 volts to the red 12v and brown ground terminals With the digital VOM set to check DC voltage connect the black VOM lead to the brown ground terminal and touch the red probe of the VOM lead to pin 2 of the I C as shown in diagram 3 Observe the voltage displayed on the VOM 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 VOM If this voltage is 1 volt 25v no further adjustment is needed If the voltage needs adjustment proceed to STEP 2F On compass boards with date of production prior to 11 01 00 using a small non magnetic blade screwdriver adjust trim pot B so that the voltage displayed on the VOM is as close as possible to 1 volt 25v Compass is defective if you cannot reach this tolerance On compass boards with date of production after 11 01 00 using a sma
121. onar unit Replace the front end bell transducer assembly on the motor and re test capacitance per above procedures 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 A Retest per Step 2 Minn Kota Universal Sonar Models 10 31 02 connector key ridge Figure 1 NOTE you cannot order transducer replacements by the P N listed below Order end bell transducer assembly per parts manual schematics Shaft Length Product Code Transducer Extension Cable P N P N 4 4 1357397 987 003 221 1405 9 ft 798 34 1230 10 1357398 987 004 221 1405 1357399 987 004 221 1405 816 87 1252 74 1366019 987 003 221 1405 1366023 987 004 221 1405 1366039 987 004 221 1405 1366042 987 004 221 1405 8 54 60 48 54 54 60 45 1352711 987 003 221 1405 32 5 60 42 52 42 E 62 AutoPilot Maxxum 1352713 987 004 221 1405 816 87 1252 74 1352721 987 004 221 1405 1352731 987 005 221 1405 847 74 1290 47 1368361 987 003 221 1400 14 5 ft 1368363 987 004 221 1400 1368371 987 004 221 1400 1368272 987 004 221 1400 1368374 987 005 221 1400 Chart A 55 55 55 55 55 65 65 55 55 74 74 65 65 74 74 74 Description Transducer 987 003 987 004 9
122. oper operation of stow deploy trim and steering systems Case VI 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 8A 9 and then may default 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 11 15 Genesis Repair Manual 12 02 02 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 A 1 Ifany of the five wires are cut broken or damaged reconnect or splice back together and retest by turning Master Switch ON and observing display A 2 If wires check okay but LCD does not display the LCD is faulty and needs to be replaced B Install new LCD P N 2224015 B 1 Cutleads 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
123. ossible problem in wiring switches or control boards of motor or in boat s supply voltage 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 is 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 1 Check for proper even torque of thru bolts 2 Check for shorted armature commutator to armature shaft should not show continuity Case VII Customer complains the trolling motor is draining battery batteries down too fast 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 A If amp draw meets or is less than stated specs the motor is not the cause of the batteries draining quickly If amp draw is higher than stated specifications B 1 Check for proper even torque of thru bolts B 2 Check for shorted armature commutator to armature shaft should not show continuity Case VIII Motor runs rough prop catches as it spins S
124. ower unit Step 4 Reassemble the motor in reverse order of disassembly Step 5 Adjust latch collar so that the latch handle firmly engages the collar and the motor lower unit is held tightly in place on the motor rest See Case VI of this section for adjustment procedures Retighten the clamping screw on the collar 3 3 04 03 03 PowerDrive Repair Manual Corded Foot Pedal Test Procedure XVW LY 0103135 SWHO Sc 653 GINOHS QL Ssoudy S JHL 20 YSONI4 ANGA HUM 104 IHL JO IHL 3 1NTUOV 8 8 555 avd mei S9vJd34 3N08NV CALWIANI SV 1531 LON 5300 delvod 70X UNOO 1009 31 SWHO Nid SSW JONVISISSU 4 0 30123736 3345 2 0001 QL 059 38 Nid 3 3J Nid 9 Nid A 9 Nid QL QL QL OL QL QL OL Woi LHOHS MOHS GINOHS WOA 98 T Nid Wodd 12986 MOMS GmMOHS WOA 9S Nid Woas vous MOHS GMOHS WON S A Wged OHS MOHS GINOHS es Nid WO3 LaOHS MOHS GINOHS ZS V Nid WO J LAOHS MOHS GINOHS 8 ALL S UMAY G ALWYN Lov 3 LVTUOV ALMIN 2 1 SMOTIOS JAV SNOLLY2I3D3dS NOWONNS JHL 37VOS X JINYLSISJY JHL NO JAS GG3W2O333d SI qMVOd LMAN 7NO3d 1003 JHL 7403 MAZI0NUd 1531 JHL 00 um C N33 9 annals 4 Aee PISDRACO NP COUR mma WoW 3 UN
125. ows the angler to erase all stored remote ID numbers fro the receiver To do so follow these steps 1 Remove 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 unr 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 1 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 B
126. p loctite 603 a 1 d llar 4 hol 56 V Pt sic key lube E 3 207 271 207 6700 76 id tension sleeve s knob tensie n sleeve xg 07 5 10 n Sj Tension t l JU d om pratt outer tube gt w ket assembly lt gt l lla d 207 15 3 zs Sb w K i Iz J A i alf collar emt P 5 4622 0 7 x 2 23 gly 2 Fig 5 Step 9 Step 10 Step 11 Step 12 Step 13 3X Steering Repair Manual 01 21 04 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 17 4 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 17 4 A Remove the four screws P N 2223468 to allow removal of the pinion assembly P N 2992205 upper bearing P N 2077305 and 4 hole collar see Fig 5 page 17 4 NOTE The four pinion assembly retaining screws are held in place with LocTiteTM during assem
