Lewmar TT 140 Quick start guide

1
Electric/Hydraulic TT Thruster 140 - 300
GB
www.lewmar.com
500100 Issue 3Electric/Hydraulic
TT Thruster 140-300
Owner’s Installation, Operation &
Basic Servicing Manual
GB
T1873 Lewmar USA4 Thruster 140 to 00 I

T1873 Lewmar USA4 Thruster 140 to

3
Electric/Hydraulic TT Thruster 140 - 300
GB
Issue 2. Electric/hydraulic TT thruster 140 - 300.
Contents
Introduction 4
Product support 4
Important information about this manual 4
Approvals 4
Safety notices 4
General 4
Thruster supply 4
Fitting 4
Electrical 4
1. Installation 5
1.1 Choosing location 5
1.2 Preparing the hole for the tube 5
1.3 Preparing for fitting the thruster 6
1.4 Installing hub unit and saddle models
140TT & 185TT 7
1.5 Gearbox position - 185TT only 7
1.6 Propeller assembly - all models 7
1.7 Installing hub unit and saddle models
250TT & 300TT 8
1.8 Electric motor unit support 9
1.9 Installing electric motor unit model
140TT & 185TT 9
1.10 Installing electric motor unit model
250TT & 300TT 9
1.11 Installing hydraulic motor unit model
185TTH to 300TTH 10
1.12 Final checks - All models 10
2. Electrical wiring installation 11
2.1 Typical electrical layout model
140TT 2.0 kW only 11
2.2 Typical electrical layout models
140TT 2.2 kW and 185TT 11
2.3 Typical electrical layout models
250TT & 300TT 12
2.4 Electric motor terminal connections 12
2.5 Battery cable connections 13
2.6 Correct cable sizes 13
2.7 Electrolytic test 14
2.8 Installing control panel - all models 14
2.9 Final checks 15
3. Operating your thruster 15
3.1 140TT 2.0 kW 15
3.2 140TT 2.2 kW to 300TT 15.0 kW
operation and safety features 16
4. Servicing your thruster 17
4.2 Changing drive pin 140TT or 185TT 17
5. Weight & specifications 18
5.1 Electric 18
5.2 Hydraulic 18
6. Parts list 19
6.1 Model 140TT 2.0 kW 12 V 19
6.2 Model 140TT 2.2 kW 12 V 19
6.3 Model 185TT/H 3.0 to 6.0 kW 12 & 24 V 20
6.4 Model 250TT/H 8.0 kW 24 V 21
6.5 Model 300TT/H 10.8 to 15.0 kW 22
6.6 Accessories 23
7. Dimensions 24
7.1 Electric 24
7.2 Hydraulic 24
8. Fault finding 25
9. Cutting templates 26
10. Lewmar limited warranty 27
T187

4Electric/Hydraulic TT Thruster 140 - 300
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:
Dear Customer,
Thank you for choosing Lewmar TT Thrusters. Lewmar products
are world renowned for their quality, technical innovation and
proven performance. With a Lewmar thruster 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:
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.
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.
• It is the unavoidable responsibility of the owner or master or
other responsible party to assess the risk of any operation on
the vessel.
Thruster supply
• The thruster is securely packed for transit. However all parts
should be inspected for signs of damage before installation. If
any parts are found to be damaged please contact lewmar.
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 motor seals etc. and the propeller will cause
serious damage to whatever comes into contact with it. This
action will 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.
Safety notices
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 thruster is ?tted.
Warning!
elpoepotyrujniesuacyamhcihwgnihtynatsniagagninrawasisihT
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”.
• Electric thrusters must be located in a dry environment.
Should there be a need to install in a damp /wet location
then the IP (Ignition Protected) version must be used.

