Lewmar 140TT Quick start guide

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Bxxx Issue 3
Electric/Hydraulic Stern Thruster
Owner’s Installation, Operation & Basic Servicing Manual
Electric Stern Thruster
Owners Installation, Operation & Basic Servicing Manual
Electric Stern Thruster
Owners Installation, Operation & Basic Servicing Manual
Electric Stern Thruster
Owners Installation, Operation & Basic Servicing Manual
Electric Stern Thruster
Owners Installation, Operation & Basic Servicing Manual
Electric Stern Thruster
Owners Installation, Operation & Basic Servicing Manual

3
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
Contents
Introduction 4
Product support 4
Important information about this manual 4
EMC Recommended guidelines 4
CE Approvals 4
Safety notices 5
General 5
Fitting 5
Electrical 5
1. Installation 6
1.1 Choosing location 6
1.2 Internal structure 7
1.3 Preparing for fitting 8
1.4 140TT & 185TT installing hub unit 9
1.5 250TT & 300TT installing hub unit 10
1.6 Preparing for final assembly 11
2. Electrical wiring installation 12/13
2.1 Typical electrical layout 12/13
3. Operating your winch 14
4. Servicing your winch 14
5. Dimensions x
6. Total weight x
12. Fault finding x
13. Lewmar limited warranty 16
Bxxx Issue 3. Electric & Hydraulic stern thrusters
models 140TT, 185T T, 250TT & 300TT.

4Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
5
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
Introduction
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.
The type of warnings, what they look like, and
how they are used in this manual are explained as
follows:
Warning!
This is a warning against anything which may
cause injury to people if the warning is ignored.
You are informed about what you must or must not
do in order to reduce the risk of injury to yourself
and others.
Safety Symbol
When you see the safety symbol it means: “Do
not...”; “Do not do this”; or “Do not let this
happen”.
Dear Customer,
Thank you for chosing Lewmar TT Thrusters.
Lewmar products are world renowned for their
quality, technical innovation and proven performance.
With a Lewmar winch you will be provided with many
years of outstanding service. We wish you happy
sailing.
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
avaiable at:
To the best of our knowledge, the information in
this manual was correct when it went to press.
However, Lewmar cannot accept liability for
any inaccuracies or omissions it may contain.
In addition, our policy of continuous product
improvement may change specifications
without notice. As a result, Lewmar cannot
accept liability for any differences between the
product and the manual.
www.lewmar.com
Approvals
For CE approval certificates contact Lewmar.
General
Please ensure that you thoroughly understand the
operation and safety requirements of the thruster
before commencing the installation. 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 tunnel installation and any hull modifications
should only be carried out by a specialist. This
manual is based on a GRP tunnel installation.
• We recommend that a qualified person install
the thruster. Faulty installation will place the
boat and crew in danger and make the warranty
invalid.
• Sailing, like many other sports can be hazardous.
Even the correct selection, maintenance and
use of proper equipment cannot eliminate the
potential for danger, serious injury or death.
• It is the unavoidable responsibility of the owner
or master or other responsible party to assess
the risk of any operation on the vessel.
• Lewmar recommends the use of appropriate
Personal Protective Equipment and hands
free communication equipment by any person
going aloft, and only then where the person
going aloft is properly trained in the use of that
equipment and where there remain sufficient
trained and experienced personnel on deck to
ensure constant observation and the continued
safe conduct both of the vessel and the hoisting
operation.
Safety notices
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.
• Electric bow thrusters use powerful electric
motors, it is very important that there is
sufficient battery capacity and large enough
cables for safe operation. Using smaller than
recommended battery and cables will cause
loss of performance and may cause dangerous
overheating.
• Electric motors spark and run hot. Do not place
near flammable or sealed areas.
• Main battery must not be connected and power
must not be switched on until all covers and
terminal protectors are correctly fitted.
• It is very dangerous to run the thruster out of
the water, even for a few seconds, the motor
will over speed by 300%, causing damage to the
seals etc. and the propeller will cause serious
damage to whatever comes into contact with it
and invalidate the warranty.
• Consult the boat manufacturer if you have any
doubt about the strength or suitability of the
mounting location.
Electrical
• Make sure you have switched off the power
before you start installing this product.
• If in doubt about installing electrical equipment
please seek advice from a suitably qualified
electrical engineer.
This manual forms part of the product
and MUST BE RETAINED along with, OR
incorporated into, the Owner’s Manual for
the vessel to which the windlass is fitted.

6Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
7
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
1. Installation
1.1 Choosing location
NOTE: This manual is to be read in conjunction
with the main manual supplied with the TT
Thruster, which has important information on
installation and use.
Ø = Tunnel Diameter.
For optimal performance the Thruster unit should
be mounted within the following:
• Chose position, ensure it is at least 1Ø below
the waterline to prevent air being sucked into
the tunnel.
• That the chosen area is flat.
• Check internal position is free of mechanical,
electrical or bulkhead obstructions.
1. Installation
Fig. 1.22
Min. 1 Ø
Min. 100 mm
Fig. 1.11
1.2 Internal structure
Fig 1.21
• The thruster must be in a watertight enclosure
that is a minimum of 150 mm (6”) above the
waterline. This space must also have adequate
ventilation. Access should be from above and the
entrance should not allow water in.
NOTE: Ensure all drainage ducts are sealed
and routed around the enclosure.
Min. 150 mm
Fig. 1.21
Fig 1.22
The internal compartment must be watertight.
Do not use the compartment as storage.
1. Installation

8Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
9
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
1.3 Preparing for fitting
The boat must be out of the water, levelled and
secure in its cradle.
A competent, marine engineer must carry out any
work on the hull of your boat.
Problems caused by faulty installation of the
tunnel are the installers full responsibility.
NOTE: Lewmar stern tubes are constructed
of polyester resin and glass fibre with a white
gell coat. Mounting template is provided with
the kit.
• Align template horizontally on transom.
OR
Offer up stern tube and level, mark holes for
drilling.
• Drill and cut all holes.
Fig. 1.31
• Seal all cut surfaces. (GRP Only).
Fig. 1.32
Stern tubes may be bonded in place. We
recommend that a qualified person carry out any
work to the hull. Faulty installation will place the
boat and crew in danger and make the warranty
invalid.
Fig. 1.33
1. Installation
Fig. 1.31
1.4 140TT & 185TT
Installing hub unit
• Place gasket on hub and locate through centre
hole.
• Apply zinc chromate paste or marine grease
to location bore and assemble saddle onto hub
(sicoflex or similar maybe used to seal saddle
in place). Apply blue loctite to bolts and hand
tighten along with supplied washers.
Fig. 1.32
• Assemble anode kit and propeller in this order:-
large washer, propeller, anode, small washer and
nyloc nut onto propeller shaft.
Tighten hub/saddle bolts to 7Nm (x.xlbs.ft)
140TT - 21Nm (15.5lbs.ft) 185TT. Check that
propeller is centred and free turning (within 10
minutes of applying Blue Loctite).
Fig. 1.33
• Tighten prop nut to 10Nm (7.4lbs.ft) 140TT
- 15Nm (11lbs.ft) 185TT , a length of wood
placed between prop blade and tunnel will stop
movement.
NOTE: Poor internal tunnel surface could cause
leakage. Apply sealant to this area and gasket
if in doubt.
Fig. 1.33
• Antifoul bronze hub.

10 Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
11
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
1. Installation
1.5 250T T & 300TT
Installing hub unit
• Place gasket on hub and locate through centre
hole.
Fig. 1.51
• Apply zinc chromate paste or marine grease
to location bore and assemble saddle onto hub
(sicoflex or similar maybe used to seal saddle
in place). Apply blue loctite to bolts and hand
tighten along with supplied washers.
Fig. 1.52
• Assemble anode kit and propeller in this order:-
large washer, propeller, anode, small washer and
nyloc nut onto propeller shaft.
Tighten hub/saddle bolts as instructed in main
thruster installation manual.
Fig. 1.53
• Tighten hub/saddle bolts as instructed in main
thruster installation manual.
NOTE: Poor internal tunnel surface could cause
leakage. Apply sealant to this area and gasket
if in doubt.
Fig. 1.54
• Antifoul bronze hub.
1.6 Preparing for
final assembly
• Before final assembly of stern tube, check
surfaces are clean, smooth and free from
grease.
Completely fill sealing groves with a contiuous
bead of Sikaflex or equivalent.
Fig. 1.61
• Bolt stern tube assembly in place large thick
washers plus springs at a length to suit transom
thickness. Bolt holes and heads must be sealed
with Sikaflex or equivalent.
Fig. 1.62
Fig 1.63
The electric motor must be supported as it is being
installed horizontally.
• Fit the motor and cables (see relevant section in
main installation manual).
Fig. 1.63
It is important that all power cables enter the
sealed installed area at a high point to avoid
possible water ingress.
A4 Stainless Steel Property class 70 or greater
Thruster Bolt
140 M8 (5/16”)
185 M10 (3/8”)
250 M10 (3/8”)
300 M10 (3/8”)

12 Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
13
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
2. Electrical wiring installation
STERN
MOTOR
FUSE
BATTERY
BLACK
BOX
CONTROL
BOX
BATTERY
SWITCH
+VE –VE
RED
VIOLET
WHITE
RED
THERMAL
SWITCH
CONTROL BOX
COVER
REMOVED
TO
CONTROLS
BLACK
BOX
BLACK
(POSITIVE) STUD*
* Solenoid appearance
may differ.
BOW
MOTOR
FUSE
BATTERY
BLACK
BOX
CONTROL
BOX
BATTERY
SWITCH
+VE –VE
Fig. 2.11

14 Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
15
Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
3. Operating your thruster
4. Servicing your thruster
NOTE: Stern thrusters are more likely to attract
‘debris’,so it is necessary to regularly check
the tunnel.
At the annual boat service.
• Remove any debris from tunnel, prop and hub.
• Replace the anode.
• If the prop is damaged or heavily contaminated,
replace it, best to be safe.
• Inspect motor, ensure all leads are still tight.
• Check all bolts and nuts are to correct torque.
• Check the motor assembly is dry and that the
compartment is water tight.
• Check stern tube for cracks or damage.
• Check and clean out thruster compartment.
NOTE: Refer to the main thruster manual for
control options.
• Please ensure that you thoroughly understand
the operation and safety requirements of the
thruster.
Fig. 3.11
Your thruster should not be operated close to
swimmers, as a powerful suction of water is
generated when in use.