127. p 6 Step 7 Step 8 Step 9 Use the AutoPilot test board P N 20 provided through the Minn Kota parts department Remove the control box cover Disconnect the 5 wires from the coil cord to the sensor board Connect the 5 wires to the Test Board and turn Switch B to Position 1 Turn the AutoPilot ON OFF switch ON and wait 2 seconds Flip Switch A to Position 1 and then Position 2 Steering motor should pulse both clockwise and counter clockwise Steering should stop at center position of Switch A 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 Turn AutoPilot ON OFF switch OFF 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 4 4 AutoPilot Repair Manual 05 14 03 AutoPilot Calibration PRIOR TO 2001 MODELS ONLY Step 1 Place stall clam
128. p 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 find 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 4 5 AutoPilot Repair Manual 05 14 03 AutoPilot Compass Control Board Trim Pot Adjustment Procedure MOTORS PRIOR TO 2001 MODELS ONLY Note You must use a non magnetic scre
129. pocket In the collar with the tab on the Bowguard unit Allgnment Pocket Alignment Tab 9 Leaving the depth collar open place It on the shaft as shown with tab engaged In pocket 10 Loosen orlentatlon block screw so key can freely slide Push on the screw and slide the orlentation block until key falls Into the stot In shaft Onentatlon Block Screw Shaft Slot 11 Once kay Is clearly In slot on shaft and collar half Nt Into place close and tighten depth collar 12 Tighten orientation block screw 17 10
130. put 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 I Case IX 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 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 I Case XI 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 4 3 AutoPilot Repair Manual 05 14 03 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 is failing to properly respond when in the AutoPilot mode Step 1 Step 2 Step 3 Step 4 Step 5 Ste
131. ransducer assembly A Remove the control box cover B Disconnect extension cable and the transducer plug assembly in the control box C Take the same type of capacitance reading as above on the Universal transducer plug exiting the shaft of the motor Refer to Chart A for the particular Universal Sonar model being tested to find the Minn Kota transducer part number P N Cross reference this part number with Chart B page 12 3 to find the minimum and maximum specifications for the particular Universal transducer assembly tested The capacitance for this reading should fall between the minimum and maximum allowable limits per Chart B and Capacitance Chart and Pin Out Diagram on page 12 5 D 1 Ifthe capacitance falls within the minimum and maximum allowable limits for the specific Minn Kota Universal Sonar motor being tested go to Step 5 D 2 Ifthe capacitance falls outside the minimum and maximum allowable limits go to Step 6 Using your VOM perform a continuity test through the extension cable see page 12 6 for pin out diagram A If there is not continuity through all the wires in the extension cable the extension cable is defective Replace extension cable and re test capacity per Step 2 B If there is continuity through the extension cable the problem is not with the transducer and plug assembly or with the extension and plug assembly Re check continuity of the adapter plug Step 3 or suspect problem with s
132. rive housing as necessary PART I Case II Drive Housing steers in one direction only AutoPilot or manual mode Step 1 Test drive housing by applying 12 volts to drive housing leads Reverse 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 4 1 AutoPilot Repair Manual 05 14 03 PART I Case Drive Housing steers with foot pedal but will not steer in AutoPilot mode Step 1 Step 2 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 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 4
133. rs pinch the retainer tabs on the cable housing Push the housing and the cable core through the bracket 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 so the top of the foot pedal is level Install replacement cable assembly in reverse order Adjust the cable core tension by tightening cable adjusting screw so the motor is held stationary and the foot pedal has 3 8 free play Test for proper 360 steering action and ease of operation Diagram 1 6 4 Foot Control Cable Steer w Control Board Repair Manual 01 26 04 Section 7 Foot Control Cable Steer Models with a Control Board Case I Motor fails to run 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 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 If motor runs reconnect motor leads and pr
