Manual CT300 Last update: February 2020

CT300
With electronic thruster control

INSTALLATION OPERATION MAINTENANCE

Serial No.: ------------------------------------------------------

Installation date: -------------------------------------------------

THIS MANUAL MUST BE KEPT ONBOARD AT ALL TIMES

Via Philips 5, 20900 Monza (MI), Italy

Tel. +39 039 200 1973-936 - Fax +39 039 2004299
www.max-power.com E-mail: contact@max-power.com
 Contents

Section Title Page

1 General installation guidelines 2
2 Tunnel 3
3 Motor support and drive leg 4
4 Electric Motor 5
5 Propellers 5
6 Protection grids 5
7 Electrical installation 5
8 Main power fuse 6
9 Batteries 6
10 Electronic control box 7
11 Control panel and thruster control box functions 7
12 Control panel installation 8
13 Tests 9
14 Electrical measurements 9
15 Operation 9
16 Alarms or thermal switch-off 10
17 Safety 10
18 Maintenance 10
19 Electrical installation diagram 11
20 Power cable connections diagram 12
21 Spare parts diagram 13
22 Spare parts list 14
23 Troubleshooting guide 15
24 Worldwide distribution network 15
25 Warranty coverage 16
26 Warranty form 18

The use of qualified marine personnel, with experience in bow thruster installation, is
strongly advised. Where possible, the boat manufacturer’s design departments, architects,
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.

IT IS ESSENTIAL TO READ THE FOLLOWING MANUAL CAREFULLY

BEFORE INSTALLING THE THRUSTER

NB : The thruster is delivered without accessories (fuse, fuse holder, control panel).

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1. GENERAL INSTALLATION GUIDELINES

In order to install the thruster in the most efficient position, follow the instructions below:

 The minimum acceptable tunnel position is 225mm below the waterline

 The tunnel is ideally positioned when the distance between the waterline
and the top of the installed tunnel is 300mm
 The tunnel must be installed as far forward as possible

NB: A thruster turbine installed above its ideal position towards its minimum depth will
lead to a progressive loss of performance.

Whether vertical, inclined or horizontal, it is recommended to support the electric motor.

The electric motor generates heat when in operation. The zone in which the thruster is
installed must therefore be dry and ventilated.
The batteries used by the thruster must be charged by both the main engine's alternator
and an appropriate battery charger.
If the thruster is installed using a dedicated battery bank, this must be as close as
possible to the thruster in order to reduce voltage loss in the electric cables.

CAUTION: In no case should flammable products be stored near to the electric

components of the motor.

The drive leg must be centered in the tunnel and under no circumstances should the
propellers protrude out of the tunnel.

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2. TUNNEL

Once the final tunnel position has been determined and all dimensions have been
checked, mark the centre-point of the tunnel on both sides of the hull and drill holes of
8 –10mm ∅ on either side.

Using a metal rod, construct a compass with a 161mm radius. Insert through the holes
and trace the ellipses, as shown below.

After cutting the holes out following the elliptical guidelines, use an abrasive disc to
prepare the inside and outside surfaces of the hull for laminating (approx. 10 to 15cm
around the holes).

Position the tunnel in the hull, mark the positions of the different components, as well as
the areas that require laminating, then remove the tunnel. It is advisable to drill the tunnel
before laminating it into position. See section 3 "Motor Support and Drive leg" for more
details.

Replace the tunnel. To secure its position apply reinforced fiberglass filler to all areas,
both inside and out, taking care to entirely fill the space between the hull and the tunnel.
Laminate using a minimum of 8 layers of ISOPHTALIC RESIN alternated with mat and
roving.

In difficult to access areas (i.e. under the tunnel), it is possible to only apply reinforced
filler.

Once the filler has set on the outside, finish with a waterproof under coat, followed by
sanding and application of a waterproof finish coat.

In order to optimize the flow of water whilst sailing, and to avoid turbulence due to the
tunnel, leave 1 to 4 cm of Finish these with several coats of reinforced filler in order to
obtain the required hydrodynamic lines.
Once all laminating work is complete, apply a watertight barrier.

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DO NOT LAMINATE THE AREA OF THE TUNNEL TO WHICH THE ELECTRICAL MOTOR
SUPPORT WILL BE FIXED.

