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Amel Super Maramu 2000

On NIKIMAT, SM2K #289 this is how we overhaul the Bow Thruster in November 2013.
We following information written by Gary Silver SM2K #335 Liahona and the notes added by Bill Rouse S/V Bebe SM2K #387 and just took pictures to show the work.

For my first time, it took 2 persons 4 half days

You know you will need the 3 neoprene seals from Amel (2 of 1 type, one of another).
Note: as of 2015, the 3 Neoprene foam seal 110x60 are of the same type.

3 bearing: 6006 JEM (Open Bearing)
Note: As of May 2016, 2 of the bearing are now closed (6006 2RS) and 1 is open (6006 JEM)

1 seal: 30 x 42 x 8
Note: as of May 2016 Amel suggest using a 29 x 42 x 8

1 seal: 60 x 80 x 12 (that goes inside the boat in the forward cabin).

O ring 78.00 x 3.00

O ring 40.00 x 2.50
Somehow on my list I have a bearing: 6204 2 RS JEM (but I think this is at the top for the electric motor, never replaced it).

You can download the information:
Bow Thruster Service (.pdf).
Bow Thruster Service (.docx).

First removed all I could (mattress, etc.)
 Amel Super Maramu 2000 Bow Thruster overhaul

Added a double layer of protection
 Amel Super Maramu 2000 Bow Thruster overhaul

Marked the bow thruster
 Amel Super Maramu 2000 Bow Thruster overhaul

Attached a clamp with a rope
 Amel Super Maramu 2000 Bow Thruster overhaul

Rope to the cleat
 Amel Super Maramu 2000 Bow Thruster overhaul

Close up of the clamp with rope
 Amel Super Maramu 2000 Bow Thruster overhaul

Added a towel so that we would not loose any parts.
 Amel Super Maramu 2000 Bow Thruster overhaul

Removed the clamp
 Amel Super Maramu 2000 Bow Thruster overhaul

We had to use 90* plyers
 Amel Super Maramu 2000 Bow Thruster overhaul

Lower the unit, now it is only hold by the clamp (and rope)
 Amel Super Maramu 2000 Bow Thruster overhaul

Install Amel special tool and attach its rope to the cleat (note we attached to the other cleat the rope attached to the clamp)
 Amel Super Maramu 2000 Bow Thruster overhaul

Originally used some rescue tape to cover all holes and spaces, but it was too thick to go through, so used regular scotch tape
 Amel Super Maramu 2000 Bow Thruster overhaul

Removed the clamp, slowly lower the unit in the water, while on the other side Mike used a hook to grab the bbow thruster.
 Amel Super Maramu 2000 Bow Thruster overhaul

Regular scotch tape we end up using.
 Amel Super Maramu 2000 Bow Thruster overhaul

Put upside down the bow thruster to collect the oil, then clean bernicles
 Amel Super Maramu 2000 Bow Thruster overhaul

Different view of bow thruster upsidedown to collect the oil.
 Amel Super Maramu 2000 Bow Thruster overhaul

Trying to properly balance the boat, I had placed lots of heavy weight forward, and noted I was (in my opinion) dangerous closed to the water (about an inch or 3 cm).
 Amel Super Maramu 2000 Bow Thruster overhaul

Removed the old seal (please note that I did not had the 2 retainer screws).
 Amel Super Maramu 2000 Bow Thruster overhaul

You can see with the new seal that there is little space arround the Amel special tool to put tape.
 Amel Super Maramu 2000 Bow Thruster overhaul

Unscrew the plastic bolts, then removing the pin that holds the hub
 Amel Super Maramu 2000 Bow Thruster overhaul

Remove the hub
 Amel Super Maramu 2000 Bow Thruster overhaul

Carefully screw 3 little screws
 Amel Super Maramu 2000 Bow Thruster overhaul

Improvised a tool to be able to pull the screws
 Amel Super Maramu 2000 Bow Thruster overhaul

Some weight at the end to pull through
 Amel Super Maramu 2000 Bow Thruster overhaul

Success, the seal is now removed!
 Amel Super Maramu 2000 Bow Thruster overhaul

We now locate at the bolt
 Amel Super Maramu 2000 Bow Thruster overhaul

Then unscrew them
 Amel Super Maramu 2000 Bow Thruster overhaul

Clean the top part
 Amel Super Maramu 2000 Bow Thruster overhaul

Gently tap on the hub
 Amel Super Maramu 2000 Bow Thruster overhaul

Which start to go out
 Amel Super Maramu 2000 Bow Thruster overhaul

And is gone
 Amel Super Maramu 2000 Bow Thruster overhaul

Pulling up the assembly
 Amel Super Maramu 2000 Bow Thruster overhaul

Here it is
 Amel Super Maramu 2000 Bow Thruster overhaul

Removing the old bearing
 Amel Super Maramu 2000 Bow Thruster overhaul

Used a bearing puller to remove the other bearing.
note the coin on top, we end up putting 4 or 5 to protect as the plastic is very tender.
 Amel Super Maramu 2000 Bow Thruster overhaul

