Ultralight 402

Ultralight 402
Ultralight 402
Operating Manual
(English)
1. Contents
1. Contents
2. Important safety and operating instructions .................................................................. 4
3. Introduction ....................................................................................................................... 6
4. About this operating manual ........................................................................................... 7
5. Conformity declaration .................................................................................................... 7
6. Warranty conditions ......................................................................................................... 8
6.1 Extent of warranty .................................................................................................... 8
6.2 Warranty process ..................................................................................................... 9
7. Equipment and operating elements . ............................................................................ 10
7.1 Supply scope .......................................................................................................... 10
7.2 Plan of operating elements ................................................................................... 11
8.
Starting up . ..................................................................................................................... 12
8.1 Attaching and aligning the outboard motor to the kayak ................................... 12
8.2 Commissioning the tilting device.......................................................................... 19
8.3 Attaching the steering . .......................................................................................... 19
8.4 Connecting the remote throttle control
with the integrated display and magnetic key...................................................... 20
8.5 Connecting the battery pack . ................................................................................ 20
9.
Operation.......................................................................................................................... 21
9.1 Battery pack and power supply unit...................................................................... 21
9.2 Tilting device and lock ........................................................................................... 22
9.3 Remote throttle with integrated display and magnetic key . .............................. 23
9.4 Pylon . ...................................................................................................................... 28
9.5 Ideal depth of immersion ...................................................................................... 29
10. Disassembly .................................................................................................................... 29
11. Storage and care instructions . ...................................................................................... 30
11.1 Corrosion protection .............................................................................................. 30
11.2 Caring for the battery ............................................................................................. 30
11.3 Changing the propeller .......................................................................................... 31
11.4 Other care instructions .......................................................................................... 31
12. Troubleshooting .............................................................................................................. 32
13. Technical data ................................................................................................................. 33
14. Disposal instructions ...................................................................................................... 34
15. Accessories ..................................................................................................................... 34
16. Torqeedo Service Centers............................................................................................... 36
Operating Manual Ultralight 402
3
2. Important safety and operating instructions
Important safety instructions
Torqeedo motors are designed to operate safely and reliably as long as they are used
according to the operating manual. Please read this manual carefully before you start
the motor. Ignoring the instructions in this operating manual can cause damage or
personal injury. Torqeedo accepts no liability for any damage caused by actions that
contradict this operating manual.
To ensure safe operation of the motor:
• Familiarize yourself with all the motor controls. For instance, you should be able to
stop the motor quickly if necessary.
• Only allow adults who have been instructed on how to operate the motor or have
read the operating instructions to run it.
• Never operate the motor if someone is in the water close to the boat. Stop the motor
immediately if someone goes overboard.
• Always take a paddle with you on board.
• Check the status and function of the device before each tour.
• Note that the on-board computer does not include changes to currents and wind
conditions in the range calculation. If you are moving with the wind or current the
remaining range is calculated assuming you continue going with the wind or current.
If you change direction or if wind/current change, your remaining range may be
significantly lower. Therefore note the effect that the wind and current along your
route have on your range.
• Never use the motor as a fixing point for your kayak; never use the motor as a handle
for lifting or carrying.
• Do not open the battery casing; protect the battery pack from mechanical damage.
• Do not short circuit the battery pack.
• Avoid submerging the battery pack and remote throttle for longer periods of time.
• If the error code E46 is shown in the display or if you changed the fuse of the battery
the information in the dispaly is not accurate any more. After a complete charge of the
battery, the information dispalyed is reliable again.
• The battery of your Ultralight motor has been declared a hazardous item in UN Class 9.
Private transportation is not critical. If shipped by a transport company the relevant
statutory provisions must be observed.
• Keep the magnetic key supplied at least 50 cm / 20 inches away from pacemakers.
• Keep the supplied magnetic key away from magnetic information media (e.g. debit/
credit cards, music cassettes, magnetic tapes etc.). The magnet integrated in the key
has enough strength to make the saved data unusable.
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Operating Manual Ultralight 402
2. Important safety and operating instructions
Important operating instructions
There follows a selection of the most important instructions for handling Torqeedo
Ultralight motors. Apart from these instructions, please observe the complete operating
instructions to prevent damage to your motor.
• Only run the motor when the propeller is under water. If it is run in the air for longer
periods, the shaft sealant rings that seal the motor to the drive shaft may become
damaged. If the motor is run in air for a longer period, the motor itself can overheat.
• The Ultralight product range, the associated remote throttle, battery pack, and all electric,
plug-in connections are protected against dirt and water in line with protection type IP68.
• The Ultralight has an integrated protective device that switches the motor off when
it reaches a particular slope (90°). This prevents the propeller from turning if the boat
capsizes or tilts.
• After use, always take the motor out of the water.
• After operation in salty or brackish water, wash all components in fresh water.
