TECH INFO MAINTENANCE GUIDE DC Thrusters

Checking and cleaning stuck thruster motor brushes

SIDE-POWER THRUSTER SYSTEMS

CONFIDENCE BY CONTROL

Stuck brushes, or brushes that are not completely loose in th thruster runbrush slowly with diminishing power. Stuck brushes, or brushes that are not completely loose in to the holder will cause the thruster to run slowly with diminishing power.

This instruction sheet is intended for experienced maintenan

This instruction sheet is intended for experienced maintenance personnel.

Under no circumstances should a lubricant or cleaning agent Doing so can a fire hazard and voltage leaks. Under no circumstances should a lubricant or cleaning agent be cause sprayed into the motor. Doing so can cause a fire hazard and voltage leaks.

The thruster motor must be removed from the vessel and bro location to complete this procedure. The motor can be remov The thruster motor must be removed from the vessel and brought to a convenient working locavessel in the water. tion to complete this procedure. The motor can be removed from the vessel with the vessel in the water.

1:

1) Shut off dedicated thruster battery switch or remove the fu Check for voltage across the positive and negative battery ca ensure battery power to the thruster is not present.

Shut off dedicated thruster battery switch or remove the fuse from the thruster circuit. Check for voltage across the positive and negative battery cable studs on the motor to ensure battery power to the thruster is not present.

2:

2) Remove Battery cables. Secure the jam nut behind the cabl outer nut. Ideally a thin wrench should be used to hold the jam 2) Remove Battery cables. Secure the jam nut behind the cabl a pair of needle-nose Vise-Grips can be used. If the stud is al outer nut. Ideally a thin wrench should be used to hold the jam motor damage can occur. a pair of needle-nose Vise-Grips can be used. If the stud is al motor damage can occur.

Remove Battery cables. Secure the jam nut behind the cable lug when loosening the outer nut. Ideally a thin wrench should be used to hold the jam nut; if one is not available a pair of needlenose Vise-Grips can be used. If the stud is allowed to turn, internal motor damage can occur.

3) Unplug 4-wire Control Harness.

3: Unplug 4-wire Control Harness.

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3) Unplug 4-wire Control Harness.

CONFIDENCE BY CONTROL Maintenance DC Thrusters - 2/8

4:

4) Remove Remove motor motor mounting mounting bolts. bolts. Lift Lift motor motor off off motor motor brac brac 4)

Remove motor mounting bolts. Lift motor off motor bracket.

5: Remove top cap or brush screen to access the brushes. There are two versions of motors utilized on Side-Power Thrusters; these two motor versions are referred to as “K” or “S” version motors.

5a:

5) 5) Remove Remove top top cap cap or or brush brush screen screen to to access access the the brushes. brushes. Th Th motors utilized utilized on on Side-Power Side-Power Thrusters; Thrusters; these these two two motor motor vv motors or or “S” “S” version version motors. motors.

5a) 5a) “K” “K” version version motors motors have have aa ventilated ventilated top top cap cap on on the the mo mo assembly and and is is held held in in place place by by either either two two or or four four bolts. bolts. “K “K assembly brushes and springs; four sets of two brushes, each brush brushes and springs; four sets of two brushes, each brush ho ho brush springs. springs. brush

“K” version motors have a ventilated top cap on the motor that encloses the brush assembly and is held in place by either two or four bolts. “K” motors have a total of 8 brushes and springs; four sets of two brushes, each brush holder has two brushes and two brush springs.

5b:

5b) “S” version motors have a brush screen wrapped around the motor which is held in place with a spring. “S” motors h in each of four brush holders. Each brush may have either o depending on the thruster model.

“S” version motors have a brush screen wrapped around the brush assembly area of the motor which is held in place with a spring. “S” motors have four brushes, one brush in each of four brush holders. Each brush may have either one or two brush springs depending on the thruster model.

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6) It is recommended to blow the motor out with compresse CONFIDENCE BY CONTROL carbon dust as possible prior to servicing. Either the top cap Maintenance DC Thrusters - 3/8 removed in order to do this depending, on the type of motor

6: It is recommended to blow the motor out with compressed air to remove as much carbon dust as possible prior to servicing. Either the top cap or brush cage will have to be removed in order to do this depending, on the type of motor you have, please see step (6) below

Caution: Blowing out the carbon dust should

be done in a well ventilated area. Proper respiratory protection must be worn to avoid inhalation of carbon dust. Avoid skin contact with carbon dust; plastic gloves should be worn. If skin contact is unavoidable then wash affected area to remove carbon dust.