5
Electric/Hydraulic TT Thruster 140 - 300
GB
1. Installation
1.1 Choosing location
The actual position of the Thruster will depend on the internal &
external construction of the Motor Boat or Sailing Yacht.
Ø = Tunnel Diameter.
For optimal performance the Thruster should be mounted within
the following:
• As far forward as possible (Fig 1.1.1 lever effect).
Fig. 1.1.1
• 1 x Ø below the waterline to prevent air being sucked into the
tunnel. (Fig. 1.1.2 0.75 x Ø minimum.).
• Minimum suggested tunnel length 2 x Ø.
NOTE: Ensure there is sufficient space
for the Thruster assembly complete with
motor and controls in the boat.
Ø
Min. 100 mm (4")
Min. 0.75 Ø
OPTIMUM AREA
Fig. 1.1.2
• The recommended tunnel is designed to fit a Lewmar saddle,
take the weight of the Thruster and the torque of the motor.
• Fig 1.1.4 - To reduce any potential loss of performance or
damage to the propeller the entrance of the tunnel can be
altered to improve thrust as well as reduce noise.
• TT Thruster can be fitted new or as a replacement for an
existing thruster (see Fig 1.1.3).
NOTE: Check mounting holes on the saw template.
Fig. 1.1.3
Fig. 1.1.4
1.2 Preparing the hole for the tube
When you are satisfied the best location for the Thruster unit has
been found within the parameters available proceed as follows.
• Fig 1.2.1 - Make a jig to precisly align the drill holes either
side of the hull.
NOTE: Double check everything before drilling.
• Drill a pilot hole in both sides of the hull.
Thruster Model (kW) Thruster I.D.
mm (inch)
Wall
mm (inch)
140 140 (51/2) 4.0 (5/32) - 5.0 (3/16)
185 (3.0 & 4.0) 185 (79/32) 4.0 (5/32) - 6.0 (1/4)
185 (5.0 & 6.0) 185 (79/32) 6.0 (1/4)
250 250 (927/32) 7.5 (9/32)
300 300 (1113/16) 9.0 (11/32)
A competent, marine engineer must carry out any work on the
hull of your boat.
The boat MUST be out of the water, levelled and secure in its
cradle.
This section is for general guidance for GRP boats only. Problems
caused by faulty installation of the tunnel are the installers full
responsibility.
A competent, marine engineer must carry out any work on the hull
of your boat.

6Electric/Hydraulic TT Thruster 140 - 300
Fig. 1.2.1
Fig. 1.2.2
• Form a wire guide to diameter of the tunnel hole, mark, check
and cut.
• Insert tube in the hole, mark and remove excess.
• Grind off gel coat etc. Insert tunnel and fix allowing enough
room inside for saddle location on the tunnel.
Gel coat finished installation and antifoul.
Fig. 1.2.3
• Drill a pilot hole in both sides of the hull.
1.3 Preparing for fitting the thruster
• The Thruster can be installed at any angle within 90° from
vertical.
Fig. 1.3.1
600 mm
(24") Max.
Fig. 1.3.2
Fig. 1.3.3
• Choose position of thruster, ensuring internal room for motor
and controls and that the propeller is easily reached from
outside.
NOTE: Fig 1.3.2. - Normal install is
to Port (single propeller unit)
• Position template on centre line, double check everything and
drill. Remove all burrs. All the holes must be on the centre
line. Poor alignment may affect hub positioning.
Fig. 1.3.4
• Place the thruster saddle in the desired position, ensure the
fit is firm and free from movement then mark centre.
• To aid installation a kit is available. See Sec 6.6 Accessories.
Electric motors must be supported if installed more than 30° from
vertical (Fig 1.8.1).
0/04/2007