• Occasionally use contact spray to care for all electronic contacts. If you use the motor in
salt or brackish water, we recommend applying contact spray once a month.
• You extend the life of your battery if you do not expose it for longer than necessary to
a very hot environment. In order to guarantee that the life of the battery is as long as
possible the battery should be stored for longer period of time (e.g. over the winter) at
around 50 % charge and between 0 °C and +15 °C / +32 °F and +60 °F.
• Only charge the battery at environmental temperatures between 0 °C and +45 °C /
+32 °F and +113 °F.
• Store the motor, battery pack, and remote throttle in the waterproof travel bag only
when dry. If storing the items for longer periods of time in the travel bag, do not close it
so it is airtight.
• Only use the travel bag for transportation not for shipping the motor. The motor stored
in the travel bag must not be adversely affected by heavy objects.
• If the motor has malfunctions an error code is shown on the display. After resolving the
error the motor can be restarted out of the stop position again. In rare cases it may be
necessary to switch the motor off using the “on/off” button. You will find descriptions
and details in Section 9.3.
• Do not disconnect the cable connections when the propeller is turning.
• If you have a problem with your motor, please follow the instructions in this operating
manual for handling warranty claims.
Operating Manual Ultralight 402
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3. Introduction
Dear customer,
We are delighted that you have chosen our motor. Your Torqeedo Ultralight is state-ofthe-art in terms of motor, battery, and propeller technology. It has been designed and
manufactured with the utmost care and with a special focus on comfort, user-friendliness,
and safety, and has been extensively tested before delivery.
Please take the time to read this operating manual carefully so that you can use the motor
properly and enjoy it for a long time.
We constantly strive to improve Torqeedo products. Should you have any comments
on the design and use of our products, we would be pleased to hear from you. Please
contact our Customer Services if you have any questions on Torqeedo products
(service_usa@torqeedo.com or service_international@torqeedo.com).
We hope you will enjoy this product.
Yours,
Friedrich Böbel, PhD Managing Director
6
Christoph Ballin, PhD
Managing Director
Operating Manual Ultralight 402
Matthias Janzen
Managing Director
3. Introduction 4. About this operating manual 5. Conformity declaration
4. About this operating manual
This operating manual will help you use your Torqeedo Ultralight safely and efficiently. All
information is given according to our latest knowledge. Subject to technical changes.
• Indicates a danger or a procedure that may cause injury
and property damage.
• Indicates a danger or a procedure that may cause property damage.
5. Conformity declaration
We, Torqeedo GmbH, with sole responsibility, declare the conformity of the Ultralight
product range with the following provisions:
Small water vehicles
Electrical systems
Low-voltage direct current (DC) systems
DIN EN ISO 10133:2000
Starnberg, in March 2009
Managing Director‘s signature
The aforementioned company holds the following technical documents available for
viewing:
- Required operating manual
- Plans/software source code (EU authorities only)
- Inspection records (EU authorities only)
- Other technical documentation (EU authorities only)
Operating Manual Ultralight 402
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6. Warranty conditions
6.1 Extent of warranty
Torqeedo GmbH, Petersbrunner Straße 3a in D-82319 Starnberg, Germany, guarantees the
final purchaser of a Torqeedo outboard motor that the product is free from material and
manufacturing faults during the period stated below. Torqeedo will indemnify the final
purchaser for any expense for the repair of a material or manufacturing fault. This indemnification obligation does not cover the incidental costs of a warranty claim or any other
financial losses (e.g. costs for towing, telecommunications, food, accommodation, loss of
earnings, loss of time etc.).
The warranty ends two years after the date on which the product was delivered to the
final purchaser. Products that are used commercially or by public authorities - even if
only temporarily - are excluded from this two-year warranty. In these cases, the statutory
warranty applies. The right to claim under warranty runs out six months after discovery of
a fault.
Torqeedo decides whether faulty parts are repaired or replaced. Distributors and dealers
who repair Torqeedo motors have no authority to make legally binding statements on
behalf of Torqeedo.
Normal wear and tear and routine servicing are excluded from the warranty.
Torqeedo is entitled to refuse a warranty claim if:
• the warranty was not correctly submitted (in particular failure to contact Torqeedo before
sending back goods, failure to present a completely filled-in warranty certificate and
proof of purchase, refer to Warranty process),
• the product has been used improperly,
• the safety, operating and care instructions in the manual were not observed,
• the product was in any way altered or modified or parts and accessories were added that
are not expressly permitted or recommended by Torqeedo,
• previous services or repairs were not carried out by firms authorized by Torqeedo, or
non-original parts were used.
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Operating Manual Ultralight 402
6. Warranty conditions
As well as the rights arising from this warranty, the customer also has legal warranty claim
rights arising from the purchase contract with the dealer that are not hampered by this
warranty.
6.2 Warranty process
Adhering to the following warranty process is a prerequisite to the satisfaction of any
warranty claims.
