MaxPower 225HYD Series Owner's manual

Hydraulic Tunnel Thruster
Series 225HYD
With Electronic Controller
INSTALLATION OPERATION MAINTENANCE
Serial N° : ----------------------------------------------------
Date of Installation : ----------------------------------------
THIS MANUAL MUST BE KEPT ON BOARD AT ALL TIMES
Via Philips 5, 20900 Monza (MI), Italy
Tel. [phone] - Fax [phone]
Manual Max Power Series 225 HYD
Last Update: December 2016
www.max-power.com E-mail:[email protected]

To ensure a proper installation, correct usage and long-lasting enjoyment of
this equipment, please take time to read this manual thoroughly.
Table of Contents
NumberDescription Page
1 General Installation Guidelines 2
2 Tunnel 2-3
3 Propeller Drive Leg & Motor Support 3
4 The Hydraulic Motor and its Adapter 4
5Propellers 4
6ProtectionGrill 4
7 Hydraulic General Remarks 4-5
8 Hydraulic Specifications 5
9 Hydraulic Custom Pack 6
10Maintenance 7
11Notes 8
12SparePartsList 9
13SparePartDiagram 10
14 Control System Connections: Electro-Hydraulic Pump 11
15 Control System Connections: Motor with Clutched Pump 12
16 Super Power Hydraulic Diagram 13
17 Positioning and Measurements 14
18 Warranty Procedures 15-16
19 List of Distributors 17-18
20 Warranty Document (to be returned) 19
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.
Your thruster should be delivered with the following parts:
Hydraulic Motor &
Coupling
Motor Support Controller HYD Drive Leg, Propeller
Pin(s) & Coupling
Propellers (2) Safety Stickers x 2 Manual
Manual Max Power Series 225 HYD
Last Update: December 2016
1

1) GENERAL INSTALLATION GUIDLINES
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 SUPER POWER due to inadequate immersion depth can be
compensated by fitting the tunnel as far forward as possible (increasing lever arm
movement).
The SUPER POWER 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 7 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.
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
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.
Manual Max Power Series 225 HYD
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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 optimise 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 10 mm = 40 Nm screw; tighten the two fixing screws alternately.
The installation of the composite drive leg is identical to that of bronze leg, except for the
following points: The composite drive leg is lubricated for life.
The composite drive leg does not require an anode.
The composite drive leg MUST NOT BE DISMANTLED, even partially.
Once tightened, ensure that the propeller/s turn freely without touching the tunnel.
Manual Max Power Series 225 HYD
Last Update: December 2016
3