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Electric/Hydraulic TT Thruster 140 - 300
GB
Fig. 1.4.1
1.4 Installing hub unit and saddle
models 140TT & 185TT
NOTE: Illustrations based on 140TT saddle.
• To suit the wiring configuration supplied fit the thruster
propeller on the port side.
• Place gasket on hub and locate through centre hole. Sealant
can be applied to gasket and flange to aid sealing.
NOTE: To achieve the correct position of the
propeller in the tunnel the gasket must be inplace.
Fig. 1.6.2
• Apply zinc chromate paste or marine grease to location bore
and assemble saddle onto hub (SikaFlex® or similar maybe
used to seal saddle in place). Apply Blue Loctite® 243 to bolts
and hand tighten along with supplied washers (Fig. 1.4.2).
NOTE: Tighten to full torque within 10 minutes.
Fig. 1.4.2
1.6 Propeller assembly - all models
• Check the hub gasket is in place.
• Fig 1.6.1 - Assemble anode kit and propeller in this order:-
large washer, propeller, anode, small washer and nyloc nut
onto propeller shaft.
Fig. 1.6.1
NOTE: Poor exterior tunnel surface could
cause leakage and noise. Apply sealant to
this area as required (Fig. 1.4.2).
Fig. 1.6.3
DO NOT allow propeller to touch tunnel.
Check the propeller has been assembled in the correct order.
1.5 Gearbox position - 185TT only
• On installation check the position of the gearbox (leg) brass
stem in the saddle.
Fig. 1.5.1
Fig. 1.5.2
• If it is above 3.5 mm (1/8”), the tunnel should be packed under
the saddle (Fig 1.5.2).
• If it is below 2 mm (1/16”), material must be removed from the
tunnel (Fig 1.5.1).
NOTE: Tighten each bolt alternately a
number of times to full torque.
• Fig 1.6.2 - Tighten hub/saddle bolts to 9 Nm (6.6 lbs.ft) for 140
or 21 Nm (15.5 lbs.ft) for 185. Check that propeller is centred
and free turning (within 10 minutes of applying Blue Loctite®
243).
T1873 Lewmar USA4 T22:30:57

8Electric/Hydraulic TT Thruster 140 - 300
Fig. 1.7.1
1.7 Installing hub unit and saddle
models 250TT & 300TT
• Place gasket on hub and locate through centre hole. Sealant
can be applied to gasket and flange to aid sealing.
NOTE: To achieve the correct position of the
propeller in the tunnel the gasket must be inplace.
LH
Fig. 1.7.2
• Apply zinc chromate paste or marine grease to location bore
and assemble saddle onto hub (SikaFlex® or similar maybe
used to seal saddle in place). Apply Blue Loctite® 243 to bolts
and hand tighten along with supplied washers (Fig 1.7.2).
NOTE: Tighten to full torque within 10 minutes.
NOTE: Tighten each bolt alternately a number of times
to full torque.
• Tighten hub/saddle bolts to 33 Nm (24 lbs.ft) for 250 or 82 Nm
(60.5 lbs.ft) for 300. Check that propeller is centred and free
turning (within 10 minutes of applying Blue Loctite® 243).
Fig. 1.7.2
• Assemble anode kit and propeller in this order:- large washer,
propeller, anode, small washer and nyloc nut onto propeller
shaft. To suit the wiring configuration supplied fit the thruster
LH propeller on the port side.
• Tighten propeller nut to 35 Nm (26 lbs.ft), a length of
wood placed between propeller blade and tunnel will stop
movement.
Fig. 1.7.4
• NOTE: Poor exterior tunnel surface could
cause leakage and noise. Apply sealant
to this area as required (Fig 1.7.2).
Fig. 1.6.4
• Tighten propeller nut to 10 Nm (7.4 lbs.ft) for 140 or 15 Nm
(11 lbs.ft) for 185, a length of wood placed between propeller
blade and tunnel will stop movement.
DO NOT overtighten propeller nuts.
• Antifoul bronze hub and propeller if desired.
DO NOT antifoul zinc anode.
DO NOT antifoul zinc anode.
Check the propeller has been assembled correctly (Fig 1.6.1).
• Antifoul bronze hub and propeller if desired.
Fig. 1.7.3
DO NOT allow propeller to touch tunnel.
DO NOT overtighten propeller nuts.
ssue8.indd8T1873 Lewmar USA4 Thruster 140 to 300 Issue 8.indd 8 30/04/2007 22:30:5730/04/2007 22:30:57

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Electric/Hydraulic TT Thruster 140 - 300
GB
1.8 Electric motor unit support
• If the electric motor is installed more than 30° from the vertical
it MUST be supported and secured to the support with a strap
(not supplied) around the main motor unit.
Fig. 1.8.1
1.10 Installing electric motor
unit model 250TT & 300TT
• Place insulator in between saddle and motor flange. Line up
key to coupling keyway.
• Remove drive shaft key retaining tie, grease shaft, slide motor
into position and align holes for most suitable installation and
bolt motor assembly to saddle applying Blue Loctite® 243 to
bolts.
Fig. 1.10.2
Fig. 1.10.1
1.9 Installing electric motor unit
model 140TT & 185TT
• NOTE: Illustrations based on 140TT saddle.
• Align motor drive pin inline with slot in shaft. Apply grease to
hub shaft.
Fig. 1.9.1
• Slide motor into position and align holes for most suitable
installation.
• Bolt motor assembly to saddle and tighten bolts to 20 Nm
(15 lbs.ft) for 140 or 35 Nm (25.8 lbs.ft) for 185. Apply Blue
Loctite® 243 to all bolts.
Fig. 1.9.2
DO NOT REMOVE the drive pin plastic retainer tie on the motor
drive shaft.
Coupling is factory fitted. DO NOT remove.