Before dispatching any apparently faulty goods, it is imperative to coordinate the delivery
with Torqeedo Services. You can contact us by phone, email or mail. The ability to make
contact via the www.torqeedo.com website is being extended successively. You can find
the contact details on the back of this manual. Please understand that we are unable to
deal with products of which we have not been notified and will therefore refuse to accept
delivery.
To check a warranty claim and to process a warranty, we require a completed warranty
certificate as well as proof of purchase.
• The warranty certificate attached to this operating manual must show contact details,
product details, serial number, and a brief description of the problem.
• Proof of purchase must indicate the purchase and the date of purchase (e.g. transaction
receipt.
For returning the motor to the Service Center, we recommend keeping the original Torqeedo packaging. If this is no longer available packaging that excludes transport damage
must be used as this is not included in the warranty.
We are available to answer any questions regarding the warranty process - simply use the
details on the back cover.
Operating Manual Ultralight 402
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7. Equipment and operating elements
7.1 Supply scope
The full supply scope of your Torqeedo Ultralight should include the following parts:
• Motor unit with shaft and connection cable (2 m / 6.5 feet),
universal joint with swing arm, pylon, and propeller
• Boom with clamping device and mounting ball
• Lithium-manganese battery with integrated GPS receiver
• Remote throttle control with integrated display
• Magnetic key
• Assembly set with fixing material, rubber rest, line, elastic cord, lock bolt
and accessories
• Allen key SW5
• Battery pack connection cable – remote throttle (1.5 m / 5 feet)
• Travel bag
• Power unit incl. European power cord, US power cord and UK adapter
• Operating manual
• Warranty certificate
• Packaging
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Operating Manual Ultralight 402
7. Equipment and operating elements
7.2 Plan of operating elements
Attachment point
for line to manually
tilt the motor
Connection cable
Swing arm
Connection to
kayak steering
or fixing the
steering
Elastic cord
Boom
Attachment point
for “reverse” line
Rubber rest
Spacer
Shaft
Mounting ball
Propeller
Pylon
Fin
Remote throttle control
Magnetic key
Battery
Operating Manual Ultralight 402
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8. Starting up
8.1 Attaching and aligning the outboard motor to the kayak
1. Prepare the motor for the mounting:
Remove the parts that belong to the Ultralight supply scope from the packaging.
Slide the boom with the clamp into the universal joint and clamp it lightly with the
two screws.
1.
2.
2. Select the position where the drive is to be attached to the kayak.
For this please note:
• You need a virtually flat surface on the kayak that is big enough to attach the
mounting ball.
• The motor‘s boom must be horizontal,
i.e. run parallel to the surface of the water.
This ensures that the shaft pipe is vertical
in the water when moving forward.
• To attach the motor to thin-walled touring kayaks it is necessary to use the rubber
rest so that the engine rests on two points on the kayak (mounting ball and rubber
rest). On thicker-walled angling and leisure kayaks it may be possible to fix the motor only with the aid of the mounting ball without a second resting point.
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Operating Manual Ultralight 402
8. Starting up
There are three options for connecting the drive to your kayak:
ANo connection of the motor to the kayak’s steering system: When travelling with
the motor you must either steer using the paddle or with a rudder that is not
connected to the motor. With this option it is not possible to move in tight circles
using the motor. This type of attachment is recommended if your kayak does not
have a steering system or if you only need the motor for
support or as a back-up on long tours (and do not have
Kayak rudder
to move in tight circles).
Motor
(Steering element fixes)
Rubber
rest
Mounting ball
Mounting at the
tail (no rudder)
Mounting
at the side
BConnecting the motor instead of the rudder to the kayak’s steering system: With
this attachment option you can move your kayak very easily using the motor; but
the rudder is not available when the motor is not in use.
Motor
Mounting ball
Steering system of
the kayak (control
over lines)
• Test whether the steering operates in the desired position before fixing
the mounting ball to the kayak.
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13
CFixing the motor to the kayak’s steering system in addition to a rudder:
We recommend this attachment option if you want to use a rudder when the motor
is running but also when paddling (while the motor is tilted out of the water).
Connection of the
motor with the rudder
system of the kayak
Steering system of the
kayak
Motor
Rudder
Mounting ball
• Test whether the steering works in the desired position and whether the
kayak’s motor and rudder can be tilted out of the water before fixing
the mounting ball to the kayak.
• The holes for the screw anchors need to have a distance of 2 cm /
0.8 inches to any edge of the kayak.
Mark the four necessary screw positions on the
mounting ball and drill the corresponding holes
(Ø 12 mm / 0.47 inches) into the kayak.
3. Attach the mounting ball to the Kayak.
You have 2 options to attach the mounting ball to the kayak. If the inside of the kayak
hull is accessible we recommend to secure the mounting ball with the screws and nuts
provided in the scope of delivery. If the inside of the kayak hull is not accessible, the
mounting ball can be mounted with the screw anchors provided in the scope of delivery.
