Lewmar 140 User manual

Product and Installation Manual
500106 -Issue 3
Product and Installation Manual
Produkt- und Installations-Handbuch
GB
D

2
2- Notices
1- Introduction
Thank you for choosing Lewmar. Lewmar products are world renowned for their quality, technical innovation and
proven performance. With a Lewmar product you will be provided with many years of outstanding service.
Product Support
Lewmar products are supported by a worldwide network of distributors and Authorised Service Representatives.
If you encounter any difficulties with this product, please contact your national distributor, or your local Lewmar
dealer. Details are available at: www.lewmar.com
CE Approvals
For CE approval certificates contact Lewmar.
Important information about this manual
Throughout this manual, you will see safety and product damage warnings.
You must follow these warnings carefully to avoid possible injury or damage.
⚠ WARNING! IMPORTANT: Read these notes before continuing.
‣ Read this manual thoroughly and ensure that you fully understand the operation and safety requirements of the
thruster before commencing the installation and operating the product.
‣ Only persons who are completely familiar with the controls and those who have been fully made aware of the
correct use of the thruster should be allowed to use it. If there is any doubt of how to install or operate this unit
please seek advice from a suitably qualified engineer.
‣ Please ensure that you thoroughly understand the operation and safety requirements of the thruster.
‣ Your thruster should not be operated close to swimmers, as a powerful suction of water is generated when in use.
‣ The thruster must not be used at speeds above 6 knots, and must be retracted at that speed.
‣ The tunnel installation and any hull modifications should only be carried out by a specialist. This manual is based on
an installation into a GRP hull. If your hull material differs, consult a relevant expert.
‣ Do not use the thruster for ANY purpose other than mooring aid.
‣ We recommend that a qualified person install the thruster. Faulty installation will place the boat and crew in danger
and make the warranty invalid.
‣ A circuit breaker/isolator should always be used with the thruster to protect the motor and cables from overheating
and damage.
‣ Always switch off the thruster at circuit breaker/isolator when not in use.
‣ It is the unavoidable responsibility of the captain (owner, master or other responsible party) to assess the risk of any
operation on the vessel. the captain is responsible for the safety of the vessel, the crew, passengers and any
thid party at all times.
‣ Thrusters must not be operated whilst under the influence of alcohol or drugs.
2.1 Fitting
‣ This equipment must be installed and operated in accordance with the instructions contained in this manual.
Failure to do so could result in poor product performance, personal injury and/or damage to your boat.
‣ Consult the boat manufacturer if you have any doubt about the strength or suitability of the mounting
location.
2.2 Electrical
‣ Make sure you have switched off the power before you start installing this product.
‣ This product requires installation by a suitably qualified electrical engineer.
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Lewmar Swing Thruster Product and Installation Manual ref 500146 iss.3 | 3
IMPORTANT: These notes must be read before attempting installation.
‣ This product requires detailed fitting and set-up to suit the particular installation. Failure
to correctly install or set-up the unit can damage the unit or result in premature failure.
‣ The thruster must be installed such that the hatch opens towards
the normal water flow direction. Failure to do so will result in
excess stresses being placed on the hatch, leg and actuator, which
could result in failure. See diagram below.
2.3- Common Installation Errors
⚠
water flow
‣ NEVER power the motor flange via the actuator without the motor bolted in
place. This will cause the motor flange to crack.
‣ The thruster uses two methods to determine the limits of the tunnel
movement.
- When deploying the tunnel, the actuator must be allowed to reach its
own internal “minimum extension” microswitch.
- When retracting the tunnel, the electronics sense a current spike when
the lid contacts with the hull and automatically cut power.
‣ When deployed, ensure that the leg of the thruster does not impact on the edge of the hull. If it does, the hull
should be filed away to give clearance.
‣ When laminating the box into the hull, the laminate layers should
extend up and over the coach bolt heads on each side of the box.
‣ NEVER cut the original cables, or attempt to connect cables with anything other than the original plugs and sockets.