3. MOTOR SUPPORT AND DRIVE LEG

The motor support and the drive leg must be centered in the tunnel.

Locate and mark the intended position of the holes for the fixing screws and the leg hub.
You can use the motor support and the leg’s gasket to mark these holes.
In some cases it will be easier to mark and drill these holes BEFORE laminating the
tunnel.
After drilling, use the gasket to verify the holes’ axes and adjust them with a round file
where necessary.
These holes must be completely clean before inserting the screws.

Position the leg, the gasket (between the leg and the tunnel) and the motor support,
and then tighten the two screws alternatively. Finally, mount the propeller(s) to control the
general alignment.

If the general set-up is correct, remove the propeller(s),the leg and the gasket.
Apply a thin coating of silicon grease or sealing compound to both sides of the gasket
(this must be resistant to hydrocarbons and water). Re-assemble all parts as before,
positioning and then tightening the two 12mm  screws alternatively, using a 8mm Allen
key, (maximum torque: 50Nm).
Check that the propellers rotate freely, without resistance or friction.

It is imperative that the holes and the screws remain free of sealing compound,
otherwise there is a risk of an incorrect assembly of the parts.

Caution: do not use graphite grease.

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4. ELECTRIC MOTOR (12 / 24 volts)

The upper coupling (motor side) is adjusted in the factory. Position the lower coupling on
the drive leg shaft and push it down as far as it will go (lightly grease the shaft
beforehand).
Place the flexible red coupler on the drive leg side coupling, (part n° 5 on the CT300 –
Spare Parts diagram, page 13)
Now fit the electric motor onto the motor support and tighten the four 12mm Ø motor
support screws alternatively (maximum torque: 40Nm).
Push the lower coupling up into place using a screwdriver et tighten the two 4 x 10mm
Allen screws (maximum torque: 10Nm).
The upper and lower couplings must be adjusted to leave 2mm of play (+/- 1mm)
between both of them.

Check that the propellers turn without resistance (a little resistance due to the motor is
normal).

Ensure that air can flow freely to allow the motor to cool whilst in operation.

Please note that the motor side coupling is already in position an d does not need
adjusting.

5. PROPELLERS

Insert the drive pin and propellers.

Check that the propellers turn without resistance (a little resistance due to the motor is
normal).
Check that the oil change screw and the anode are in place and correctly tightened.
Position the propeller blades so as the y are not in horizontal alignment and not
directly opposite each other.
Tighten the 24mm nut (maximum torque: 30Nm) while holding the propeller tightly with
your hand.
Protect your hands during this operation to avoid risks of injuries caused by the edges of
the propeller.

IMPORTANT: to prevent against calcium deposits that damage the seals, we

recommend that you coat the shaft and stainless steel cover with silicon grease.

6. PROTECTION GRIDS

It is possible to install protection grills; however installation of such grills will affect
thruster performance.

7. ELECTRICAL INSTALLATION

CAUTION: an incorrect electrical installation will cause rapid deterioration or even failure
of the thruster. Excessive voltage drop will cause premature wearing of the relays and
brushes. Special attention should be given to the quality, capacity and condition of your
batteries, as well as cable sections used. Last but not least, the installer is responsible to
protect the electrical components of the thruster assembly against direct water contact.

Ensure that all electrical connections are correctly tightened.

Under no circumstances should an y flammable products be stored next to the

electrical components of the thruster.

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 It is essential to ins tall a manual battery isolator and if possible an electric
battery isolator at the base of the thruster motor power line.
When using a manual battery isolator it must be visible, clearly marked & easily
accessible.

Thruster motor power supply (24V):

These values are given as an indication, assuming that the batteries are charged at
100% and in charge, that is 25.4V.

The performance data of the CT300 is measured with an approx. consumption of 980A
and 22V at the motor’s connections.

Please refer to the characteristics given by the manufacturer of the batteries that will be
used (see section 9 “Batteries”).

Power wiring:
1. Measure the shortest and most direct route possible between the battery(ies) and the
electric motor; remembering to allow for both “positive and negative” cables.
2. The power cables must be located in a well ventilated area.
3. The material of the cable insulation should be from PVC and with thermal rating 105 degrees
Celsius and above.

