Torqeedo Travel 401 S User manual

Travel 401 S
Travel 401 L
Travel 801 S
Travel 801 L
Operating Manual
(Englisch)

3
Operating Manual Travel 401/801
1. Contents
1. Contents
2. Important safety and handling instructions 4
3. Introduction 6
4. About this instruction 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 Assembly of the drive 12
8.2 Fitting the outboard motor to the boat 14
9. Operation 16
9.1 Battery and charger 16
9.2 Transom bracket 18
9.3 Tiller 18
9.4 Pylon 20
9.5 Optimal submergence depth 21
10. Dismantling 21
11. Storage and care instructions 22
11.1 Corrosion protection 22
11.2 Battery care 23
11.3 Other care instructions 23
12. Trouble-shooting 23
13. Technical data 25
14. Disposal instructions 25
15. Accessories 26
16. Torqeedo Service Centers 28

4Operating Manual Travel 401/801
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 these instructions can cause property damage or personal injury.
Torqeedo accepts no liability for damage caused by actions that contradict this operating
manual.
To ensure safe operation of the motor:
•Familiarize yourself with all the motor controls. You should be able to stop the motor
quickly if necessary.
• Only allow adults who have been instructed on how to operate the motor to run it.
• Follow the boat manufacturer‘s instructions on the permissible motorization of your
boat. Do not exceed the capacity limits.
• Stop the engine immediately if someone goes overboard.
• Do not run the motor if someone is in the water near the boat.
•Do not use the motor as a lashing point for your boat. Do not use the motor as a handle
for lifting or carrying smaller boats.
• Do not open the battery case and protect the battery pack from mechanical damage.
• Do not short circuit the battery.
• Do not submerge the battery in water or other liquids.
• Only charge the battery at ambient temperatures between 0° and 45°C.
• The battery of your Travel Motor is classified as a hazardous item under the UN 9
classification. Transport for private use is not critical. If sending by courier, the
appropriate legal regulations must be observed.

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Operating Manual Travel 401/801
2. Important safety and operating instructions
Important operating instructions
Here are the most important instructions on operating Torqeedo Travel 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, 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.
• When mounted, the battery is protected against rain and spray water. Do not submerge
it, and keep the contacts as well as the charger port dry. If water enters the battery via
the contacts or the charger port, this can cause irreparable battery damage. If liquid has
entered the battery, first drain off the liquid through the battery case openings. Then dry
the battery in a dry, warm environment up to 50°C before you use it again or before you
press the „Battery charge“ button.
•After use, always take the motor out of the water. You can do this using the tilt
mechanism of the transom mount.
• After use in salt or brackish water, rinse the motor (but never the battery) with fresh
water.
• Occasionally use contact spray to care for the battery contacts, the shaft head contacts,
the steering cable plug as well as the steel bolts at the joints of the folding shaft. If you
use the motor in salt or brackish water, we recommend applying contact spray once a
month.
•You will prolong the life of your battery if you do not expose it to a very hot environ-
ment or store it fully charged for longer than necessary. When you store the battery
over an extended period (e.g. over the winter), charge it to about 80-97% and store it at
-20°C to +15°C to ensure a long battery life.
•Always store the motor and battery dry in the drybag.
• Only use the drybag for transport, not for shipping. Do not place heavy objects on top
of the motor stowed in the drybag.
• If the motor malfunctions, first switch the tiller control to the stop position for approx.
2 seconds. The stop position has a reset function and may correct minor faults itself.
• If the battery malfunctions (all LEDs flash), remove the battery from the shaft head. Wait
until the LEDs go out (approx. 3 seconds) and press the „Battery charge“ button. This
features an integrated reset function and may correct minor faults itself.
• If you have a problem with your motor, please follow the instructions in this manual for
handling warranty claims.