AMounting with screws and nuts:
(recommended if kayak inside is accessible)
Drill four holes in the marked positions
Ø 6.5 mm (15/32 inch).
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Operating Manual Ultralight 402
8. Starting up
Attach the mounting ball with the screws and nuts provided in the scope of delivery.
To close the boreholes watertight and to compensate for slight curvature of the kayak
surface, use the rubber gasket between the kayak and the mounting ball. To reinforce
the kayak hull under the mounting ball, place the white plastic plate with 8 holes from
the inside between the kayak hull and the nuts.
Screws
Insulating sleeve
Mounting ball
Rubber gasket
Kayak-hull
Plasticplate
Disk
Nut
BMounting with screw anchors:
(recommended if kayak inside is not accessible)
Drill four holes in the marked positions
Ø 12 mm (15/32 inch).
To ease fixing the screws, apply some
grease or oil to the screw and the screw
anchor.
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15
Take the screws out of the screw anchors.
Place the aluminum key onto one of the screw
anchors. The aluminum key prevents the screw
anchor from turning when the screw is screwed
in.
Place the screw anchor in one of the boreholes.
Please note that the screw anchor needs to fit
easily through the borehole without being
compressed at the sides.
If possible, place the white plastic plate with 8
holes from the inside of the kayak over the screw
anchor. This reinforces the kayak hull at the
mounting point.
If this is not possible, the screw anchors can be
fixed without the plastic plate.
Put a screw through the aluminum key into the
screw anchor. Firmly tighten the screw while
fixing the screw anchor with the aluminum key.
Kayak inside
Note that the screw anchor will expand on the
inside of the kayak. Chose a position for the
wall anchor which allows sufficient space for
this expansion.
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Operating Manual Ultralight 402
8. Starting up
Unscrew the screw and take the aluminum key
off the screw anchor.
Fix the other screw anchors to the kayak in the
same way.
Place the rubber gasket over the four screw
anchors.
Place the mounting ball onto the rubber gasket.
Insert the plastic insulating sleeves into the
holes of the mounting ball. Insert the four screws
through the insulating sleeves and tigthen them
firmly into the screw anchors.
Operating Manual Ultralight 402
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4. Assemble the drive by clamping the ball
receiver to the mounting ball. For this the
boom must be aligned horizontally to the
water line. When tightening the screws in
the ball clamp, ensure that the gap on both
sides of the clamp is the same distance.
5. If desired, mount the rubber rest on the second motor resting point. Select the desired
location and use the spacers supplied to balance out the height. Attach the rubber rest
in the same fashion used to attach the ball mount by using two screw anchors. Fix
boom to the rubber rest using the elastic cord.
1.
2.
Elastic
cord
6. Loosen the screws on the two clamping rings and
position the motor so low that the propeller does not
draw air even at full throttle. Then retighten the two
screws. Ensure that the upper clamp ring is
perpendicular to the propeller axis.
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Operating Manual Ultralight 402
Spacer
8. Starting up
• If you are unsure about the position and assembly of your motor contact
your Torqeedo dealer.
• Ensure that when tilting the motor the cables are not crimped.
8.2 Commissioning the tilting device
1. Mount a clamp block at the level of the driver’s
seat. Position the clamp block so that it will hold a
line if it is pulled towards the stem of the kayak.
2. Cut the supplied line to 2 x 3 m (10’) and 2 x 0.5 m (2.5’).
Melt the ends e.g. with a lighter.
3. Firmly tie one of the 3 m (10’) lines to the top of the swing arm. Guide the line
through the loop on the ball clamp and fix it in the clamp block. In this way you have
the opportunity to tilt the motor out of the water and to hold it in the tilted position.
2.
1.
4. If you want to use the motor in reverse, mount the second clamp block and guide the
line to the lower end of the pivot arm. This protects the motor from undesired tilting up.
8.3 Attaching the steering
The following steps are only relevant if you want to connect the motor to the kayak’s
steering system.
1. If you want to connect the motor with the kayak’s steering system instead of the
rudder: Fix the lines from the kayak’s steering with the triangular clamp ring at the
upper end of the motor shaft. Extend the lines for the kayak’s steering as far as
necessary, if appropriate you can use the supplied snap hooks to fix the lines
to the clamp ring.
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2. If you want to connect the motor to the kayak’s rudder (and via the rudder to the
steering system): Fix the two snap hooks supplied to the short lines. Now connect the
kayak’s rudder with the triangular clamp ring at the upper end of the motor shaft using
the short lines. To do so insert the snap hooks into the
holes in the clamp ring and tie the other end of
the line to the kayak’s rudder. Movements of the
rudder to the left or right should produce the
corresponding steering movements of the motor.