134. s 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 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 Tighten this 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 17 3 A Position the control box so that the handle end of the box is opposite the tilt detent spring in the gear carrier B 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 flats 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 4 20 x 7 8 phillips head pivot knob screws C 1 The two soft plastic pivot knob covers 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
135. s 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 Lower Unit Repair 01 27 04 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 gt 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 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 Case III Motor runs backwards Step 1 Polarity reversed to armature Possible causes include A Wired backwards B Brush plate in upside down C Magnet shell upside down on 3 4
136. s to test unit for proper function 11 5 Genesis Repair Manual 07 23 03 Case VIII Motor steers in circles when foot pedal is turned ON 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 11 23 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 A B If steering pot tests bad follow instructions as directed page 11 23 If steering pot tests good proceed below to Step 2 With Master Switch OFF remove the control box cover A B Slip the belt off the primary gear and steering potentiometer gear 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 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 Reset the
137. sed 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 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 When receiver is powered up it sounds one of the following beep patterns 1 long beep 2 short beeps pause repeat Step 1 The foot pedal MOM CON switch is in the CON position A The foot pedal switch must be placed in the MOM position The beeping sound will continue until the foot pedal switch is placed in the MOM position 4 chirps followed by a second long beep Step 1 Receiver has not learned the ID number of the remote receiver memory is empty A Remote needs to be learned See ADDING REMOVING REMOTES below Case III The prop is not turning but the Prop On audio tick is still going Step 1 Prop speed is set at 0 Increase the prop speed above 0 Step 2 PROP ON tick occurs only in Audio mode 3 A Switch Audio mode to either Audio 1 or 2 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
138. set Emergency Stow Procedure to set the shaft position counter see page 11 21 Turn the Master Switch back ON Deploy the motor by pressing the Mode Switch Turn the Master Switch OFF Step 2 Setting Left and Right Park Positions B 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 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 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 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 LCD on motor should now read 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 is motor lower unit at a 90 angle to t
139. setting into the main board memory should be displayed on the LCD Turn Master Switch OFF Installing the Compensation Magnet Rods C Remove the sideplate that was temporarily placed over the compass assembly to block 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 11 29 Genesis Repair Manual 12 02 02 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 run
140. ssary B If motor does run check speed selector switch connections and test speed selector switch for continuity across A terminal to terminals 1 2 3 etc If switch tests okay proceed to Step 3 Replace speed switch Test motor for proper operation 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 the 12 24 switch for continuity Gil Terminal A Terminal Terminal 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 A terminal 1 If no continuity is noted replace the 12 24 switch Test motor for proper operation 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 working 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 b
141. sure Master Switch on foot pedal is OFF Then remove the belt mark the potentiometer pulley and test the potentiometer A B 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 If any rough spots or catching occurs replace the potentiometer board as instructed in Step 4 below 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 If the steering potentiometer tests fine re orient Steering Potentiometer to Motor Position see page 11 19 Check the coil cord for continuity replace if necessary Step 4 To replace the steering potentiometer board
142. switch depressed B 1 If no continuity is noted replace foot pedal ON OFF switch Test for proper operation Case If motor runs in 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 Remove the control board and potentiometer from foot pedal base Step 2 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 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 Foot Control Cable Steer w Control Board Repair Manual 01 26 04 If the test light motor is intermittent as the potentiometer shaft is turned clockwise OR as the 3 conductor lead connected to the potentiometer is flexed near the potentiometer end the potentiometer leads are broken and the control board needs to be replaced Case III Motor runs fine but steering is loose soft or