10 Electric/Hydraulic TT Thruster 140 - 300
1.11 Installing hydraulic motor unit
model 185TTH to 300TTH
• Place insulator in between saddle and motor flange. Line up
key to coupling keyway.
• Remove drive shaft key retaining tie, grease shaft, slide motor
into position and align holes for most suitable installation and
bolt motor assembly to saddle and tighten.
Fig. 1.11.2
Fig. 1.11.1
• Motor ports require male/female connectors with correct size
hydraulic sealing washers.
185TT Main ports = 3/8” BSPP.
Main ports =
3/4” BSPP.
Drain ports =
1/4” BSPP.
NOTE: It is advisable to fit insulated pipe
sections to prevent thruster corrosion.
Fig. 1.11.3
Fig. 1.11.4
Model Part
No.
Max.
Output
Motor
Disp. DELTA Flow Max. Thrust
185TTH 591820 7 kW 6 cc/rev 210 bar 26 l/min 100 kgf
250TTH 592520 15 kW 26 cc/rev 122 bar 81.5 l/min 200 kgf
250TTH 592521 15 kW 17 cc/rev 190 bar 52.3 l/min 200 kgf
300TTH 593020 22.5 kW 30 cc/rev 182 bar 82.1 l/min 300 kgf
300TTH 593021 22.5 kW 26 cc/rev 210 bar 71.7 l/min 300 kgf
1.12 Final checks - All models
Check list hydraulic
• Check drain line fitted.
• All fittings are tight with seals in place.
• Hydraulic system has been checked and adjusted to correct
pressures and flows.
Operation of Hydraulic unit
• Refer to system suppliers instructions.
Check list mechanical
• Check all bolts and nuts are tight.
• Check the propeller/s are correctly installed and the nuts
tightened.
• Check the motor control box cover is in place.
• Check the propeller/s can be turned - before working on unit
check battery switch is off or remove the fuse.
NOTE: Saddle and motor are
firmly seated on the tube.
Coupling is factory fitted. DO NOT remove.

11
Electric/Hydraulic TT Thruster 140 - 300
GB
2. Electrical wiring installation
Blue
Thermal
Switch
FUSE
BATTERY
SWITCH
BATTERY
140TT 2.0 kW
Motor
CONTROL BOX
COVER
REMOVED
+VE –VE
Black
Red
Fuse 3 A
5 x 20 mm
Grey
Black
To Controls
Blue
Red
Grey
Fig. 2.1.1
2.1 Typical electrical layout
model 140TT 2.0 kW only
•. If the thruster operates in an opposite
direction to the control panel, swap the
grey and blue wire connections on the
contactor coils.
NOTE: Automatic battery
switch can not be used
with this product.
Loom Wiring
Red +VE
Blue Thrust port switch
Grey Thrust starboard switch
Black Not Used
2.2 Typical electrical
layout models 140TT
2.2 kW and 185TT
•. If the thruster operates in an opposite
direction to the control panel, swap the
white and violet wire connections on
the contactor coils.
NOTE: Automatic switch (if
fitted). Main power is switched
on when panel is switched on.
MOTOR
FUSE
BATTERY SWITCH
OR
AUTOMATIC BATTERY
SWITCH 589034
(If fitted)
BATTERY
CONTROL BOX BLACK
BOX
+VE –VE
RED
VIOLET
WHITE
RED
THERMAL
SWITCH
CONTROL BOX
COVER
REMOVED
TO
CONTROLS
BLACK
BOX
BLACK
(POSITIVE) STUD*
* Solenoid
appearance may differ.
Fuse 5 A
5x20 mm
Fig. 2.2.1
To satisfy International standards, a
suitably sized battery switch should
be fitted to the thruster +VE supply.
Lewmar recommend this as best
practice for safe installations.
It is vital that the positive battery
lead is connected to the positive motor
terminal or damage to the electronics
will occur.
Loom Wiring
Red +VE
Blue Thrust port switch
Grey Thrust starboard switch
Black –VE
Positive Switching
Negative Switching
Harness reversed on 2.0 kW