7: With a small hook (a small Allen wrench works well), pull back the brush spring to free the brush from tension. Be careful not to let the spring slip and become dislodged, they are not easily re-installed and they can fall into the motor which can require complete motor break-down.

the motor which is held in place with a spring. “S” motors h in each of four brush holders. Each brush may have either o depending on the thruster model.

6) It is recommended to blow the motor out with compresse carbon dust as possible prior to servicing. Either the top cap removed in order to do this depending, on the type of motor below

Caution: Blowing out the carbon dust should be done in a w respiratory protection must be worn to avoid inhalation of ca contact with carbon dust; plastic gloves should be worn. If s then wash affected area to remove carbon dust.

7) With a small hook (a small Allen wrench works well), pu 6) is recommended to blowBethe motornot outtowith compresse freeIt the brush from tension. careful let the spring s carbon possible prior toand servicing. the the top mot cap they aredust not as easily re-installed they canEither fall into removed in order to do this depending, on the type of motor complete motor break-down. below

Caution: Blowing out the carbon dust should be done in a w respiratory protection must be worn to avoid inhalation of ca contact with carbon dust; plastic gloves should be worn. If s then wash affected area to remove carbon dust.

7) With a small hook (a small Allen wrench works well), pu free the brush from tension. Be careful not to let the spring s they are not easily re-installed and they can fall into the mot complete motor break-down.

8) Gently pull the brush out of the holder. The brushes must holder, if there is any friction at all between the brush and th run properly. The brush and holder will need to be cleaned s completely loose. 8:

Note: it is not necessary to unbolt the brush wire to complete

Gently pull the brush out of the holder. The brushes must be completely loose in the holder, if there is any friction at all between the brush and the holder the motor will not run properly. The brush and holder will need to be cleaned such that the brush is completely loose. Note: it is not necessary to unbolt the brush wire to complete this step.

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9) Inspect brushes for damage. If any of the brushes show si the complete set of brushes will have to be replaced. When o BY CONTROL or springs specifyCONFIDENCE the thruster model and if you have an “S” Maintenance DC Thrusters - 4/8

9:

applied. In such instances the brushes are typically damaged brush replacement. Use caution to avoid allowing brush deb motor.

Inspect brushes for damage. If any of the brushes show signs of damage or overheating the complete set of brushes will have to be replaced. When ordering replacement brushes or springs specify the thruster model and if you have an “S” or “K” version motor. If a brush is not easily removed then use pliers to hold the brush so more force can be applied. In such instances the brushes are typically damaged during removal necessitating brush replacement. Use caution to avoid allowing brush debris to get lodged within the motor.

10) After removing the brush, the spring can be rested on th dislodged. If any of the brush springs are corroded or if one than the rest then the complete set of brush springs must be

10) After removing the brush, the spring can be rested on th dislodged. If any of the brush springs are corroded or if one than the rest then the complete set of brush springs must be

10: After removing the brush, the spring can be rested on the holder to avoid it becoming dislodged. If any of the brush springs are corroded or if one brush spring feels weaker than the rest then the complete set of brush springs must be replaced.

11) Use a small wire brush or file to clean the brush holder u using a file be careful not to file any metal off the holder, us remove carbon dust, debris, or corrosion. Pull the brush spri the holder as necessary. 11: Use a small wire brush or file to clean the brush holder until the brush fits loosely. If using a file be careful not to file any metal off the holder, use of a file is only intended to remove carbon dust, debris, or corrosion.

11) Use a small wire brush or file to clean the brush holder u using a file be careful not to file any metal off the holder, us remove carbon dust, debris, or corrosion. Pull the brush spri the holder as necessary.

Pull the brush spring out of the way to access the holder as necessary.

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CONFIDENCE BY CONTROL Maintenance DC Thrusters - 5/8

complete this step. Only remove the brush or brushes from o prevent the brush holder bridge bars from becoming displac 12: On occasion the brush will still not fit loosely in the holder after cleaning the holder. If this is the case the brush can be very gently sanded on a flat surface a small amount just until it fits loosely. Note: Complete removal of the brush, including unbolting the brush wire, is necessary to complete this step. Only remove the brush or brushes from one holder at a time, this will prevent the brush holder bridge bars from becoming displaced.

13) The commutator surface is often carbonized if one or m their holder. The commutator can be cleaned by applying el a cloth or cotton swab, hold the cloth against the commutato motor shaft. Note: Great care is to be taken to avoid contact armature commutator with hard tools.