16 Electric/Hydraulic Stern Thruster
Models 185TT, 250TT & 300TT
GB
13. Lewmar limited warranty
LIMITED WARRANTY and
KEY TERMS OF SUPPLY BY LEWMAR
Lewmar warrants that in normal usage and with proper
maintenance its products will conform with their specification
for a period of three years from the date of purchase by the end
user, subject to the conditions, limitations and exceptions listed
below. Any product, which proves to be defective in normal usage
during that three-year period, will be repaired or, at Lewmar’s
option, replaced by Lewmar.
A CONDITIONS AND LIMITATIONS
i Lewmar’s liability shall be limited to the repair or replacement
of any parts of the product which are defective in materials or
workmanship.
ii Responsibility for the selection of products appropriate for the
use intended by the Buyer shall rest solely with the Buyer and
Lewmar accepts no responsibility for any such selection.
iii Lewmar shall not be liable in any way for Product failure, or
any resulting loss or damage which arises from:
a use of a product in an application for which it was not designed
or intended;
b. corrosion, ultra violet degradation or wear and tear;
c. a failure to service or maintain the product in accordance with
Lewmar’s recommendations;
d. faulty or deficient installation of the product (unless conducted
by Lewmar);
e. any modification or alteration of the product;
f. conditions that exceed the product’s performance
specifications or safe working loads.
iv Product subject to a warranty claim must be returned to the
Lewmar outlet which supplied the product for examination
unless otherwise agreed by Lewmar in writing.
v This warranty does not cover any incidental costs incurred for
the investigation, removal, carriage, transport or installation
of product.
vi Service by anyone other than authorised Lewmar
representatives shall void this warranty unless it accords
with Lewmar guidelines and standards of workmanship.
vii Lewmar’s products are intended for use only in the marine
environment. Buyers intending to use them for any other
purpose should seek independent professional advice as to
their suitability. Lewmar accepts no liability arising from such
other use.
B EXCEPTIONS
Cover under this Warranty is limited to a period of one year from
the date of purchase by the end user in the case of any of the
following products or parts of products:
• Electric motors and associated electrical equipment
• Electronic controls
• Hydraulic pumps, valves and actuators
• Weather seals
• Products used in “Grand Prix” racing applications
C LIABILITY
i Lewmar’s liability under this warranty shall be to the exclusion
of all other warranties or liabilities (to the extent permitted
by law). In particular (but without limitation):
a Lewmar shall not be liable for:
• Any loss of anticipated turnover or profit or indirect,
consequential or economic loss ;
• Damages, costs or expenses payable to any third party;
• Any damage to yachts or equipment;
• Death or personal Injury (unless caused by Lewmar’s
negligence).
Some states and countries do not allow the exclusion or limitation
of incidental or consequential damages, so the above limitation or
exclusion may not apply to you.
b Lewmar grants no other warranties regarding the fitness for
purpose, use, nature or satisfactory quality of the products.
ii Where applicable law does not permit a statutory or implied
warranty to be excluded, then such warranty, if permitted by
that state or country’s law, shall be limited to a period of one
year from the date of purchase by the end user. Some states
and countries do not allow limitations on how long an implied
warranty lasts, so this limitation may not apply to you.
D PROCEDURE
Notice of a claim for service under this warranty shall be made
promptly and in writing by the end user to the Lewmar outlet which
supplied the product or to Lewmar at Southmoor Lane, Havant,
Hampshire, England PO9 1JJ.
E SEVERANCE CLAUSE
If any clause of this warranty is held by any court or other
competent authority to be invalid or unenforceable in whole or in
part, the validity of the remaining clauses of this warranty and the
remainder of the clause in question shall not be affected.
F OTHER RIGHTS
This warranty gives you specific legal rights, and you may also
have other legal rights, which vary, from state to state and country
to country.
In the case of European States a Consumer customer (as defined
nationally) has legal rights under the applicable national law
governing the sale of Consumer Goods; this Warranty does not
affect those rights.
G LAW
This warranty shall be governed by and read in accordance with
the laws of England or the state or country in which the first end
user is domiciled at the time of purchase of the product.
H DISPUTES
Any dispute arising under this warranty may, at the option of the
end-user, be referred to alternative dispute resolution under the
rules of the British Marine Federation or to the Courts of the
State whose law shall govern the warranty or to the Courts of
England and Wales.
The British Marine Federation may be contacted at Marine House,
Thorpe Lea Road, Egham, England, TW20 8BF