12 Electric/Hydraulic TT Thruster 140 - 300
2.3 Typical electrical layout
models 250TT & 300TT
•. If the thruster operates in an opposite
direction to the control panel, swap the
white and violet wire connections on
the contactor coils.
NOTE: Automatic switch (if
fitted).Main power is switched
on when panel is switched on.
MOTOR
FUSE
BATTERY
BLACK
BOX
CONTROL
BOX +VE
–VE
BATTERY SWITCH
OR
AUTOMATIC BATTERY
SWITCH 589034
(If fitted)
RED
VIOLET
WHITE
RED
THERMAL
SWITCH
CONTROL BOX
COVER
REMOVED
TO
CONTROLS
BLACK
BOX
BLACK
(POSITIVE) STUD*
* Solenoid
appearance may differ.
Fuse 5 A
5x20 mm
Fig. 2.3.1
Fig. 2.41
2.4 Electric motor
terminal connections
• Terminals must be correctly clamped
to motor studs. Use a pair of spanners
- the one nearest motor to stop rotation
of the stud.
• Spanner sizes are 13 mm for 140TT and
17 mm for 185TT - 300TT. Tighten the
bolts to 20 Nm (15 lbs.ft).
Loom Wiring
Red +VE
Blue Thrust port switch
Grey Thrust starboard switch
Black –VE
Negative Switching
NOTE: For dual thruster
controls see stern thruster
manual included in sternkit
or on www.lewmar.com
It is vital that the positive battery
lead is connected to the positive motor
terminal or damage to the electronics
will occur.
DO NOT overtighten electric motor
terminal nuts.

13
Electric/Hydraulic TT Thruster 140 - 300
GB
2.6 Correct cable sizes
NOTE: Cable length is total from
battery to thruster and back.
• Example: Measure the total cable run
from the battery to thruster and back
in metres. Grey area on the table shows
a total of 28 m (92 ft) of cable with a
model 250 8.0 kW thruster would need
95 mm CSA (000 AWG) cable.
• Battery crank capacity should be at
least equal to the thruster current.
• Main power cables should be run from
the batteries and must have an inline
fuse fitted.
• The cables should be terminated with
a ring terminal corresponding to the
motor studs, 8 mm (5/16”) for 140TT
and 10 mm (3/8”) for 185TT, 250TT
and 300TT. It is important that this
termination is secure so that the high
current is transferred to the motor
efficiently. The minimum voltage at
motor when running should be 10 V
for 12 V and 21 V for 24 V units.
• Ensure the insulating boots, supplied
with the unit, are correctly fitted.
NOTE: If very large cables are
used discard supplied boots
and fit appropriate sized ones.
CABLE CSA mm - Cable length in metres
TT Model Current
(A) 25 35 50 70 95 120 150 175
140 2.0 kW-12 V 270 6 10 16 22 - - - -
140 2.2 kW-12 V 280 6 10 15 21 - - - -
185 3.0 kW-12 V 330 6 8 10 15 21 - - -
185 3.0 kW-24 V 160 18 22 - - - - - -
185 4.0 kW-12 V 470 4 6 8 12 16 21 26 30
185 4.0 kW-24 V 235 12 16 25 33 - - - -
185 5.0 kW-12 V 480 4 6 8 12 16 20 25 29
185 5.0 kW-24 V 240 12 16 24 32 - - - -
185 6.0 kW-12 V 700 - - 6 8 12 15 21 28
185 6.0 kW-24 V 370 9 12 16 24 32 - - -
250 8.0 kW-24 V 500 7 10 12 21 28 36 45 -
250 9.6 kW-48 V 330 - 26 37 50 64 - - -
300 10.8 kW-24 V 650 4 6 9 12 16 21 25 30
300 15.0 kW-48 V 420 - 24 35 48 62 - - -
CABLE AWG - Cable length in feet
TT Model Current
(A) 3 2 1 0 00 000 0000 2x0000
140 2.0 kW-12 V 270 20 31 42 53 64 - - -
140 2.2 kW-12 V 280 20 30 40 50 60 - - -
185 3.0 kW-12 V 330 19 24 30 37 49 62 - -
185 3.0 kW-24 V 160 63 80 - - ----
185 4.0 kW-12 V 470 14 18 23 30 38 48 60 -
185 4.0 kW-24 V 235 42 50 68 80 100 - - -
185 5.0 kW-12 V 480 14 18 23 29 37 47 59 -
185 5.0 kW-24 V 240 42 50 68 80 100 - - -
185 6.0 kW-12 V 700 - 13 16 21 28 35 50 100
185 6.0 kW-24 V 370 - 37 45 60 74 97 - -
250 8.0 kW-24 V 500 - 32 41 52 66 84 105 -
250 9.6 kW-48 V 330 - 80 98 118 154 - - -
300 10.0 kW-24 V 650 - 19 24 31 39 49 65 130
300 15.0 kW-48 V 420 - 74 92 112 148 - - -
2.5 Battery cable
connections
• Correct installation. Supplied cable
boots are used and no bare wires
exposed (Fig 2.6.1).
• Live wire exposed! (Fig. 2.6.2). Correct
the cable installation to match (Fig
2.6.1).
• Terminal or motor is damaged. Contact
Lewmar Limited (Fig 2.6.3).
• Crimp inverted and is touching
motor! (Fig 2.6.4). Correct the cable
installation to match as (Fig 2.6.1).
Boot
✓
Fig. 2.5.1
✗
Fig. 2.5.2
Boot
✗
Fig. 2.5.3
Boot
✗
Fig. 2.5.4
To battery
To battery
To battery
To battery
Incorrect installation of battery cables
or damage to connection studs may
result in a short to the thruster body.
Use the examples above to check for
a correct installation on both +V and
-V battery connections.
The installation MUST have a battery
switch that is switched off whilst the
thruster is not in use or the boat is
unoccupied.