143. t kit Use a drop of red LocTite on the eyelet threads prior to installing the jam nut Case V Customer complaint that the motor slides down in the bracket doesn t maintain consistent depth setting 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 set screws The Installation Kit includes a jig and a drill bit so you can properly align the set screw holes 6 3 Foot Control Cable Steer w Speed Coil Repair Manual 01 26 04 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 Lift the cable drum pulley off of the drive pinion Remove the barrel end of each cable core from the pulley Using a needle nose plie
144. t operation of reassembled motor to complete the repair 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 shaft 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 3 2 PowerDrive Repair Manual 10 31 02 Case VII Latch collar on shaft is broken and needs to be replaced Grip Glide models manufactured for 2001 or later Step 1 Remove any remnants of the original collar Step 2 Remove control box cover and control box from the motor composite shaft Loosen drive collar and slide motor lower unit and shaft out of the drive housing Step 3 Using a large blade screwdriver as a wedge pry open the new latch collar by inserting the blade of the screwdriver in the split of the new collar Spread the collar open far enough to allow it to be slid down the shaft from the top to the bottom threaded section of the shaft right above the motor l
145. t rotate into the horizontal position for proper stowing NOTE Ensure the lift cam is in 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 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 12 02 02 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 lea
146. tch is turned ON the LCD briefly displays LP 1 2 hours 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 When Master Switch is turned 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 wit
147. 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 1 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 yoke P N 2051510 see figure 6 page 10 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 10 4 Vantage Repair Manual 12 04 02 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 10 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 1 2 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 wh
148. the control board is defective Replace control board or module as needed 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 d If motor is EM96 EP96 or EP 130 test second control module If both modules test fine problem is in the Y splitter cable Replace Y cable as needed Case II Motor runs 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 14 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 Case III EM 96 EP96 130 twin motor units only 1 motor runs 1 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 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 T
149. the input shaft gear assembly Remove the input shaft gear assembly 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 ho
150. 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 still present proceed to Step 1B Armature bent shaft or out of balance armature stack C 1 Remove the prop from the armature shaft 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 13 2 Lower Unit Repair 01 27 04 Case VI Customer complains of low power thrust 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 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 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 P
151. time procedure to initially orient straight ahead on bowmount 3X models 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 2 Set the depth collar aside until the motor Is mounted and aligned 3 DEPLOY THE UNIT MAKING SURE THE MOTOR IS SUPPORTED BELOW THE MOTOR WILL FALL DOWN UNITL THE HANDLE HITS THE MOTOR MOUNT IF NOT SUPPORTED WHEN DEPLOYING 4 The motor will come un allgned similar to the picture to the right 5 Allgn 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 6 Ralse the motor and place a support under the lower unt NOTE At tnis point the handle tension knob outer shaft keyway and lower unit should now be aligned If not repeat steps 2 5 17 9 3X Steering Repair Manual 01 21 04 7 If mounting configuration or option 2 Is preferred the orientation block must be rotated 180 The orlentation block must be removed and rotated so the retaining Is on the right hand side of the screw The picture below shows orientation block configuration or option 1 Orlentation Block 8 Open the depth collar and the
152. tings go 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 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 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 238 Moly Ultra Supreme grease or a similar lubricant 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 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 Tes