Recommended cable sections:

Cable lengths CT300
L ≤ 5 m (2,5 x 2) 95mm²
5< L ≤ 10 m (5 x 2) 150mm²
10 < L ≤ 15 m (7,5 x 2) 240mm²
15< L ≤ 20 m (10 x 2) 300mm²

For all connections, use appropriate terminals for the cable sections chosen.
It is possible to reduce the cable section to facilitate easy connection but only over a
short distance. In this case, appropriated crimp fittings should be used at the
connections.

Please consult the "Electrical installation" diagram p. 11 for more information

8. MAIN POWER FUSE

Fuse sizes for over current protection are to be determined on the basis of the cable
sections in the circuit and NOT the amperage drawn by the appliance (thruster motor) in
the circuit.

Thruster Maximum Amperage Max Power Ceramic

Model Fuse
CT300 980 A 400 A

9. BATTERIES

Thrusters are high amperage consumers with instantaneous demands, thus, we

recommend you use maintenance-free “starting” type batteries, with high CCA outputs.

For example: Exide Maxxima 900, 12V, capacity 55Ah / starting current 800CCA.

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10. ELECTRONIC CONTROL BOX

Install a fused circuit breaker / switch in the boat's main DC distribution panel marked
BOW THRUSTER.
This circuit breaker / switch should ideally be supplied from a different battery bank to the
one used for powering the thruster.

The installer must protect the positive supply cable of the thruster’s control box by means
of a 8A fuse. The size of the power cables (red & black) depends on the length of the
cable run, the voltage drop in these cables should not exceed 5% of the nominal battery
voltage.

For safety reasons, and in order to obtain all the functions provided by the thruster
controller, an electric battery isolator needs to be installed in the thruster motor positive
supply cable.

Max Power advises the use of an electric battery isolator ref. 318401.

If an electric battery isolator is not used then simply seal-off the two grey wires coming
out of the control box. It is important to isolate the thruster motor power circuit by means
of a manual battery isolator after having used the thruster.

Please refer to the drawing “Power cable connections” p. 12 for more detail on the
wiring of the control box to the thruster.

11. CONTROL PANEL AND THRUSTER CONTROL BOX FUNCTIONS

To switch the thruster ON or OFF follow the instructions given in the diagrams on the
following page.
When switched ON the control panel will beep once and the green LED in the red push-
button will light up.
When switched OFF the control panel will beep twice and the green LED in the red push-
button will go out.
The thruster controller provides a time delay between left and right thrust in order to avoid
rapid direction changes. There is no delay when thrusting to same side.
If the thruster motor overheats the control panel will start beeping and the green LED will
flash until the thruster motor has cooled down.
As soon as the overheating alarm sounds, there are 10 seconds of actual thruster use
before the unit automatically shuts down. It will then not be possible to switch the thruster
on until the motor has cooled down.

If the thruster has not been used for a perio d of thirty minutes it will automatically
switch itself off.

Before switching off automatically the control panel will beep once followed by a second
beep a few seconds later, after which the thruster switches itself off.
In order to isolate the thruster motor power circuit, as described in the previous two
paragraphs, it is necessary to install an electric battery isolator, as advised by Max
Power.

Please consult the "Electrical installation" diagram p. 11 for more information

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12. CONTROL PANEL INSTALLATION

Control panels should be protected from the natural elements while the thruster is not in
use.
Install the control panel(s) in easily accessible positions, without obstructing the main
engine and/or steering controls.
When fixing the panel with the stainless steel screws, make sure to install the pre-cut
rubber seal, as supplied with the panel, ensuring that it is in the correct place.
Only when totally finished and satisfied with the wiring and positioning of the unit,
clip-on the face panel/cover.
Please note that panels are only fully waterproof from the front, if installed correctly.
However the area behind the dashboard should be kept dry to avoid the risk of
oxidization of the cable connecter contacts.
For full control panel installation instructions, please refer to the “Installation
Guidelines" as supplied with each control panel.