4) THE HYDRAULIC MOTOR AND ITS ADAPTER
Do not separate the motor from its adapter.
Insert the lower metal coupling on the greased leg shaft.
Fit the flexible coupling, then the motor and its adapter, tighten the screws (∅10mm) to a
torque of 40 Nm.
IMPORTANT: Using a screwdriver push the lower coupling up towards the motor, the
contact between these parts must be without any slack or play.
Tighten locking screw for drive key to ensure coupling is kept in place.
5) PROPELLERS
Check the tightness of the oil drain screw (8 mm Allen Key) and the anode (a 10 mm key).
IMPORTANT: To prevent limestone deposits from forming (causing damage to the joints),
we highly recommend applying silicone grease to the shaft and the joints
before assembling the propellers.
Fit the propeller pins and propellers
NOTE: Position the propeller blades opposed and not in line with one another.
Make sure that the propellers turn freely. A certain amount of resistance from the motor is
normal.
Tighten the 22 mm nuts on each propeller to 27 Nm.
Ensure correct protection of hands against the propellers blades.
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.
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.
Manual Max Power Series 225 HYD
Last Update: December 2016
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The pump can be driven by either an internal combustion engine (crankshaft pulley or
gearbox PTO) or an electric motor. Depending on the speed and choice of drive, but should
always comply with the rated pressure/flow of the thruster.
For an internal combustion engine with fixed or variable speed, 3 types of pumps can be
used, depending on the unit to be fitted:
Direct PTO:
Fixed flow pump (***)
Variable displacement pump, depending on the model (**) (*)
Fixed flow pump with bypass (**) (*)
PTO with clutch:
Fixed flow pump (**) (*)
Variable displacement pump depending on the model (**) (*)
Fixed flow pump with bypass (**) (*)
On a DC or AC electric motor the following types of pumps can be used:
DC MOTOR:
Fixed flow pump (*)
AC MOTOR:
Fixed flow pump or other (**) (*)
(***) 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.
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
SUPER POWER Series 225 HYD: Flow = 33/35 litres/Min Pressure = 200/220 bars.
Detailed instructions and diagrams are delivered with each pack, specific to the installation
chosen.
Manual Max Power Series 225 HYD
Last Update: December 2016
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9) HYDRAULIC CUSTOM PACK.
Tailor made according to specifications.
ELECTRO PUMP PACK: 1 x Electro Pump 24 Volt
1 x Power Relay
1 x Fuse Holder
1 x Power Fuse
HYDRAULIC CONTROL PACK (12 V / 24 V):
1 Directional Control Valve (Including pressure gauge & Pressure Relieve Valve)
1 Control Panel.
RESERVOIR PACK
Oil Reservoir 12 / 18 / 40 litres including: Return Filter
Suction Strainer
Oil Level Sight Gauge/ Thermometer
Filler Cap
Motor Drain Connection
INTERIOR DIAMETERS AND MODULES of the piping between the hydraulic elements.
M4 = 1/4’’ M5 = 5/16’’ M6 = 3/8’’ M8 = 1/2’’
M10 = 5/8’’ M12 = 3/4’’ M16 = 1’’
INTAKE DIAMETERS of standard hydraulic elements MAX POWER.
1 / 2 / 11 = Female BSP 3/4'' 3 / 6 / 7 / 8 / 9 = Female BSP 1/2'',
4 / 5 = Female BSP 3/8'' 10 / 12 = Female BSP 1/4''
Reservoir
Pump
Motor
Filter
Directional Control Valve
11
2
3
12
10
9
8
6
5
4
7
M4
M8
M8
M8
M12/16
1
M8
No Longer than 1.5m
If longer increase size.
Manual Max Power Series 225 HYD
Last Update: December 2016
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10) MAINTENANCE
In order to ensure peak performance from your SUPER POWER, 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 drive leg oil, if classic (bronze) leg.
CHECK the oil and the hydraulic filtration circuit (only if necessary).
EVERY 5 YEARS: DRAIN hydraulic oil system and change the filter and refill.
THE MAX-POWER TEAM WISHES YOU SUCCESSFUL MANOEUVRING AND
ENJOYABLE CRUISING.
IT IS IMPORTANT TO KEEP THIS MANUAL ON BOARD!
Manual Max Power Series 225 HYD
Last Update: December 2016
7

Installation Notes
Manual Max Power Series 225 HYD
Last Update: December 2016
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Manual Max Power Series 225 HYD
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Manual Max Power Series 225 HYD
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MAX POWER 225 HYD

Manual Max Power Series 225 HYD
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11

Manual Max Power Series 225 HYD
Last Update: December 2016
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Manual Max Power Series 225 HYD
Last Update: December 2016
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WL
E
D
Super Power Hydraulic: Positioning and Measurements
A
B
C
T
E Ideal
Model
Dim (mm) 125 225
185
197
210
6
185
250
264
210
7
250
E Mini 110 140
Weight 9 Kg 12 Kg
325
315
333
220
9
315
160
20 Kg
D 190 220 280
A
B
T
C
Manual Max Power Series 225 HYD
Last Update: December 2016
14