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3- Installation instructions
Kit includes the following parts:
DESCRIPTION NUMBER
Handbook 1
Installation instructions 1
Bowthruster with motor and tube 1
Bolts for connecting the motor 4
Washers for connecting the motor 4
Stop plate for brace* 1
DESCRIPTION NUMBER
Drive shaft 1
Plastic shear pin for actuator (spare) 1
Metal shear pin for thruster (spare)* 1
Fuse holder 1
Fuse 1
*Not for model 250
Start by marking out the centre line on the outside of the hull, e.g. by sighting between a point right forward and
the keel. Using the 3mm hole drilled in step 3.1 as a centre point, mark the outline of the hatch using the dimen-
sions in the table below.
140 Thruster Width = 220 mm Length = 274 mm
185 Thruster Width = 255 mm Length = 346 mm
250 Thruster Width = 375 mm Length = 480 mm
The bowthruster should be placed as far forward as possible, without the top of the box coming above the
waterline, otherwise it could be difficult to fit or remove the motor. Measure out the most suitable location from
inside the boat. Drill a 3 mm hole as close as possible to the centre line, within the area in which the hatch will
eventually sit. This hole will be used as a reference point for locating the mould on the outside of the hull. The
installation kit does not include the mould, since the mould must be manufactured on site in order to fit the
shape of the hull of your boat.
3.1 Mark out the position fore and a
3.2 Placing the mould
⚠ ATTENTION! DO NOT power the motor flange with the actuator until the motor has been bolted in place.
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Lewmar Swing Thruster Product and Installation Manual ref 500146 iss.3 | 5
Cut the marked up hole in the hull with a jigsaw. We recommend you cut with an angle of 40 degrees to the hull
(see picture below).
A
140 Thruster A=160-170 mm
185 Thruster A=200-210 mm
250 Thruster A=300 mm
Locate the box with the inside of the a-edge a maximum of the width of the flange (10 mm) a of the hole.
Measure out dimension A and calculate the difference between the measured dimension A and the value for A
given in the table. Transfer this measurement to the fore-and-a side of the box using a marking gauge. Cut the
box to this line. The thwartships sides (fore and a) are fitted to the shape of the inside of the hull. Put the box in
place and check that dimension A has been accurately marked.
3.3 Fitting the box
Orientate the box such that the hatch will open up towards the normal water flow
direction.
3.4a Installing the box (standard)
⚠ ATTENTION!
Sand the outside of the box for a height of about 10 cm all-round to ensure good adhesion to the GRP.
Locate the internal rear edge of the box a maximum of the width of the flange (10 mm) a of the opening. Adjust
the lateral position of the box until the thruster tunnel goes down through the hole and the clearance on each
side of the tunnel is the same, so that it is centred athwartships. Then attach the box using a little rapid-curing
filler.
Check carefully that the sides of the box are not concave. If they have become concave, the sides of the box
must be pushed out with a strut while the box is being glassed-in.
Then check that the tunnel can move freely, and that, when it is deployed, the thruster wash will miss the hull.
NB! Do not apply the final laminations until the hatch has been fitted. Check carefully that the hatch clears the
hull.
Centre line
Hull
Hull
Box
40°

6
A flange base version is available for high volume customers performing installations in the same location
repetitively. This requires an appropriate recess moulding in the hull and a custom box produced by Lewmar to fit
it. Please contact Lewmar for further information on this facility.
3.4b Installing the box (flange base)
The flange base thruster is supplied as a complete unit. The bot-
tom flange is custom made to match the contour of the hull. The
hatch is also pre-fitted to the tunnel.
Ensure moulded recess in hull is clean and ready for bonding.
Exact details on preparatory steps should be taken from the
instructions from the bonding agent to be used.
Perform the recommended preparatory work to the flange of
the thruster box itself. Apply the chosen bonding agent as
instructed and position the box into the recess, holding in place
using strapping or suitable support for the duration of the stated
curing time.
Once the bonding agent has cured, finish and fair the installation
as required to achieve a seamless blend between flange and
hull.
Proceed to step 3.9
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Lewmar Swing Thruster Product and Installation Manual ref 500146 iss.3 | 7
Trim the sawn-out section of hull until it is a good fit against
the angled surface formed as above. Adjust the hatch with filler,
so it fits perfectly in opening. When the hatch is in place in the
opening, the outside of the hatch at the forward edge must be
at least 1 mm higher than the outside of the hull. The aer edge
and sides of the hatch must be flush with the outside of the hull.
Locate the hatch provisionally using rapid-curing filler. Check
that the hatch is centred in the opening when the thruster is
retracted. The hatch must be adjusted to the tunnel, so that the
hatch is no thicker than 5-7 mm where the ends of the tunnel lie
against the hatch.
A stainless square washer is included, and this is to be glassed in as a stop for the brace. It may be necessary to
glass a projection onto the hull in the centre of the brace to ensure that the motor is at the correct angle in the
retracted position.
To adjust the length of the brace: Retract the thruster. Check that the hatch is lying against the lip, and does not
stand proud of the hull. Then tighten the screw until its head touches the washer on the lip. Lock the nut.
NB! On the model 250, the lip must be moulded by the installer/boatbuilder.
3.5 Install the hatch
Consult the boat designer on the number of layers and the method to
be used. The lamination must not be less than 6 layers and must be
tapered, starting with 1x300gm mat and then 5x600gm.
To prepare the box, sand the area to be laminated and then clean with
solvent.
On the sides and the rear of the box, lamination should cover at least
100mm up the box and cover over the coach bolt heads. On the front
of the box, lamination should go up to a point just below the hinge.
3.6 Glass in the finished box, and
the tunnel to the hatch
Check that the shear pin on the motor goes into the channel in the sha. Turn the motor slowly forward and back
to find the correct position. Insert the bolts and washers on the motor.
3.7 Install the drive sha and motor assembly
3.8 Brace