6Operating Manual Travel 401/801
3. Introduction
Dear Customer,
We are delighted that you have chosen our motor. In terms of motor, battery and
propeller technology, your Torqeedo Travel outboard motor is cutting-edge technology.
It has been designed and manufactured with the utmost care and with a special focus on
comfort, user-friendliness and safety, then exhaustively tested before delivery.
Please take the time to read these operating instructions 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
([email protected]).
We hope you have a lot of fun with this product. You will be surprised at how much power
this lightweight electric outboard packs.
Yours,
Dr. Friedrich Böbel Dr. Christoph Ballin
Managing Partner Managing Partner

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Operating Manual Travel 401/801
3. Introduction 4. About this instruction manual 5. Conformity declaration
4. About this instruction manual
This instruction manual will help you use your Torqeedo Travel 40 1/801 safely and
efficiently. All information is given according to our latest knowledge. Subject to technical
changes.
•Highlights a danger or process which could lead to injury
or property damage
•Highlights a danger or process which could lead to property damage
5. Conformity declaration
We, Torqeedo GmbH, with sole responsibility, declare the conformity of the Travel 40
1/801 product range with the following provisions:
Small water vehicles
Electrical systems
Low voltage-direct current (DC) units
DIN EN ISO 10133:2000
Starnberg, November 2006
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)

8Operating Manual Travel 401/801
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 submitted properly (see Warranty process)
• the product was not treated in accordance with the instructions
• 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
unless the consumer can prove that the facts that led to the warranty being void did not
affect the development of the fault.

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Operating Manual Travel 401/801
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 which 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 post. You can find the
contact details on the back of this manual. Please note 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 fault.
• Proof of purchase must indicate the purchase and the date of purchase (e.g. till receipt,
invoice or receipt).
When shipping, it must be noted that the LIMA battery is classed as a UN9 hazardous
item. If the dispatched product includes a LIMA battery (either by itself or with the motor),
posting and packing must be in accordance with the relevant directive. In this instance we
recommend keeping the original Torqeedo packaging. The enclosed drybag is not to be
used as a shipping package.
We are available to answer any questions regarding the warranty process - simply use the
details on the back cover.
6. Warranty conditions

10 Operating Manual Travel 401/801
7. Equipment and operating elements
7.1 Supply scope
The full supply scope of your Torqeedo Travel should include the following parts:
• Folding shaft assembly group
• Transom bracket assembly group
• Tiller assembly group
• Battery assembly group
• Tiller handle
• 2 bolts (to attach the battery)
• 2 on/off pins
• Drybag
• Charger including Euro charger cable, US charger cable and UK adapter
• Operating instructions
• Warranty certificate
• Packaging

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Operating Manual Travel 401/801
7.2. Plan of operating elements
7. Equipment and operating elements
Tension screw (to fit
the folding shaft)
Shaft head
Assembly group battery
On/off pin (to turn on/off the engine)
Tiller handle
Eye (to secure the battery)
Bolt (to fit the battery
to the shaft)
Cable duct
Control cable
Opening button
(to change the
length of the tiller)
Dead bolt
Rest button
(to tilt the engine)
Friction screw
(to lock the steering)
Mounting Clamp (to fit
the engine to the boat)
Assembly group transom bracket
Assembly group folding shaft
Propeller with sacrificial anode
Pylon
Fin
Assembly group tiller

12 Operating Manual Travel 401/801
8. Starting up
8.1 Assembly of the drive
1. Remove all the components, assembly groups and parts delivered with your Travel
from the packaging.
2. Open the folding shaft on an even surface.
3. Straighten out all the parts of the folding shaft. Ensure that the cable and the cable
stem are not twisted. Now assemble the shaft parts, as below.
4. Turn the tension screw on the shaft clockwise until you feel a definite resistance.

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Operating Manual Travel 401/801
5. Put the tiller handle on the tiller. Make sure you align the opening button on the tiller
with the recesses in the tiller handle. The opening button must click into place audibly.
6. Place the tiller above the deadbolt (A) on the folding shaft. The steering cable must
come out under the tiller. Now slide the tiller to the required height. Close the tension
bolt and tighten both wing nuts lightly. The height of the tiller can be adjusted after
fitting.
7. Connect the control cable.
8. Push the transom bracket under the deadbolt (A) onto the folding shaft. Adjust to a
suitable shaft length according to the conditions of your boat. The shaft length can also
be adjusted once fitted. Close the tension bolt and tighten both wing nuts.
A
1.
2.
8. Starting up
A