13. TESTS

Activating the thruster when the boat is out of the water, is not advised under
any circumstances.
Tests must be carried out with the boat in the water, the battery(ies) charged a t
100% and in charge, and the engines running.
The maximum continuous operating runtime corresponds to S2-3mn norm.
However, this can be affected by the ambient temperature.

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14. ELECTRICAL MEASUREMENTS

In normal “usage” mode, i.e. thrusters running, boat in the water, with fully charged
batteries under ongoing charge (alternator), electrical measurements should be made at
the following points:
At the batteries
At the battery cut-off switch
At the fuse
At the electric motor’s connections
At the power supply arriving at the thruster control box
These measurements will enable you to detect voltage drop.

NOTE: the voltage reading between the motor’s negative and positive connections
should be approx. 22V for a 24V system.

The cumulative effect of voltage drops at these points can severely impair the
thruster's performance.

Should the voltage measured be too low, the following points need checking:
Are the batteries of sufficient capacity?
Are the batteries good quality?
Are the batteries sufficiently charged?
Are appropriate cable sections being used?
Are the connections sufficiently tightened?

15. OPERATION

With the control system circuit breaker/ switch and manual battery isolator switched on:

Switch on the control panel, as previously described in the manual.

Push the red button or incline the joystick to the left and the boat moves to the left.
Push the green button or incline joystick to the right and the boat moves to the right.
If, during tests the boat moves in the wrong direction, change around the blue and the
brown wires on your power relay.
When manoeuvring remember that the boat’s momentum continues after you release the
joystick / button, therefore remember to release the control prior to reaching your desired
position.
Care must be taken not to use the thruster in areas where there may be people
swimming or floating debris.

Maximum running time: 2-3 min (depending on ambient temperature).

16. ALARMS OR THERMAL SWITCH-OFF

The thruster's electric motor is fitted with a thermal switch as standard. If the thruster
motor overheats the buzzer in the control panel will start beeping and the green LED in
the red-push button will flash until the thruster motor has cooled down again.
As soon as the overheating alarm sounds, there are 10 seconds of actual thruster use
before the unit automatically shuts down. The unit will then not be able to be switched on
again until the motor has cooled down.

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17. SAFETY

Switch off means to cut the power at both the DC equipment panel (control power supply)
& the thruster battery isolator (thruster power supply) after having used the thruster.
Under no circumstances should any flammable products be stored next to the electric
components of the thruster. Care must be taken not to use the thruster in areas where
there may be people swimming or in the water close to the thruster.

CAUTION: Never tamper with the thruster / thruster turbine if not 100% sure that
both the control and power circuits have been isolated, except if taking electrical
measurements on the thruster motor or relay.

18. MAINTENANCE

Control panels should be protected from the natural elements while the thruster is not in
use.
The thruster requires a minimum of ongoing maintenance:
Check the condition and charge of the batteries regularly, as voltage drop is the most
frequent cause of rapid deterioration of the relay.
Carry out a regular check of all electric components: batteries, connections, power
cables.
Remove the motor and clean out dust from the motor-brushes with compressed air.
The electric motor must be kept dry and well-ventilated.
Change the drive leg oil every year. See diagram below:

When the boat is out of the water, check that there are no fishing lines, plastic bags, etc.
caught in the propellers.
Paint the drive leg and propellers with antifouling (make sure that they were well
prepared and primer has been used).
Do not paint the anode.
Always keep the propellers and tunnel clean.
To prevent the build up of calcium on the drive shafts, which would damage the oil seals,
cover the drive shaft and the oil seals’ stainless steel covers with silicon grease before
fitting the propeller(s). This should be done on an annual basis after the cleaning of the
outside of the leg. Do not use aggressive solvents as they may damage drive leg seals.
If drive leg oil seals are found to be worn, replace the drive leg with a standard exchange
unit.

NOTE: All maintenance should be carried out by qualified and authorized personnel.