For good steering it is not essential for the
steering movements to be identical.
snap hook
8.4 Connecting the remote throttle control with the integrated display and
magnetic key
Position the remote throttle in the desired position and fix it, e.g. with a RAM mount
holder (M4 thread in the base of the remote throttle control) or a commercial Velcro strip
(not within the scope of supply).
8.5 Connecting the battery pack
1. Insert the battery pack in the desired position in the kayak and fix it if necessary with
straps (not within the scope of supply). When doing so ensure that the top of the
battery (aerial icon) is showing upwards in order to provide the GPS function. Do not
cover the battery pack with metallic objects or those containing metal (e.g. rescue
blankets etc.).
2. Connect the cable from the motor to the battery pack. Ensure that there is a waterproof bayonet closure that is placed in a particular position and screwed into place.
3. Connect the cable from the remote throttle to the battery pack. Ensure that the
connection is waterproof and screwed into place. It can only be fixed in one position.
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Operating Manual Ultralight 402
8. Starting up 9. Operation
9. Operation
9.1 Battery pack and power supply unit
The battery pack is equipped with high performance lithium manganese batteries,
so-called LIMA cells. The LIMA cells have a self-discharge of under 1 % per month at
20 °C / 70 °F, have stable cycles, and no memory effect. The lithium battery can be used
at environmental temperatures from -20 °C to +60 °C / -4 °F to +140 °F.
A controller that has several functions to protect and care for your battery is integrated
in the battery pack. The controller, amongst other functions, protects the battery from
fully discharging and overcharging. Therefore you can connect the battery to the charger
without worrying or empty it completely.
During the charging process the controller contained in the battery pack controls the
charging current.
The capacity of the battery pack changes over time. To adjust the capacity indicator we
recommend emptying the fully charged battery completely once a year at average speed.
The battery pack has a 20 A safety fuse. Open the marked cover in the battery’s base to
exchange the fuse. When closing the cover ensure the cover and seal sit properly (label to
the outside).
The charging unit supplied is modified to the controller and charges the Ultralight’s
battery pack in approximate 8 hours. When charging at high environmental temperatures
(> 35 °C / > 95 °F) longer charging times may occur as the controller is equipped with a
temperature-dependent charging power off switch which ensures a proper and gentle
charging of the cells. For charging, connect the charging unit with the battery pack and
the power supply. To do so remove the motor cable on the battery pack and use the same
jack for charging.
You can charge the battery pack without the remote throttle being inserted. If the
remote throttle is connected with the battery pack the current charging status in
percent and „charging“ is displayed in the topmost field on the display.
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21
• The battery is protected from water penetration (IP68).
• Use the Ultralight battery 402 exclusively with the Ultralight 402 outboard
motor.
• Only use the power supply unit supplied or one authorized by Torqeedo to
charge the battery pack.
• Only charge the battery at environmental temperatures between 0 °C and
45 °C / +32 °F and +115 °F.
• You extend the lifespan of your battery if you do not expose it to hot
environments for longer than necessary. In order to guarantee the longest
possible lifespan of the battery if you store it for a long time (e.g. over the
winter) it should be charged to around 50 % and stored between 0 °C and
+15 °C / 32 °F and +60 °F.
• Protect the battery pack from mechanical damage. If the housing of the
battery is damaged, do not use the battery.
• Do not short circuit the battery pack.
• Avoid submerging the battery pack for longer periods of time.
• The LIMA battery cells only catch fire if they are exposed to temperatures
over 300 °C / 570 °F. This is an important advantage over other lithiumbased battery systems. If this should occur try to put the battery in a
location where it will not cause damage. If this is not possible, keep
your distance or cover the battery with sand or other dry, non-flammable
materials.
9.2 Tilting device and lock
For normal movement the fixing lines that go to the lower end of the swing arm should
not be fixed in the clamp block. This enables the motor to tilt up if it gets in contact with
obstacles under water. To move in reverse the lower fixed line must be fixed to the clamp
block.
To tilt the motor the lower fixing line must be released. By pulling the upper line the motor can be tilted out of the water and fixed in that position using the second clamp block.
The motor does not start if it is tilted up.
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Operating Manual Ultralight 402
9. Operation
Loosen the upper line to lower the motor.
To lock the steering of the motor insert the lock bolt into the
desired position in the upper clamp ring.
This blocks the steering function.
Lock bolt
• Only tilt the shaft when the lower fixing line is loose.
• For steering the lock bolt must be removed from the upper clamp ring.
9.3 Remote throttle with integrated display and magnetic key
Control the drive power – speed and rotation direction - by adjusting the remote throttle.
Forward movement of the remote throttle means the kayak moves forward, backward
movement of the remote throttle means the kayak moves backwards. Please note that
reverse movement does not have the same output as forward movement. The middle
position corresponds to the stop position.
The remote throttle is equipped with a magnetic key with an on/off function. The motor
only works if you place the magnetic key supplied on the proper location on the remote
throttle control (see drawing). If the magnetic key is removed the motor stops. You can
Operating Manual Ultralight 402
23
only start the motor again if you first replace the magnetic key and then move the remote
throttle to the central position (stop position).