14 Operating Manual Travel 401/801
• Make sure you do not crush the control cable.
• Do not place the transom mount onto the shaft above the deadbolt to
avoid damage to the shaft and the transom mount.
• Only fix the battery pack once the drive has been mounted and
straightened.
8.2 Fitting the outboard motor to the boat
1. Suspend the drive in your boat and tighten the capstan-head screws. Ensure the
weight is spread evenly in the boat.
2. To trim the motor, pull the stopper button of the transom mount and position the
folding shaft vertically to the water surface.
3. To adjust the shaft length, loosen both wing nuts on the transom bracket and adjust
the shaft length to your boat so that the propeller has the required submergence depth.
Note that the submergence depth has a major influence on the efficiency of your drive.
To optimize the submergence depth, please read the operating instructions in section 9.5.
4. To adjust the height of the tiller, loosen the respective wing nuts and pull the tiller to
the required height. Once you have the required height, tighten the wing nuts again.
5. The tiller handle can be adjusted in length by pressing the opening button. Ensure that
the button engages.
6. Turn the tiller handle to the stop position until
it engages.
7. Fit the battery pack. To do this, lift it with both
hands and fit it into the shaft head from above.
Then swing the battery to the rear until it sits
properly and engages.

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Operating Manual Travel 401/801
8. Additionally you can secure the
battery with the enclosed bolts
to prevent it from coming loose
accidentally. You may also slip a
safety line through the eye on
the bottom of the battery.
9. Insert the on/off pin into the
opening on the top of the tiller.
10.The Travel 401/801 is ready to go.
You can download a video showing the assembly of the Travel at www.torqeedo.com.
• When loosening the wing nuts, hold the motor by the shaft head to
avoid unintentional slipping. There is a danger that you might crush
your fingers or cut the control cable.
• Never loosen the wing nuts on the transom with the battery in place.
•When handling the outboard, ensure a secure hold to avoid accidentally
falling overboard.
• Make sure you do not crush the control cable.
8. Starting up

16 Operating Manual Travel 401/801
9. Operation
9.1 Battery and charger
The battery is equipped with high-performance lithium-manganese cells, so-called LIMA
cells. The LIMA cells have a self-discharge of under 1% per month at 20°C, are cyclically
stable and have no memory effect. The lithium battery can be used at an ambient
temperature of between -20°C and +45°C.
The battery has an integrated control system that has several functions for protecting and
caring for your battery. Among other functions, the control system protects the battery
against overdischarge as well as overcharging. So you can leave the battery on the
charger or empty it completely without worry.
The current charge status can be determined by pressing the „battery charge“ button at
any time. After pressing the button, the LEDs will illuminate for approx. 10 seconds and
show the charge level of the battery as a percentage.
When charging, the battery‘s control system regulates the charging current. The light
diodes glow permanently on the capacity areas that are already charged. The light diodes
of the capacity areas that are currently charging flash. Once charging is complete and the
battery is fully charged, the LEDs extinguish.
The real capacity of your battery is subject to technical fluctuations. Its capacity will also
change over time. To compensate for the capacity change, the charge indicator will adjust
LEDs on LEDs flashing
(1Hz)
Remaining charge in percent
of capacity
– – 0%
– 20 1-19%
20 – 20-39%
20-40 – 40-59%
20-40-60 – 60-79%
20-40-60-80 – 80-96%
20-40-60-80-100 – >96%
– 20-40-60-80-100 Fault

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Operating Manual Travel 401/801
to the battery‘s capacity. In order to ensure the charge indicator continues to show reliable
values, it is necessary to empty the battery to below 20% and then fully charge it once a year.
The enclosed charger is adjusted to the control system and charges the
Travel‘s battery in approximately 10 hours. When charging in high
ambient temperatures (>35°C), it could take longer, as the control
system is fitted with a temperature-dependent current regulator.
This ensures gentle charging of the cells. Connect the charger
and the cold battery to the mains for charging.
•When mounted, the battery is protected against rain and spray water.
Do not submerge it, and keep the contacts as well as the charger port
dry. If water enters the battery via the contacts or the charger port, this
can cause irreparable battery damage. If liquid has entered the battery,
first drain off the liquid through the battery case openings. Then dry the
battery in a dry, warm environment up to 50°C before you use it again or
before you press the „Battery charge“ button.
•Only use the Travel 401 battery with the Torqeedo Travel 401 outboard
motor and the Travel 801 battery only with the Travel 801.
• Only use the enclosed charger or one authorized by Torqeedo to charge
the battery.
• If a fault (all LEDs flashing) shows on the battery, take the battery off the
shaft head. Wait until the LEDs go out (approx. 3 seconds) and press
the „Battery charge“ button. This features an integrated reset function
and may correct minor faults itself.
•Never open the battery case and protect the battery pack from
mechanical damage.
• Do not short circuit the battery.
•Do not submerge the battery in water or other liquids.
• Only charge the battery at ambient temperatures between 0° and 45°C.
• LIMA battery cells only catch fire if they are exposed to temperatures
above 300°C. This is a major advantage over other lithium-type battery
systems. Should this occur, try and position the battery so it will cause
no damage. Should this not be possible, keep your distance or cover the
battery with sand or other dry, non-flammable materials.
9. Operation