14 Electric/Hydraulic TT Thruster 140 - 300
2.8 Installing control panel - all models
• A 63.5 mm (21/2”) hole saw is required. Ensure there is
sufficient depth for the control panel and access for the switch
leads and plug (see saw template).
Min.
40 mm Min.
50 mm
Fig. 2.8.1
• The panel has an integral seal and can be clamped from the
rear or with the bezel from the top. Trim clamp depending on
panel thickness.
>15 mm
Fig. 2.8.2
589002
589003
589004
589001
589002
589003
589004
2.7 Electrolytic test
• Test 1. Fig.2.7.1
With the negative not connected and the positive cable
connected but with battery switch off or fuse removed. Use a
continuity tester to check for a connection between the –VE
stud and motor body and also between +VE stud and motor
body. In both cases the meter should give no indication of an
electrical connection.
If a connection is measured between the +VE stud and the
motor body, check installation for cables or wires touching
the assembly or for damage to assembly.
If a connection is measured between the –VE stud and the
motor body, remove any bonding straps attached to the
assembly and check as before.
ΩΩ
Fig. 2.7.1
V
Fig. 2.7.2
• Test 2. Fig 2.7.2
With the battery applied: Use a voltmeter to test the
voltage between the –VE motor stud and the thruster
motor body. If the supply voltage (12 V/24 V)
is measured, disconnect power immediately and inspect the
assembly for faulty installation or damage.
To prevent electrolytic corrosion or faults, the thruster motor
body and assembly MUST remain isolated from any power supply
or grounds. The installer can check for this using a multimeter in
the following ways.
Fig. 2.8.3 589001
589002
589003
589004
589001