Remote throttle control
Magnetic key
The remote throttle is equipped with an on-board computer
with an integrated display and three buttons.
If you press the “on/off” button for 1 second you switch
the motor on. Pressing the button again for 3 seconds
switches the motor off again. You can switch the motor off
in any operating mode. If there is no activity for one hour
the motor switches off automatically. Press the button
again to switch it back on.
Use the “setup” button to set the units for the display. You enter the menu by pressing the
“setup” button for 3 seconds. First you can select the units in which the remaining range
is displayed. By pushing the button in the center of the display you select between kilometers, miles, nautical miles, and hours. You confirm your selection by pressing “setup”
again. You then enter the speed indicator setting. You can choose between kilometers
per hour, miles per hour, and knots. Again you select the units with the center button and
confirm your selection and leave the “setup“ menu again by pressing the “setup” button
again.
The “cal” label on the center button stands for “calibration”. If the display shows a relevant
error message you can recalibrate the motor with the help of this button. You will find details
on this in the „error codes” table in this section.
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Operating Manual Ultralight 402
9. Operation
Display in normal operation:
Battery charge status in percent
Remaining range at current speed
Ground speed
Power consumption in Watt
Other indicators:
Drive slowly: Is displayed when the battery capacity is < 20 %.
Charging: Is displayed when charging. Refer to Section 9.1.
: The GPS module integrated into the battery pack searches for
satellite signals to determine the position and speed. If no GPS signal
is received within 5 minutes the display switches in the second field
from “remaining range at current speed” to “remaining time at current
speed”. In addition, a clock icon is displayed. If the remaining duration is
more than 10 hours it is indicated in whole hours. If it is less it is shown
in hours and minutes.
: This icon is displayed if the remote throttle must be placed in the
central position (stop position). This is necessary before starting off.
: Is displayed if the temperature of the engine or battery is too high.
The motor decreases the input power automatically.
Error: If an error occurs the error icon and a two-digit code are displayed
in the bottom field. The code shows the component causing the error
and the error itself. You will find details about the error codes in the
following table.
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25
• For reverse movement the fixing line that goes to the lower end of the
swing arm should be fixed in the clamp block.
• The remaining distance or time at the current speed shown on the
display is a calculated theoretical value. Please be aware that the actual
outstanding range or duration may vary.
• The high thrust of the drive makes it necessary to familiarize yourself
with the characteristics of your Torqeedo Ultralight 402. Practice
handling the motor and maneuvering in open water.
• We recommend fixing the magnetic key lanyard to a personal flotation
device (PFD).
• Keep the magnetic key supplied more than 50 cm / 20 inches away
from pacemakers as strong magnets could affect the operation of the
pacemaker.
• Keep the supplied magnetic key away from magnetic information
media (e.g. debit/credit cards, music cassettes, magnetic tapes etc.).
The magnet integrated in the key has enough strength to make the
saved data unusable.
• If the remote throttle’s casing is damaged there is a risk of water
infiltration which could cause the propeller to turn uncontrollably.
For this reason the remote throttle must be exchanged immediately.
The following table contains a list of possible error codes. After resolving the error the
motor can be moved out of the stop position again. In rare cases it may be necessary to
switch the motor off using the “on/off” button on the remote throttle control.
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Operating Manual Ultralight 402
9. Operation
Fault codes
Display
Cause
What to do
E02
Stator over-temperature
(engine overheating)
Motor can be used again after a short wait
(about 10 minutes). Contact Torqeedo Service.
E03
Motor tilted during
operation
Motor can be used again after tilting it down
and pressing on/off.
E04
Motor put into operation
while tilted
Motor can be restarted from the stop
position after being tilted down.
E05
Motor/propeller blocked
Loosen blockage and turn propeller one
revolution by hand.
E06
Voltage in the motor too
low
Low battery charging status. Motor can be
used again slowly from the stop position.
E07
Motor overcurrent
Continue at low output. Contact Torqeedo
Service.
E08
Circuit board overheating
Motor can be used again after a short wait
(about 10 minutes). Contact Torqeedo Service.
E21
Remote throttle
calibration defective
• Re-calibrate:
Press “cal” button for 10 seconds.
• The display shows “cal up”:
Press remote throttle control forward to
full gas then press the “cal” button.
• The display shows “cal stp”:
Return remote throttle control to central
position then press the “cal” button.
• The display shows “cal dn”:
Press remote throttle control reverse to full
gas then press the “cal” button.
E22
Magnetic sensor
defective
Re-calibrate (refer to E21).
E23
Value range false
Re-calibrate (refer to E21).
E30
Motor communication
error
Check the motor cable’s plug-in connection.
Check the motor cable for damage. Check the
fuse at the underside of the battery. It applicable replace fuse. If the fuse was replaced
the information display will not show correct
data until the battery is fully charged again.