13: The commutator surface is often carbonized if one or more brushes are not loose in their holder. The commutator can be cleaned by applying electrical component cleaner to a cloth or cotton swab, hold the cloth against the commutator surface while spinning the motor shaft. Note: Great care is to be taken to avoid contact and damage of the rotating armature commutator with hard tools.

13) The commutator surface is often carbonized if one or m their holder. The commutator can be cleaned by applying el a cloth or cotton swab, hold the cloth against the commutato motor shaft. Note: Great care is to be taken to avoid contact armature commutator with hard tools.

14a) Notice for “K” motor reassembly: When replac that no brush wires get pinched between the top cap

14a: Notice for “K” motor reassembly: When replacing the top cap on “K” motors ensure that no brush wires get pinched between the top cap and the motor body.

14a) Notice for “K” motor reassembly: When replacing the top cap on “K” motors ensure that no brush wires get pinched between the top cap and the motor body.

14b) Notice for “S” motor reassembly: When replac cage is not touching either the positive or negative b to cut away the cage in the area of the battery cable dislodged and making contact with the battery cable

SIDE-POWER THRUSTER SYSTEMS

CONFIDENCE BY CONTROL Maintenance DC Thrusters - 6/8

14b) Notice for “S” motor reassembly: When replacing the brush cage, ensure that the

to cut away the cage in the area of the battery cable dislodged and making contact with the battery cable 14a:

14b) Notice for “S” motor reassembly: When cage is not touching either the positive or neg to cut away the cage in the area of the battery dislodged and making contact with the battery

Notice for “S” motor reassembly: When replacing the brush cage, ensure that the cage is not touching either the positive or negative battery cable stud. It is recommended to cut away the cage in the area of the battery cable studs to reduce the cage being dislodged andmotor making contact withWhen 14b) Notice for “S” reassembly: the battery cable studs.

replacing the brush cage, ensure that the cage is not touching either the positive or negative battery cable stud. It is recommended to cut away the cage in the area of the battery cable studs to reduce the cage being dislodged and making contact with the battery cable studs.

15) Reverse procedures to re-install motor. Rememb battery cables; use a thin wrench or needle nose Vis to 15Nm or 11 lb. /ft.

15) Reverse procedures to re-install motor. Re battery cables; use a thin wrench or needle no to 15Nm or 11 lb. /ft. 15: 15) Reverse procedures to re-install motor. Remember to use caution when installing Reverse to re-install motor.or needle batteryprocedures cables; use a thin wrench Remember to 15Nmtooruse 11 caution lb. /ft. when installing battery cables; use a thin wrench or needle nose Vise-Grips to secure the jam nut, torque to 15Nm or 11 lb. /ft.

nose Vise-Grips to secure the jam nut, torque

16: Always check the operating voltage at the thruster motor after servicing. 12 volt thrusters typically run between 9.5v and 10.5v, 24 volt thruster typically run between 19v and 21v. Operating volts below 9v on 12v thrusters and below 18v on 24v thrusters should be addressed. Please contact a qualified marine electrician, your Side-Power dealer, or Imtra if you have low operating volts. SIDE-POWER THRUSTER SYSTEMS

CONFIDENCE BY CONTROL Maintenance DC Thrusters - 7/8

Distributors Argentina Trimer SA Buenos Aires Tel: +54 11 4580 0444 Fax: +54 11 4580 0440 www.trimer.com.ar [email protected] Australia AMI Sales Freemantle, WA Tel: +61 89 331 0000 Fax: +61 89 314 2929 [email protected] Austria G. Ascherl GmbH Hard, Bregenz Tel: +43 5574 899000 Fax: +43 5574 89900-10 www.ascherl.at offi[email protected] Benelux ASA Boot Electro Watergang Tel: +31 20 436 9100 Fax: +31 20 436 9109 www.asabootelectro .nl [email protected] Brazil Electra Service Ltda. Guaruja Tel: +55 13 3354 3599 Fax: +55 13 3354 3471 www.electraservice.br.com [email protected] Bulgaria Yachting BG Burgas tel: +359 56 919090 fax: +359 56 919091 www.yachting.bg [email protected] Canada Imtra Corporation New Bedford, MA Tel: +1 508 995 7000 Fax: +1 508 998 5359 www.imtra.com [email protected] China/Hong Kong Storm Force Marine Ltd. Wanchai, Hong Kong Tel: +852 2866 0114 Fax: +852 2866 9260 www.stormforcemarine.com [email protected] Croatia Yacht Supplier Icici Tel: +385 51 704 500 Fax: +385 51 704 600 [email protected]