THE MAX-POWER TEAM WISHES YOU SUCCESSFUL MANOEUVRING AND

ENJOYABLE CRUISING

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19. ELECTRICAL INSTALLATION DIAGRAM

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20. POWER CABLE CONNECTIONS

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21. SPARE PARTS DIAGRAM

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 22. SPARE PARTS LIST

N° Description Quantity Old Code New Code

1 Electric Motor CT300 1 MP203000 312862

Motor Brushes 8 MPOP3559 310382

Spring 8 MPOP3520 310383

2 Screws 4 MPOP4070 630496

3 Rondelles 4 -

4 Coupling aluminium 2 MP662000 633751

5 Coupling PG66 1 MP661000

6 Motor Support CT300 1 633740

7 Ring 1 MP205038 633712

-
8 Shaft Pin 1 MP205035 312020

9 Gearbox main Shaft 1 MP205040 310116

10 Bearing 1 MP205045 310342

11 Lower Bearing 1 MP205050 310341

12 Gearwheel 1 MP205001 633701

13 Circlips 1 MP205002 310295

14 Screws 2 MP204000 630507

15 Leg gasket 1 MP205055 310253

16 Inox Nut 2 MP204005 633697

17 Propeller300 2 MP205015 313810

18 Propeller Pin 2 MPOP5530 312059

19 Propeller seal 2 MP205065 310276

20 Screws 4 MP204010 630504

21 Flange 2 MP205095 310214

22 Flange seal 2 MP205090 310257

23 Propeller bearing 2 MP205085 310348

24 Set of spacers (1 mm) 2 MP205080 310226

25 Propeller gearwheel 1 MP205006 630483

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26 Pin for propeller shaft 1 MP205035 312020

27 Propeller shaft 1 MP205070 310117

28 Leg body 1 MP205060 633717

29 Seal 1 MPOP2050 310248

30 Screw 1 MPOP5300 312131

31 Anode 1 MPOP5390 630506

32 Anode screw 1 MPOP5311 312120

33 Relay and Control box assembly 1 MP208055 315334

34

Relay 24 V 1 MP203101/2 312922

35 Electronic Controller 1 MPOP5701 315308

36 Metal leg CT300 1 MP208100 315388

37 Fuse holder T2 1 OPTI3091 35018

38 Fuse 400 A 1 OPTI3145 35028

- Extraction handle for T1 & T2 1 OPTI3118 312882

- Heat sensor 1 MPOP3720 311363

 23. TROUBLESHOOTING GUIDE

Before contacting your nearest Max Power service station, please check the below
troubleshooting guide and our online trouble shooting videos:

https://www.max-power.com/troubleshooting

Problem Check

The control panel does not light  Check the 6 wire connector behind the joystick
up
 Check the thruster's electronic control box 6 wire
connector
 Check the circuit breaker / switch in the boat's
main DC distribution panel
 Check the control box's power fuse (8 A)

The relay is clicking but the motor  Check the motor's power fuse
is not running
 Check the main battery isolator
 Check the internal relay contacts
 Check battery conditions and connections

The motor is running but the  Check the propellers are fitted
thruster is not working
 Check the motor / drive leg assembly
 Check that the tunnel is not obstructed or the
propellors blocked

The thruster lacks power  Check the propellers are fitted

 Check the size of the batteries
 Check the batteries are sufficiently charged
 Check the connections are tightened correctly
 Check the power cables sections
(See p. 6 : Recommended cable sections)

24. WORLDWIDE DISTRIBUTION NETWORK

To locate the nearest Max Power distributor, please consult the section
"Worldwide Distribution" on our website: www.max-power.com

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1. WARANTY 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 the owner:

Name of owner: Tel.:

Address: Email:

Postcode: Country:
Name of skipper: Tel:
Owner's signature: Date:

To be completed by the installer:

Installation details

Thruster model: Electric/Hydraulic:

Installation date: Date of launching boat:
Model and hull number of boat: Builder:
Build
year:
Pleasure or commercial boat? : Hull construction material:

L.O.A: Width:
Waterline length: Poids total en charge:
Tunnel Diameter, Thickness, Material & If Electric, Battery Type, Size & Number:
Length:

Installation checklist:

Electric : Before using During use:

thruster
Voltage at batteries
Voltage at thruster motor
Ampere in motor power circuit

Mechanical: YES / NO
Check if the drive coupling between the motor and drive leg is
correctly tightened:
Check cable connections are sufficiently tightened:
The thruster installation has been checked and the thruster functions
correctly?

Important: Please consult this manual for more details

Name of Installer: ……………………………. Signature:.…………………………………..