Operating Manual Ultralight 402
27
Fault codes
Display
Cause
What to do
E32
Remote throttle control
communication error
Check the remote throttle control cable’s
plug-in connection. Check the cable.
E33
General communication
error
Check the plug-in connections and cables.
Switch the motor off and on again.
E41, E42
Incorrect charging
voltage
Check whether the power supply unit used
has an output voltage between 10 V and 20 V.
If necessary contact Torqeedo Service.
E43
Battery empty
Charge battery. Motor can be used again
slowly from the stop position if necessary.
E45
Battery overcurrent
Switch motor off and on again. The information display will not show correct data after
this error occurred. The battery needs to be
fully charged to reset the information system.
E46
Battery operating
temperature error
Battery cells outside operating temperature
between -20 °C and +65 °C / -4 °F and +150 °F.
The motor can be used again when the
temperature has stabilized.
E48
Charging temperature
error
Charging will continue when the cell
temperature is between 0 °C and +45 °C /
+32 °F and +115 °F.
Other error
codes
Defects
Contact Torqeedo Service and notify them of
the error code.
9.4 Pylon
The motor and the electronic control system are located in the pylon and generate the
propulsion. In addition, several protective functions are integrated:
1. Temperature protection: If the motor overheats, the motor control system reduces the
output of the drive until a temperature equilibrium is established between generated
and disposed heat. Above a critical temperature the motor stops and the display shows
error code E02 or E08.
2. Blocking protection: If the propeller is blocked or stuck, the motor would normally
consume too much power. In this case, the motor is switched off within a few
hundredths of a second to protect the electronics, motor winding, and propeller.
After removing the blockage you can switch the motor on again. If there is a blockage
the display shows error code E05.
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Operating Manual Ultralight 402
9. Operation
3. Cable break protection: If the connection cable is damaged, i.e. if the connection to the
remote throttle, battery or motor is broken the motor will not start or stops. An error
code starting with E3 and containing another number is shown on the display.
4. Throttle control: The propeller rev change responds slowly to protect mechanical drive
components and avoid short-term power peaks.
5. Location sensor: The Ultralight has an integrated protective device that switches the
motor off when it is beyond a particular slope (90°). This prevents the propeller from
turning if the boat capsizes or tilts further.
• If the motor has a defect an error code is shown on the display. After
resolving the error the motor can be moved out of the stop position
again. You will find descriptions and details in Section 9.3.
The Fin supports steering movements and protects the propeller from hitting obstacles
under water.
• Only run the motor when the propeller is under water. If it is run in the
air, the shaft sealant rings that seal the motor to the drive shaft may
become damaged. If the motor is run in the air for a longer period, the
motor itself can overheat.
• After use, always take the motor out of the water. The tilting mechanism
can be used for this.
9.5 Ideal depth of immersion
The depth of immersion of the propeller in the water affects the efficiency of your drive.
You can optimize the propeller’s depth of immersion with the help of the information on
speed and consumption shown on the display.
10. Disassembly
1.Move the remote throttle control into the stop position and remove the magnetic key
from the remote throttle. Then press the on/off switch to turn off the motor.
2.Remove all electrical connections between the remote throttle, battery pack, and motor.
3.Remove all lines for steering and locking.
4.Remove the four screws on the ball clamp and remove the drive.
Operating Manual Ultralight 402
29
• The pylon may be hot.
• Ensure that the motor’s individual parts are dry before stowing it in the
travel bag.
• Ensure you do not bend the cable and tackle line around sharp edges.
• Only use the travel bag for transportation not for shipping the motor.
The motor stored in the travel bag may not be affected by heavy objects.
11. Storage and care instructions
11.1 Corrosion protection
Materials were chosen with a high level of corrosion-resistance. All of the materials used
in the Ultralight 402 are, as with most leisure maritime products, classed as “seawater
resistant”, not “seawater-proof”.
• After use you should always remove the motor from the water.
The tilting mechanism can be used for this.
• After operation in salty or brackish water, wash all components in fresh
water.
• Store the motor, battery pack, and remote throttle in the waterproof
travel bag only when dry. If storing the items for longer periods of time
in the travel bag, do not close it so it is airtight.
• Treat all electronic parts with contact spray once a month
• Check the cable regularly for damage.
11.2 Caring for the battery
You extend the lifespan of your battery if you do not expose it to hot environments for
longer than necessary. In order to guarantee the longest possible lifespan of the battery if
you store it for a long time (e.g. over the winter) it should be charged to around 50 % and
stored between 0 °C and +15 °C / 32 °F and +60 °F.
30
Operating Manual Ultralight 402
11. Storage and care instructions
11.3 Changing the propeller
1. Loosen the cable between the motor and battery.
2. Loosen and unscrew the central nut on the propeller.
3. Pull the propeller from the motor shaft.
4. Pull cylinder pin from the motor shaft and remove the disk spring from the motor shaft.
5. Connect the cable between the motor and battery. Allow the motor to run slowly and
check whether the shaft is turning unevenly at the shaft sealing ring. Contact Torqeedo
Service if the shaft is damaged or uneven.