Service Centres Cyprus Ocean Marine Equipment Ltd Limassol Tel: +357 253 69731 Fax: +357 253 52976 [email protected] Denmark Gertsen & Olufsen AS Hørsholm Tel: +45 4576 3600 Fax: +45 4576 1772 www.gertsen-olufsen.dk [email protected] Estonia/Latvia/Lithuania Miltec Systems OÜ Tallin Tel: +372 5013997 Fax: +372 6442211 www.miltec.ee [email protected]

Israel Atlantis Marine Ltd. Tel Aviv Tel: +972 3 522 7978 Fax: +972 3 523 5150 www.atlantis-marine.com [email protected]

South Africa C-Dynamics Cape Town Tel: +27 21 555 3232 Fax: +27 21 555 3230 www.c-dynamics.co.za [email protected]

Italy Saim S.P.A. Assago-Milan Tel: +39 02 488 531 Fax: +39 02 488 254 5 www.saim-group.com

Spain Imnasa Marine Products Girona Tel: +34 902 300 214 Fax: +34 902 300215 www.imnasa.com [email protected]

Japan Turtle Marine Inc. Nagasaki Tel: +81 95 840 7977 Fax: +81 95 840 7978 www.turtle-marine.com [email protected]

Sweden Sleipner AB Strömstad Tel: +46 526 629 50 Fax: +46 526 152 95 www.sleipnerab.se

Finland Nautikulma OY Turku Tel: +358 2 2503 444 Fax: +358 2 2518 470 www.nautikulma.fi nautikulma@nautikulma .fi

Malta S & D Yachts Ltd. Cali Tel: +356 21 339 908 Fax: +356 21 332 259 www.sdyachts.com [email protected]

Switzerland Marine Parts Technics AG Volketswil Tel: +41 1 997 40 90 Fax: +41 1 997 40 94 www.marineparts.ch [email protected]

France Kent Marine Equipment Nantes Tel: +33 240 921 584 Fax: +33 240 921 316 www.kent-marine.com [email protected]

New Zealand Advance Trident Ltd. Auckland Tel: +64 9 845 5347 Fax: +64 9 415 5348 www.advancetrident.com [email protected]

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Germany Jabsco GmbH Norderstedt Tel: +49 40 535 373-0 Fax: +49 40 535 373-11 Greece Amaltheia Marine Athens Tel: +30 210 2588 985 Fax: +30 210 2588 986 www.amaltheiamarine.com [email protected] Iceland Maras EHF Reykjavik Tel: +354 555 6444 Fax: +354 565 7230 www.maras .is gummi@maras .is

Norway Sleipner Motor AS Fredrikstad Tel: +47 69 30 00 60 Fax: +47 69 30 00 70 www.side-power.com [email protected] Poland Taurus Sea Power SP. Z.O.O Gdansk Tel: +48 58 344 30 50 Fax: +48 58 341 67 62 Portugal Krautli Portugal Lda. Lisboa Tel: +351 21 953 56 00 Fax: +351 21 953 56 01 www.krautli.com [email protected]

Taiwan Mercury Marine Supply Kaohsiung Tel: +886 7 3317 293 Fax: +886 7 3314 232 Turkey Denpar Ltd. Istanbul Tel: +90 212 346 1332 Fax: +90 212 346 1329 [email protected] UK Sleipner Motor Ltd. South Brent Tel: +44 1364 649 400 Fax: +44 1364 649 399 [email protected]

United Arab Emirates Russia Teignbridge Propellers & Marine India Equipment Co. Ltd. Indo Marine Engineering Co. Pvt. Ltd Standarte Dubai Starbeyevo Pune, Maharashtra Tel: +7 495 575 67 23 Tel: +971 4 324 0084 Tel: +91 20 2712 3003 Fax: +7 495 575 39 77 Fax: +971 4 324 0153 Fax: +91 20 2712 2295 www.standarte.ru [email protected] [email protected] [email protected] Ireland USA Imtra Corporation Sleipner Motor Ltd. New Bedford, MA South Brent ALL OTHERS: Tel: +1 508 995 7000 Tel: +44 1364 649 400 Fax: +1Sleipner 508 998 Motor 5359 AS Fax: +44 1364 649 399 www.imtra.com P.O. Box 519, [email protected] [email protected]

N-1612 Fredrikstad, Norway Tel: +47 69 30 00 60 Fax: +47 69 30 00 70 Confidence by Control Sleipner Motor AS • P. O. Box 519, N-1612 Fredrikstad • Norway [email protected] Tel: +47 69 30 00 60 • Fax: +47 69 30 00 70 • [email protected] • www.side-power.comwww.side-power.com

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