WARRANTY COVERAGE
Introduction
The purpose of this document is to set out the terms of warranty cover offered in relation to
products purchased by the End User from Max Power or its approved network of resellers.
This document will adhere to the following format: -
Section 1 Definitions
Section 2 Period of Coverage
Section 3 Warranty Registration
Section 4 Warranty Terms
Section 5 Warranty Exclusions
Section 6 Procedural Guidelines
Section 7 Service Centers
Authorized Repair Number – The number given by Max Power on reporting a fault
with your thruster
Dealer – An authorized Max Power sales center
End User – The boat supplied with supplied equipment and the owner thereof
Installer – The authorized center responsible for the installation of your thruster
Manufacturer – supplier of the equipment under warranty
Pleasure Craft – Vessels used for owner’s personal use that have no commercial use
(i.e. Charter boats or work boats)
Resellers – Max Power approved distributors and dealers
Serial Number – Number in upper right hand corner of Warranty document
Supplier – The manufacturer (Max Power)
Warranty – The terms and conditions that are covered by the manufacturer
2) Period of Coverage
The equipment manufactured by the Supplier is guaranteed to be free from defective
workmanship, components and materials under normal usage conditions for a period of two
years from the date of purchase by the End User. This warranty is transferable to subsequent
owners of this equipment during the period of coverage.
3) Warranty Registration
Register your purchase now to receive free extended warranty coverage. This can be done
using one of the following methods (NB. proof of purchase must be included to establish
that equipment is still under warranty):
a) The quickest and easiest method to register your warranty is to fax the attached
installation check list and warranty registration to the Manufacturer
(Fax: [phone])
b) Mail in your warranty registration document, please ensure that you make a copy
before sending it. (10 Allée F Coli, 06210 Cannes-Mandelieu, France)
Warranty Document Cont.
Manual Max Power Series 225 HYD
Last Update: December 2016
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4) Warranty Terms
If the material is used for anything other than for pleasure craft, the guarantee is limited to a
six-month period.
Year 1 - All factory testing, diagnosis, repairs and replacements are performed at no
charge to the End User. All parts and up to two hours of labour are covered for
repairs and replacements conducted in the field.
Year 2 - All factory testing, diagnosis, repairs and replacements are performed at no
charge to the End User. This excludes any damage or faults occurring from normal
wear and tear on the following items: engine, oil seals, relay contacts (If warranty is
registered within the 3 month period following installation)
5) Warranty Exclusions
Damage due to modifications or installation contrary to published specifications
Cost of hauling the boat
Damage due to repairs performed by an unauthorized service center
Damage due to lack of normal maintenance services
Damage due to water
Parts replaced due to normal wear and tear
Repairs performed without knowledge of manufacturer (please contact dealer to receive
Repair Authorization Number)
Tampering of equipment by the End User
Cost of travel to and from the job site
Cost of economic loss, including injury to any person, damage to property, loss of income or
profit, communication, lodging, inconvenience
Consequential damage due to failure, including those arising from collision with other
vessels or objects
6) Procedural Guidelines
PLEASE VIEW THE TROUBLE SHOOTING LIST TO ASCERTAIN OR SOLVE ORIGIN OF
PROBLEM PRIOR TO CONTACTING THE DEALER/INSTALLER
1) Contact your dealer/installer to report the problem.
a. If you do not know who this is contact the nearest Max Power distributor
b. If you are in foreign waters please contact the nearest Max Power distributor
2) Ensure you have your serial number and model number to hand (top right hand
corner of warranty)
3) Dealer/Installer will come to site to decipher the cause of the fault
4) If the cause of fault is due to a manufacturing problem the dealer will contact Max
Power to receive Repair Authorization Number.
5) If the problem is due to an installation error please contact your installer.
IF POSSIBLE: PLEASE TAKE PHOTOGRAPHS OF THE THRUSTER TO SHOW PROBLEM
The warranty as outlined above is only applicable to Max Power manufactured thrusters and optional equipment
as used in marine pleasure industry. The supplier holds the exclusive right to test the product and determine
whether it is defective.
Manual Max Power Series 225 HYD
Last Update: December 2016
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DISTRIBUTER CONTACT LIST:
SOUTHERN EUROPE:
CYPRUS
OCEAN MARINE EQUIPMENT LTD
Limassol
Tel: + 357 53 69 731
Fax: + 357 53 52 976
Email: [email protected]
CYPRUS
TUTI MARE TRADING
Limassol
Tel: + 357 25 431 313
Fax: + 357 25 431 300
Email: [email protected]
FRANCE
ACCASTILLAGE BERNARD
Cannes La Bocca
Tel: + 33 493 90 47 47
Fax: + [phone]
Email: [email protected]
GREECE
ALEX MARINE
Piraeus
Tel [phone]
Fax: + 30 10 41 12 932
Email: [email protected]
ITALY
Siemens VDO Trading srl
via Vialba, 50 20026 Novate Milanese (MI)
Tel: + 39 02 3568 04 81
Fax: + 39 02 35680325
[email protected]
PORTUGAL
PLASTIMO PORTUGAL (SIROCO)
Lisbon
Tel: + 351 21 362 04 57
Fax: + 351 21 362 29 08
Email: [email protected]
SPAIN
ACASTIMAR
Cambrils Tarragona
Tel: + 349 77 36 2118/9074
Fax: + 349 77 36 2687
Email: [email protected]
TURKEY
EGEMAR
Tuzla - Istanbul
Tel:[phone]
Fax:[phone]
Email: [email protected]
CROATIA
ANORTI ADRIA
Mirosevecka c 122, Zagreb
Tel: [phone]
Fax: [phone]
Email: [email protected]
SLOVENIA
ANORTI
Kavciceva 66 Ljubljana
Tel: [phone]
Fax: [phone]
Email: [email protected]i
MALTA
STRAND MARINE
Triq Is Sebh, Qormi
Tel: [phone]
Fax: [phone]
Email: [email protected]
NORTHEN EUROPE:
DENMARK
PALBY MARINE
Vejle
Tel: + 45 75 88 13 11
Fax: + 45 75 88 17 01
Email: [email protected]
GERMANY
LEAB
Schlieswig, Busdorf
Tel.: [phone]
Fax: [phone]
Email: [email protected]
ICELAND
VELASALAN
101 Reyjavik
Tel : [phone]
Fax : [phone]
Email: [email protected]
HOLLAND & BELGUIM
NAVIMO HOLLAND
Schoonhoven
Tel: [phone]
Fax: [phone]
Email: [email protected]
FINLAND
MASTERVOLT FINLAND
Raisio
Tel: + 358 2 4339990
Fax: + 358 2 4350085
Email: [email protected]
HOLLAND
KEMPER EN VAN TWIST
Dordrecht
Tel: + 31 078 61 30 155
Fax: + 31 078 61 36 746
Email: [email protected]
NORWAY
PROGRESS INGENIORFIRMA AS
Kjeisaas
Tel: + 47 22 02 79 00
Fax: + 47 22 02 79 01
Email: [email protected]
SWEDEN
PLASTIMO NORDIC
Henan
Tel: + 46 304 360 60
Fax: + 46 304 307 43
Email: [email protected]
Manual Max Power Series 225 HYD
Last Update: December 2016
17