6. Loosen the cable between the motor and battery. Place a disk spring onto the motor
shaft. Note the direction of the disk spring: The inside rim of the disk spring needs to
be in contact with the motor housing.Insert the new cylinder pin centrally to the motor
shaft.
7. Place the propeller onto the motor shaft and turn the propeller so that the cylinder pin
is aligned with the groove in the propeller.
8. Place a disk spring onto the motor shaft behind the propeller. Note the direction of the
disk spring: The outside rim of the disk spring needs to be in contact with the propeller.
9. Tighten the central nut on the propeller by hand.
Disk spring
Selflocking
nut M8
Pin 2.5 x 20
Disk spring
11.4 Other care instructions
Ensure that the storage points on the universal joint and shaft pipe are clean.
To clean the motor you can use any cleaning agents suitable for plastic - follow the
manufacturer’s instructions. Cockpit sprays available for cars achieve good results on the
plastic surfaces of the Torqeedo Ultralight.
Operating Manual Ultralight 402
31
12. Trouble shooting
Motor does not run?
No message on the display?
yes
no
Error code on the display?
yes
no
•Check plugs, if necessary clean
with contact spray (e.g. WD40)
•Charge battery
•Check fuse
•Refer to Section 9.3 in this
operating manual
Activate motor
Motor does not work?
yes
no
•Check that the magnetic key
is in the right location on the
remote throttle, if necessary
turn magnetic key through 180°
Set remote throttle to
stop position
Speed indicator does not
work even after 5 minutes?
yes
no
Contact Torqeedo Service
(for contact details refer to
back page)
32
Operating Manual Ultralight 402
•Check whether the satellite
icon is shown upwards on the
battery and is not covered
12. Trouble shooting 13. Technical data
• Repairs may only be carried out by authorized Torqeedo Service Centers.
If you attempt to make repairs yourself the warranty terminates
immediately.
• In case of a warranty claim, please follow the warranty instructions at
the beginning of the operating manual.
13. Technical data
Ultralight 402
Input power in watts
400
Rated voltage in volts
28.8
Final voltage in volts
33.2
Propulsive power in Watts*
180
Comparable gas outboard motor (propulsive power)
1 HP
Comparable gas outboard motor (thrust)
2 HP
Maximal overall efficiency in %
Static thrust in lbs
45
33.0
Battery capacity in Wh
230 LIMA
Total weight in kg / lbs
7.0 / 15.4
Weight of motor without battery in kg / lbs
4.5 / 9.9
Weight of integrated battery in kg / lbs
2.5 / 5.5
Shaft length in cm / inches
45 / 17.7
Propeller dimensions in inches
8x8
Propeller speed at full power rpm
1,200
Control
Remote throttle control
Steering
Provision for connection to kayak rudder; lockable
Tilting device
Stepless forward/reverse drive
Manual with grounding protection
Yes using remote throttle control
(reverse 50 % power)
*The effective output available to drive the boat (measured after deducting all losses incl. losses in the
propeller). Definition of forward movement = thrust x speed.
Operating Manual Ultralight 402
33
14. Disposal instructions
Torqeedo Ultralight motors are manufactured in accordance with
EU Directive 2002/96. This directive regulates the disposal of electrical
and electronic devices to protect the environment.
You can, in line with local regulations, hand in the motor at a
collecting point. From there it will be professionally disposed.
15. Accessories
Item no.
34
Product
Description
1411-00
Spare battery
Ultralight 402
LIMA-high-performance battery with integrated
GPS receiver, 230 Wh, 28.8 V, 8 Ah
1412-00
Charger for spare battery
Ultralight 402
54 watt charger (12 V, 4.5 A) for chargingng Ultralight 402 batteries, for power connection with 100240 V and 50-60 Hz
1912-00
Spare propeller
Ultralight models
8‘‘ x 8‘‘ variable-pitch-variable-camber (VPVC)
propeller, developed especially for kayaks and other
ultra-light boats. Made of impact-resistant glassfibre reinforced PBT (polybutylene terephthalate),
complete with nuts, disc springs and shear pin
Operating Manual Ultralight 402
Version 1.0
039-00009
Torqeedo Service Centers
Europe and international
Torqeedo GmbH
Petersbrunner Str. 3a
82319 Starnberg
Germany
service_international@torqeedo.com
T +49 - 8151 - 268 67 -26
F +49 - 8151 - 268 67 -29
North America
Torqeedo Inc.
171 Erick Street, Unit A-1
Crystal Lake, IL 60014
USA
service_usa@torqeedo.com
T +1 – 815 – 444 88 06
F +1 – 847 – 444 88 07
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