Hold tight the end of shaft of the bow thruster so it would not rotate
 Amel Super Maramu 2000 Bow Thruster overhaul

Unscrew the other end of the shaft
 Amel Super Maramu 2000 Bow Thruster overhaul

Remove the shaft
 Amel Super Maramu 2000 Bow Thruster overhaul

Put new besring
 Amel Super Maramu 2000 Bow Thruster overhaul

Gently tap in place with rubber hammer
 Amel Super Maramu 2000 Bow Thruster overhaul

To add new bearing to the assembly we used a PVC pipe on one side to hold.
 Amel Super Maramu 2000 Bow Thruster overhaul

And the old bearing on the other and gently tap
 Amel Super Maramu 2000 Bow Thruster overhaul

For the other bearing, we used another smaller PVC pipe
 Amel Super Maramu 2000 Bow Thruster overhaul

Since I did not had a press, I used my old car and a hydraulic lift (it required a lot of force to put the bearing in)
 Amel Super Maramu 2000 Bow Thruster overhaul

Then start to rebuild the unit
 Amel Super Maramu 2000 Bow Thruster overhaul

Close up of the bearing inside the bow thruster
 Amel Super Maramu 2000 Bow Thruster overhaul

Entering the shaft
 Amel Super Maramu 2000 Bow Thruster overhaul

Close up how it passes through the bearing
 Amel Super Maramu 2000 Bow Thruster overhaul

Then reattach the gear
 Amel Super Maramu 2000 Bow Thruster overhaul

With bolt
 Amel Super Maramu 2000 Bow Thruster overhaul

Then tight
 Amel Super Maramu 2000 Bow Thruster overhaul

Again by holding the other side of the shaft tight.
 Amel Super Maramu 2000 Bow Thruster overhaul

Then the bolts
 Amel Super Maramu 2000 Bow Thruster overhaul

Then put back the assembly
 Amel Super Maramu 2000 Bow Thruster overhaul

Here in place
 Amel Super Maramu 2000 Bow Thruster overhaul

Added some sealant
 Amel Super Maramu 2000 Bow Thruster overhaul

Back in place
 Amel Super Maramu 2000 Bow Thruster overhaul

Make sure the bold align
 Amel Super Maramu 2000 Bow Thruster overhaul

Some sealant as well
 Amel Super Maramu 2000 Bow Thruster overhaul

Putting enough
 Amel Super Maramu 2000 Bow Thruster overhaul

Put back the bolts
 Amel Super Maramu 2000 Bow Thruster overhaul

Add sealant to the seal on the other side
 Amel Super Maramu 2000 Bow Thruster overhaul

Use another PVC tube to gently press in place
 Amel Super Maramu 2000 Bow Thruster overhaul

Here it is
 Amel Super Maramu 2000 Bow Thruster overhaul

After totally rebalancing the boat, I now have 3 inches or 7 cm (instead of the 1 inch or 3 cm)
 Amel Super Maramu 2000 Bow Thruster overhaul

Add antofooling on the bow thruster unit
 Amel Super Maramu 2000 Bow Thruster overhaul

Carefull in some place
 Amel Super Maramu 2000 Bow Thruster overhaul

Put back hub and pin, then propeller with new plastic bolt
 Amel Super Maramu 2000 Bow Thruster overhaul

Here it is
 Amel Super Maramu 2000 Bow Thruster overhaul

Now we are going to install little retainer screw and washer, we put blue tape to only drill a little.
 Amel Super Maramu 2000 Bow Thruster overhaul

We put the seal and foam seal through the Amel tool. Put some grease on the seal.
to send back the Amel special tool in the water, since it is made of wood and float, I added a small scuba weight.
 Amel Super Maramu 2000 Bow Thruster overhaul

Put in place seal with sealant, the put in place the first retainer screw and bolt
 Amel Super Maramu 2000 Bow Thruster overhaul

Then second one
 Amel Super Maramu 2000 Bow Thruster overhaul

Put the contact cement on the foam seal
 Amel Super Maramu 2000 Bow Thruster overhaul

Put in place
 Amel Super Maramu 2000 Bow Thruster overhaul

Add the 0.3 Liter of 90 weight oil
Add grease arround the shaft of the bow thruster
 Amel Super Maramu 2000 Bow Thruster overhaul

Then add the round spacer
 Amel Super Maramu 2000 Bow Thruster overhaul

Add the Amel special tool and scotch tape to cover all openings
 Amel Super Maramu 2000 Bow Thruster overhaul

Lower the Bow Thruster unit in the water and gently pull it up
 Amel Super Maramu 2000 Bow Thruster overhaul

In order to bolt it back, it was easier to lower a little the electric motor.
 Amel Super Maramu 2000 Bow Thruster overhaul