U.K
PLASTIMO UK
Eastleigh, Hampshire
Tel: + 44 870 751 4666
Fax: + 44 870 751 1950
Email: [email protected]
U.K.
AR PEACHMENT
Norfolk
Tel: + 44 1603 714 077
Fax: + 44 1603 714 211
Email: [email protected]
AMERICAS :
ARGENTINA
BARON SRL
Buenos Aires
Tel: + 54 11 4580 55 56
Fax: + 54 11 47 46 16 96
Email: [email protected]
CANADA
REKORD MARINE ENTERPRISES LTD
Vancouver
Tel: + 1604 325 52 33
Fax: + 1604 325 03 26
Email: [email protected]
BRAZIL
SAILING PRODUCTS
Rio de Janeiro
Tel: + 55 21 494 7222
Fax: + 55 21 494 7223
Email: [email protected]
U.S.A.
SCANDVIK
Vero Beach, Florida
Tel: + 1 561 567 28 77
Fax: + 1 561 567 91 13
Email: [email protected]
AUSTRALIA, INDIA & ASIA:
AUSTRALIA
OCEANTALK
Sydney
Tel: + 612 9981 9500
Fax: + 612 9981 9555
Email: [email protected]
NEW ZEALAND
POWER & MARINE
Wiri Auckland
Tel: + 64 9 914 55 55
Fax: + 64 9 914 55 88
Email: [email protected]
CHINA
RONSIL DEVELOPMENT
Hong Kong
Tel: + 852 2834 1633
Fax: + 852 2834 0201
Email: [email protected]
CHINA
HOLYLIGHT TRADING
Hong Kong
Tel: + 852 2543 7048
Fax: + 852 2543 6156
Email: [email protected]
JAPAN
KAZ MARINE
Yamato City, Kanagawa
Tel: [phone]
Fax: [phone]
Email: [email protected]
SINGAPORE
OCEANTALK ASIA
Singapore
Tel: + 65 6543 4041
Fax: + 65 6543 4042
Email: [email protected]
INDIA
Indo Marine Engineering Co. Pvt. Ltd.
Pune 411- 026 Maharashtra
Tel: [phone]
Fax: [phone]
Email: [email protected]t
MIDDLE EAST & AFRICA
ISRAEL
YAMIT
PO Box 6158
Tel Aviv
Tel: + 972 3 527 1779
Fax: + 972 3 527 1031
Email: [email protected]
SOUTH AFRICA
MANEX & POWER
5 Industry Street
Paarden Eiland
Tel: + 27 21 511 72 92
Fax: + 27 21 510 14 89
Email: [email protected]
EGYPT
Seheemy Company
Nasr City,Cairo
Tel: [phone]\4041950
Fax: [phone]
E-mail : [email protected]
Manual Max Power Series 225 HYD
Last Update: December 2016
18