18 Operating Manual Travel 401/801
9.2 Transom bracket
The power needed for steering can be adjusted with the friction screw. Turning the screw
clockwise increases the necessary steering power up to locking the motor. Turning anti-
clockwise reduces the necessary steering force.
Pulling the stopper button unlocks the folding mechanism. The drive can be locked into
position at 0°, 8°, 16°, 24°, 36°, 49°, 62° and 75 °. If a boat does not have a vertical
mounting, it is thus possible to adjust the motor to ensure it is at a right angle to the
water surface.
•Only tilt the shaft if the battery is removed or fixed to the shaft head
with the bolt.
•When using the tilting mechanism, hold the shaft until you feel it lock
into place.
9.3 Tiller
The tiller can be lifted up two notches by up to 20°.
The opening button on the aluminum tube allows the length of the tiller to be adjusted.
Press this button into the aluminum tube to adjust the length in three stages.
•Ensure that the button engages again.
You can shut down the drive quickly by pulling the on/off pin. Simply remove this pin by
pulling it out. The drive will only start again when the pin is re-inserted. The tiller must be
positioned in stop-mode to do this.
The digital power control combines continuously variable speed with fixed locking points
for pre-defined speeds. The following diagram shows the different control points as seen
from the boat.

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Operating Manual Travel 401/801
9. Operation
STOP
Continuously
variable forward
Continuously
variable reverse
Max thrust
Fixed time
Max range
Tiller position Function Application example
Continuously variable
reverse
Continuously variable reverse
drive
• Maneuvring
Continuously variable
forward
Continuously variable forward
drive
• Normal steering
• Maneuvring
Max thrust Short term maximum thrust
forwards (< 10 minutes)
• Only available if battery
is relatively full
• Especially effective on heavier
boats; no effect on light boats,
which do not use the full
thrust of the engine
• Rapid acceleration
• Maneuvring
Fixed time Travelling speed with fixed time.
If the battery is fully charged, the
following times are set:
• Travel 401: 2 hours
• Travel 801: 1 hour
Times relate to use of the Travel
LIMA battery
• Travel on controlled
timescale
(without using the
battery charge indicator)
Max range Slow travel with speed close to
range maximum (50 W initial
power for Travel 401 and 801,
i.e. approx. 6 hours travel time)
However, the optimum distance
operation varies widely from
boat to boat.
• Reaching the mooring
point on low battery
charge
• Long range when using
in lulls

20 Operating Manual Travel 401/801
9.4 Pylon
The motor and the electronic control system are located in the pylon. They 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.
2. Undervoltage protection: If the voltage falls below 9 V (Travel 401) or 17 V (Travel 801),
the electronic controller switches the drive off to avoid overdischarging the battery.
Even beforehand, the output of the motor is regulated so that high currents of over 37 A
do not occur.
3. Blocking protection: If the propeller is blocked or stuck, the motor would normally take
in 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 unblocking, the
motor can be re-started out of the stop position after about 1 second.
4. Cable damage protection: If the steering cable is damaged, i.e. if the connection to the
tiller is broken, the motor will not start, or it stops.
5. Acceleration control: The alteration speed at which the speed of the propeller adjusts
to a changed tiller position is limited in order to protect mechanical drive parts and to
avoid short-term peak current.
•If the motor malfunctions, first switch the tiller control to the stop
position for approx. 2 seconds. The stop position has a reset function
and may correct minor faults itself.
The highly efficient variable pitch variable camber (VPVC) propeller is equipped with
a mechanical slip clutch that protects the drive from mechanical damage on sudden
blockages of the propeller. The slip clutch is designed as a redundant safety feature to the
electronic blocking protection described above.
The fin supports steering movements and protects the propeller when it comes into
contact with the bottom.
The sacrificial anode protects the metallic components that are located under the
water from corrosion, especially in salt water.