MaxPower CT550 User manual

INSTALLATION MANUAL CT550

CT550 MANUAL

INSTALATION OPERATION MAINTENANCE

Last update: June 2020

Serial N° : ..........................................................................................................................

Date of Installation : …………………………………………………………………………..

IT IS IMPORTANT TO KEEP THIS MANUAL ON BOARD!

Address :5, Via Philips Str, 20900 Monza (MI),

Italy Tel: +39 039 2001973 Fax: +39 039 2004299

INSTALLATION MANUAL CT550

Table of Contents

1. GENERAL INSTALLATION GUIDLINES .............................................................................................................................. 4

2. TUNNEL ........................................................................................................................................................................... 4

3. PROPELLER DRIVE LEG & MOTOR SUPPORT................................................................................................................... 5

4. THE HYDRAULIC MOTOR................................................................................................................................................. 6

5. PROPELLERS .................................................................................................................................................................... 6

6. PROTECTION GRILLS........................................................................................................................................................ 6

7. HYDRAULIC (general remarks) ........................................................................................................................................ 7

8. HYDRAULIC SPECIFICATIONS........................................................................................................................................... 8

9. MAINTENANCE................................................................................................................................................................ 8

10. CT550 PART LIST ....................................................................................................................................................... 10

11. WIRING DIAGRAM .................................................................................................................................................... 12

12. HYDRAULIC DIAGRAM............................................................................................................................................... 13

13. POSITIONING AND MESURMENTS............................................................................................................................ 14

14. PROPELLER ASSEMBLY .............................................................................................................................................. 15

15. MAIN DIMENSIONS................................................................................................................................................... 16

16. WARRANTY COVERAGE............................................................................................................................................. 17

Definitions............................................................................................................................................................................. 17

Period of Coverage ............................................................................................................................................................... 17

Warranty Registration .......................................................................................................................................................... 17

Warranty Terms .................................................................................................................................................................... 17

Warranty Exclusions ............................................................................................................................................................. 17

Procedural Guidelines........................................................................................................................................................... 17

INSTALLATION MANUAL CT550

Your thruster is a high quality technical product and should be treated as such. The employment of qualified

marine personnel, with experience in bow thruster installation, is strongly advised. Where possible, the boat

manufacturer’s architects, design departments and/or shipyards should be consulted, prior to installation taking

place. For any boat requiring official classification, bodies of approval should also be consulted at the earliest

opportunity. In any case, all other bodies, governmental or otherwise, should be contacted to ensure

conformity with legal regulations relating to the boat in question.

Congratulations on choosing a Max-Power thruster –Characterised by its performance, durability, reliability

and ease of installation.

To ensure a proper installation, correct usage and long-lasting enjoyment of this equipment, please

take time to read this manual thoroughly.

INSTALLATION MANUAL CT550

1. GENERAL INSTALLATION GUIDLINES

Decide on the best location for the thruster. (See drawing: “Positioning & Measurements” at back of manual).

The tunnel must be as low as possible and as far forward as possible.

The propellers must not protrude beyond the hull line.

The ideal position of the tunnel is such that there is at least the depth of one tunnel diameter from the water

line to the top of the fitted tunnel. Decreased performance of the thruster due to inadequate immersion depth

can be compensated by fitting the tunnel as far forward as possible (increasing lever arm movement).

Hydraulic thrusters can be fitted vertically, horizontally or tilting.

IMPORTANT: When using tunnels of different thickness (example: metallic tunnel) it is imperative that the area

between the drive leg/gasket and the motor support, matches the thickness as indicated in the table on the

drawing “Positioning & Measurements” at back of manual and that the motor support is stable.

If you have less than 12 mm thickness, you will require an extra hard rubber gasket between the motor support

and the tunnel.

2. TUNNEL

When the final tunnel position is determined (and all dimensions have been checked), mark the centre of the

tunnel’s position and drill a Ø 10 mm hole. Make up a metal compass from 8 mm rod with 212 mm radius.

Fit compass into the Ø 10 mm holes and trace the form of the tunnel on to the hull (elliptical).

After cutting out the elliptic hole, disc the interior surface of the hull, by approx. 10 to 15 cm around the holes.

The outside surface of the tunnel is then ready to be fibre-glassed.

Do not

stratify over

this zone

INSTALLATION MANUAL CT550

Fit the tunnel and mark the areas to be fibre-glassed. Sand these areas inside and out.

In certain installations it is preferable to drill the position of the thruster support before the installation of the

tunnel.

Refit the tunnel. Apply reinforced fibreglass filler to all areas, taking care that you fill the gap between hull and

tunnel. Stratify with a minimum of 8 coats of material and ISOPHTALIQUE RESINE alternating with mat and

roving. In inaccessible areas (i.e. under the tunnel), it is possible to simply apply reinforced filler.

CAUTION: Do not fibre glass the area of the motor support. It is recommended to lightly sand down the area

where the motor support is fitted.

On the outside, when the ISOPHTALIQUE RESIN has set, finish with an application of resin and material,

followed with an additional coat on the hull, in the tunnel area. To optimize the flow of water while sailing,

deflectors & a relief should be fashioned. These can be made up with several coats of reinforced filler in order

to obtain the required hydrodynamic lines.

Once all fibreglass work is complete, apply a coat of epoxy or gel-coat to waterproof the entire area.