15
Electric/Hydraulic TT Thruster 140 - 300
GB
• The small plug connects at the panel. If two or more panels
are installed use the optional Y connectors (Sec 6.6).
• The auxiliary wire is used to connect an automatic battery
switch. Please refer to the units instructions. If automatic
battery switch not fitted, disregard auxiliary wire.
3mm
Fig. 2.8.4
589001
589002
589003 589004
2.9 Final checks
Check list electrical
• Check motor connections are tight with rubber boots in
place.
• The correct fuse is in place.
• Check all switch wires are connected to correct motor
terminal.
Now the cables can be connected to the battery.
• Perform electrical check , Section 2.8.
Operation of electrical unit
• Ensure batteries are fully charged before switching on the
main power.
• When first operating the thruster, make sure you are not close
to other vessels.
3. Operating your thruster
3.1 140TT 2.0 kW
The thruster can be operated using the Lewmar locking joystick
(Part No. 589003) or any water proof momentary two direction
switch with a 5 amp rating.
• Switch ON the battery switch.
• Lift the ‘top hat’ and move the joystick in the desired direction.
When the boat movement has been achieved return the
joystick to the central position (spring return).
Fig. 3.1.1
The thruster must not be operated unless it is in water.
Check the power is OFF.
DO NOT frequently move port to starboard on the joystick in quick
succession as this could damage the electric motor.
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.

16 Electric/Hydraulic TT Thruster 140 - 300
3.2 140TT 2.2 kW to
300TT 15.0 kW operation
and safety features
Safety Features
• Lewmar control panel 589001 and
589002.
NOTE: If Thruster is operated
constantly for 3 minutes it
will power down. Panels will
deactivate.
NOTE: Dual Thruster panel
has same functions as single.
NOTE: The system is designed to
automatically power down after
no operation for 20 minutes.
• To activate the control panel press
and hold for 1 second (Fig 3.2.1).
1
Sec.
Fig. 3.2.1
• Changing direction.
Press the button or move the joystick
for the direction you wish to thrust.
Press the opposite button or move the
joystick to change direction (Fig 3.2.2).
After 1 second thruster activates.
NOTE:If thermal cut-out is
activated all power to the
controls is disabled.Wait
for unit to cool down.
1
Sec.
Fig. 3.2.2
• Additional controller
Pressing opposite button on a second
control panel when thruster is operating
will cancel operation of thruster (Fig
3.2.4).
Fig. 3.2.4
• Additional controller
Operating same direction button when
still in operation on other control panel
will hane no effect(Fig 3.2.5).
Fig. 3.2.5
Fig. 3.2.3
• To cancel either thruster direction stop
pressing button or return joystick to
central position (Fig 3.2.3).
DO NOT press both buttons at the
same time.

17
Electric/Hydraulic TT Thruster 140 - 300
GB
4. Servicing your thruster
4.1 Service schedule
NOTE: Thrusters are more likely to attract ‘debris’, so it
is necessary to regularly check the tunnel.
New install:
• The anode should be checked after approximately 3 - 4 months
to gauge an appropriate replacement schedule. .
At the annual boat service:
• Remove any debris from tunnel, propeller and hub.
• Replace the anode.
• If the propeller 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 and clean out thruster compartment.
• Apply grease to exposed thruster seal and shaft.
• If hub is removed the tunnel gasket must be replaced.
Electric:
• Inspect electric motor, ensure all leads are still tight.
• Brush out carbon dust from top of electric motor especially
on aluminium boats. Recommend qualified electrician.
Hydraulic:
NOTE: Refer to hydraulic system
supplier for service requirements.
4.2 Changing drive pin 140TT or 185TT
• Cut cable tie on shaft - (If Fitted)
Fig. 4.2.1
Fig.4.2.2
Fig. 4.2.3
• Punch out pin parts.
• Tap in new pin and secure with new plastic cable tie.
ehtevomerroffosihctiwsyrettabkcehctinunognikrowerofeB
fuse.