153. 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 two teeth clockwise on transom mount 3X models the two raised bumps will be oriented toward the nose of the motor lower unit C 1 The second tooth clockwise from the bumps must be lined up with the timing mark in the gear carrier NOTE The timing mark used for transom mount 3X models is a small raised rib on the inside circumference of the gear carrier Located in the 1 30 o clock position when the gear carrier is held with the detent spring towards the viewer and viewed from above 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 tilt detent spring P N 2072705 towards the of the motor lower unit 17 6 3X Steering Repair Manual 01 21 04 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 i
154. u should see continuity across the black and yellow wire pin locations orange brown green 1K ohm potentiometer Black wire Green wire Brown Yellow e o White wire Open Orange wire VA Plug End x Hand Controller Plug End Pin End View B 2 If the hand controller tests okay the problem is with the control module or Y splitter Test control module s to verify problem a Connect control module to appropriate power source 12vdc for EM42 EM44 amp EP42 24vdc for EM48 54 EM96 EP48 EP96 amp EP130 b Plug in known good tested as per above hand controller directly to control module bypass remove Y splitter from circuit if motor is an EM96 EP96 or EP130 and check each control module individually 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 14 1 amp 10 31 02 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 1 If there is no output voltage at board terminals
155. urs running time press and hold the Mode Switch for 2 seconds to initiate stow sequence 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 If the motor is not properly aligned repeat Step 3B 3 until motor is rotating into position and properly stowing when the Mode Switch is pressed 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 11 27 11 19 Genesis Repair Manual 12 02 02 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 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
156. using Remove the strain relief bracket screw and bracket item 14 and 13 on the Base Housing parts explosion from the base extrusion Disconnect 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 B 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 anon 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 is included with the new AutoPilot control board assembly early units did not utilize compensating magnets See figure below If you 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
157. using back onto the right half taking care to properly position the lift belt and tube bearings items 48 and 49 on the Lift Housing parts explosion Be certain that the thrust washer is 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 pr
158. ving the lift belt in place through the lift housing assembly ATTENTION For proper reassembly 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 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 2
159. 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 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 lift gear from the lift screw shaft See figure 5 page 10 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 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 10 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 10 7 h Lift the top plate and motor assembly off the housing and install
160. wdriver 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 control board can be left in the motor control box Be sure to follow the wiring connections as outlined and shown in this procedure for Sensor 1 voltage reading h touch red VOM lead here Sensor 1 Trim Pot for Sensor 2 voltage reading f amp touch red VOM lead here Sensor 1 Resistor 4 ee TII La ILS Lo Sensor 2 Resistor ma 4 Sensor 2 Trim Pot diagram 1 Step 1 Test adjust the sensor 1 voltage see diagram 1 for component location A Tightly cover the compass card with a shop rag to block any light source on the optical sensors B With the compass level and pointed southeast connect 12 volts to the orange 12v and brown ground terminals see diagram 2 C 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
161. y harness 14 3 DeckHand Electric Anchor 12 11 02 Section 15 DeckHand Electric Anchor models DH1 DH18 DH20 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 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 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 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 bre
162. y that splits vertically left and right casting 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 eyelet opening and secure it with the jam nut provided in the eyelet kit Use a drop of red on the eyelet threads prior to installing the jam nut Case V Customer complaint that the motor slides down in the bracket doesn t maintain consistent depth setting 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 set screws The Installation Kit includes a Jig and a drill bit so you can properly align the set screw holes 7 2 Foot Control Cable Steer w Control Board Repair Manual 01 26 04 Motor Control Box Maxxum amp All Terrain Steering Cable Replacement Foot Pedal Base ge ft LIA Rub f pud pL 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 o

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