3. PROPELLER DRIVE LEG & MOTOR SUPPORT

The leg’s gasket and the motor‘s support can be used to mark up the drilling position, in some cases it might

be easier, to mark out the position, and drill before the stratification of the tunnel.

Centre and trace the drilling positions for the leg and its support.

Fit the leg along with the gasket, in the tunnel.

Check general positioning of the propellers.

Small pieces of folded cardboard can be used to check the spacing between the propeller tips and the tunnel is

even all round. Slight adjustment to align the leg in its tunnel may be necessary.

After checks, remove leg etc; remount the assembly, covering the gasket with an oil and salt water resistant

jointing compound. After fitting, remove all excess compound.

The gasket must be between the leg and the tunnel, and not between the motor support and the tunnel.

Care must be taken at all times when fitting the leg into the motor support to ensure that the mating

components are dirt free and covered with a light film of grease.

IMPORTANT: GRAPHITE GREASE MUST NOT BE USED.

Torque values: screw Ø 12 mm = 80 Nm screw; tighten the two fixing screws alternately.

Once tightened, ensure that the propeller/s turn freely without touching the tunnel.

INSTALLATION MANUAL CT550

4. THE HYDRAULIC MOTOR

Insert the lower drive coupling onto the leg drive shaft (lightly grease the shaft before doing this).

Then position the motor and tighten the 4 x 12 mm to 80Nm.

IMPORTANT: Please note that the above coupling might need to be adjusted if any other tunnel than a Max

Power tunnel (thickness 12-14mm) is used.

The top and bottom coupling pieces should fit tightly together to ensure maximum gripping between them.

Check that the propellers turn freely and that there is no tight spot. A certain amount of resistance is normal

from the motor. When all is assembled recheck the tightness of all the motor bolts.

NOTE: The coupling on the motor side is in place when delivered, do not touch this.

5. PROPELLERS

The positioning of the propellers is indicated at the end on chapter “PROPELLER ASSEMPLY”.

6. PROTECTION GRILLS

With a shallow tunnel installation, we recommend that you protect the propellers by fitting horizontal protection

grills. These grills will however modify thruster performance.

INSTALLATION MANUAL CT550

7. HYDRAULIC (general remarks)

A typical installation of the hydraulic power thruster requires the following elements:

oil reservoir/tank

hydraulic pump

directional control valve

hydraulic motor

circuit piping

oil cooler (depending on type of installation)

The oil reservoir/tank with return filter and suction strainer should be as close to the pump as possible and on

charge. Meaning that the level of the oil should be above the pump, preferably with the oil tank above the water

line.

For future maintenance, make sure that the return filter is easily accessible. An isolation valve can be fitted

to the suction.

The pump can be driven only by internal combustion engine (crankshaft pulley or gearbox PTO).

For an internal combustion engine with fixed or variable speed, 2 types of pumps can be used, depending on

the unit to be fitted:

Direct PTO:

1. Fixed flow pump (***)

2. Variable displacement pump, depending on the model (**) (*)

3. Fixed flow pump with bypass (**) (*)

PTO with clutch:

1. Fixed flow pump (**) (*)

2. Variable displacement pump depending on the model (**) (*)

3. Fixed flow pump with bypass (**) (*)

(***) always require oil cooler

(**) require oil cooler when time of operation exceeds 15 minutes,

(*) oil cooler not necessary

Note: The above choices also depend on capacity of the oil tank etc.

INSTALLATION MANUAL CT550

The hydraulic directional control valve (DCV) must be equipped with a pressure gauge and pressure relief

valve and should preferably be placed as close as possible to the thruster unit.

The piping can be flexible or a mix of rigid and flexible type and should have crimp-connected fittings.

The piping should match interior diameters and the service pressure equal or above that which has been

recommended.

The circuits must be as direct as possible and avoid any bends and joints.

The circuits must be clean and closed-off until final connection takes place.

The thruster hoses arriving at the thruster must be of the thermo-plastic non-conductive type.

The hydraulic motor drain line and the return T-line of the DCV should each go separately and directly, back

into the top of the oil tank.

Use synthetic, mineral or vegetable hydraulic oil, to ISO standard 32 to 48

8. HYDRAULIC SPECIFICATIONS

CT550 Specifications

Power

49 KW

Pressure

250 bar

Flow

125 - 141 lt/min

Detailed instructions and diagrams are delivered with each pack, specific to the installation chosen.

9. MAINTENANCE

In order to ensure peak performance from your thruster, the tunnel, the leg and the propellers must be kept

clean.

IMPORTANT: In order to prevent chalky deposits, which cause damage to the oil seals, we recommend

cleaning the shaft and the oil seals first, then applying a layer of silicon oil before assembling the propellers.

ANNUAL BASIS:

CHANGE the anode (if necessary).

CHANGE the gear oil a minimum of every second year. Check the gearoil quality in the gearhouse

every time the boat is out of the water

CHECK the oil and the hydraulic filtration circuit (only if necessary).

EVERY 5 YEARS:

DRAIN hydraulic oil system and change the filter and refill.

INSTALLATION MANUAL CT550

Installation Notes

THE MAX-POWER TEAM WISHES YOU SUCCESSFUL MANOEUVRING AND

ENJOYABLE CRUISING.

IT IS IMPORTANT TO KEEP THIS MANUAL ON BOARD!

INSTALLATION MANUAL CT550

10. CT550 PART LIST

Table of contents

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