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The panel must be installed in a dry location. The rear of the panel is not watertight, and must be protected
against water entry.
Circuit diagram for single thruster
Electric motor
3.9 Position and install the panel
3.10 Connect the electrics
Combining a Tunnel Thruster
If combining an existing Lewmar tunnel thruster
into a dual swing/tunnel system, then the black
box must be removed from the tunnel thruster
and conversion box 58991011 installed as per
this diagram in its place. The RMC joystick must
then be used as existing Lewmar controls will
not be compatible.
Never attempt to join cables with anything other than the original plugs / sockets.
⚠ ATTENTION!
⚠
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Windlass
Panel
Contactor
Battery isolator
Auto
Windlass
Panel
Motor Cable
Battery Isolator
1. White
2. Brown
3. Green
4. Yellow
1. White
2. Brown
1. Pink
2. Grey
3. Blue
4. Red
5. Yellow
6. Brown
7. White
8. Green
Grey Blue GND Red 12V Pink Yellow Green Brown White
1. Red
2. Yellow
3. Green
4. Brown
5. Pink
6. Grey
7. White
8. Blue
Yellow
White
Brow
White
Green
Connect direct to battery via 10A fuse
DO NOT connect to motor power supply
White Common plus
Brown Up/Down
Yellow Up/Down
Red +12/24V
Blue GND
Pink not in use
Grey not in use
Battery power
On/Off
STB
PRT
Heat fuse
Brow
Green
White
Yellow White
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Circuit diagram for dual thrusters
Windlass
Joystick
Contactor
Contactor
Battery isolator Battery isolator
Auto
Auto
Windlass
Stern
Thruster Comms
Drive Unit
Bow
Thruster
Panel Panel
Battery
Isolator
Motor Cable Motor Cable
Battery
Isolator
1. White 2. Brown 3. Green 4. Yellow
1. White 2. Brown 1. White
2. Brown
1. Red 2. Yellow 3. Green 4. Brown 5. Pink 6. Grey 7. White 8. Blue
Yellow
Yellow
White
White Brow Brow
White Green
To rear lugs of box
Connect direct to battery via 10A fuse DO NOT connect to motor power supply
Connect direct to battery via 10A fuse DO NOT connect to motor power supply
White Common plus Brown Up/Down Yellow Up/Down
Red +12/24V Blue GND Red +12/24V
Blue GND
Pink not in use Pink not in use Grey not in use Grey not in use
Battery power Battery power
White Green

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When deploying, the actuator must be allowed to reach its own internal minimum extension limit switch.If the
tunnel is not sufficiently clear of the hull in the deployed position, you can adjust the vertical position of the
tunnel using an adjustment screw. Slacken the nut (1) on the forward edge of the fitting slightly and tighten the
nyloc nut (2) on the aer edge of the fitting until the water flow through the tunnel is not disturbed by the hull.
Then lock the adjustment by tightening the nut (1) again.
1
2
3.11 Adjustments
Next, adjust bracket (3) so that the side support bolt (4) is centred on its surface when the thruster is in the fully
deployed position. To do this, loosen the nut holding on the bracket (3), move position and re-tighten nut.
3
4
Finally, adjust bolt 4 so that there is a gap between the end of the bolt and the side support bracket of 0.5-1mm.
The bolts on either should not press on to the brackets when the thruster is not running.
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