Serial N°:
WARRANTY FORM
VERY IMPORTANT
Please complete this form and fax a copy to Max Power with a copy of the installation
invoice or the invoice of the yacht/boat in order for the warranty to come into effect.
To Be Completed by Owner:
Name of Owner:…………………………….Contact No. :……………………….………….
Address: ……………………………………..E-mail: …………………………………………
Country:……………Postcode: …………….
Name of Skipper:……………………………Contact No. :…………………………………..
Signature of Owner: ………………………...Date: …………………………………………..
To Be Completed by Installer:
Installation Details:
Thruster Model :…………………………… Electric/Hydraulic :………………………………..
Date of Installation :……………………….. Date of Launching Boat : …………………….….
Type and model of Boat : ……………………….Builder:………………… Build Year: ………
Pleasure or Commercial craft?:……………. Sail or Motor:…………. Rig:…………………..
Navigates at Sea or River or Canals?……… Hull construction material :………………………
L.O.A. :………………L.W.L. :…………… Beam :………………Free Board:………………...
Displacement Weight at Full Load: :……… Height & Length of Superstructure:……………..
Tunnel Diameter, Thickness, Material & Length:………………………………………………….
If Electric, Battery Type, Size & Number: ………………………………………………………….
Installation Checks:
Before Operating Thruster While Operating Thruster
Electrical: Voltage at Batteries ………………………….. ………………………….
Voltage at Thruster Motor………………………….. ………………………….
Charge at Alternator in Amps…………………………………………………………..
Ampere in Motor Power Circuit ……………………………………………………….
Mechanical:
Verify if drive coupling between motor and drive leg is correctly tightened:………....Yes / No
Verify if all cable connections is sufficiently tightened:……………...……………..…...Yes / No
If hydraulic verify all hydraulic connections: ………………………………………........Yes / No
Thruster installation tested and working correctly: …………………………………….Yes / No
Important: Refer to installation manual for full installation details.
Name of Installer: …………………………. Signature:.……………………….
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TO GAIN YOUR EXTRA WARRANTY COVERAGE
Manual Max Power Series 225 HYD
Last Update: December 2016
19