18 Electric/Hydraulic TT Thruster 140 - 300
5. Weight & specifications
5.1 Electric
5.2 Hydraulic Model kW hp Tunnel (mm) Propeller/s Thrust Weight
kgf lbs kg lbs
185TTH 7 10 185 Single 5 Blade 100 220 8 17.5
250TTH 15 20 250 Twin CR 5 Blade 200 240 13 28.5
300TTH 22.5 30 300 Twin CR 5 Blade 300 660 17 37.5
Part Number Model Voltage
V
Power Gearbox Mtl Tunnel
(mm) Propeller Thrust Weight
kW hp kgf lbs kg lbs
591402 140TT 2.0 12 2.0 2.7 Bronze 140 Single 5 Blade 37 81 13 29
591401 140TT 2.2 12 2.2 3.0 Bronze 140 Single 5 Blade 42 92 13 29
591801 185TT 3.0 12 3.0 4.0 Bronze 185 Single 5 Blade 58 128 20 43
591802 185TT 3.0 24 3.0 4.0 Bronze 185 Single 5 Blade 58 128 20 43
591807 185TT 4.0 12 4.0 5.4 Bronze 185 Single 5 Blade 65 143 20 43
591808 185TT 4.0 24 4.0 5.4 Bronze 185 Single 5 Blade 65 143 20 43
591803 185TT 5.0 12 5.0 6.7 Bronze 185 Single 5 Blade 82 180 27 59
591804 185TT 5.0 24 5.0 6.7 Bronze 185 Single 5 Blade 82 180 27 59
591805 185TT 6.0 12 6.0 8.0 Bronze 185 Single 5 Blade 97 213 27 59
591806 185TT 6.0 24 6.0 8.0 Bronze 185 Single 5 Blade 97 213 27 59
591833 185TT 5.0 12 IP 5.0 6.7 Bronze 185 Single 5 Blade 82 180 27 59
591834 185TT 5.0 24 IP 5.0 6.7 Bronze 185 Single 5 Blade 82 180 27 59
591836 185TT 6.0 24 IP 6.0 8.0 Bronze 185 Single 5 Blade 97 213 27 59
592501 250TT 8.0 24 8.0 10.8 Bronze 250 Twin CR 5 Blade 140 308 46 102
592502 250TT 9.6 48 9.6 13.0 Bronze 250 Twin CR 5 Blade 170 374 50 110
592503 250TT 8.0 24 8.0 10.8 Aluminium 250 Twin CR 5 Blade 140 308 46 102
593001 300TT 10.8 24 10.8 14.5 Bronze 300 Twin CR 5 Blade 250 550 65 143
593002 300TT 15.0 48 15.0 20.0 Bronze 300 Twin CR 5 Blade 280 616 68 150
593003 300TT 10.8 24 10.8 14.5 Aluminium 300 Twin CR 5 Blade 250 550 65 143
Part Number Model Voltage
V
Fuse Holder
Std - 589006 T2 - 589013
591402 140TT 2.0 12
591401 140TT 2.2 12
591801 185TT 3.0 12
591802 185TT 3.0 24
591807 185TT 4.0 12
591808 185TT 4.0 24
591803 185TT 5.0 12
591804 185TT 5.0 24
591805 185TT 6.0 12
591806 185TT 6.0 24
591833 185TT 5.0 12 IP
591834 185TT 5.0 24 IP
591836 185TT 6.0 24 IP
592501 250TT 8.0 24
592502 250TT 9.6 48
592503 250TT 8.0 24
593001 300TT 10.8 24
593002 300TT 15.0 48
593003 300TT 10.8 24
200
200
250
130
400
130
400
130
500
325
400
130
325
400
250
400
500
400
400
Fuse
(A)
Fuse
Part Number
589012
589012
589008
589007
589010
589007
589010
589007
589011
589009
589010
589007
589009
589010
589008
589010
589011
589010
589010

19
Electric/Hydraulic TT Thruster 140 - 300
GB
1
9
9
4
5
6
8
7
3
2
10
6. Parts list
Item Part No. Description
1 581027 Motor Assembly
2 553034 Cover
3B11126 Solenoid
559039 Solenoid Loom
4 551052 Mounting Saddle
5 551035 Tunnel gasket
6 581001 Hub assembly
7 589151 Propeller
8 589150 Propeller anode kit
9 589152 Installation fixing kit
10 559018 Drive pin
Item Part No. Description
1 581026 Motor Assembly
2 553034 Cover
3B11126 Solenoid
559003 Black Box
4 551052 Mounting Saddle
5 551035 Tunnel Gasket
6 581001 Hub Assembly
7 589151 Propeller
8 589150 Propeller Anode Kit
9 589152 Installation Fixings Kit
10 559018 Drive pin
6.1 Model 140TT 2.0 kW 12 V 6.2 Model 140TT 2.2 kW 12 V

20 Electric/Hydraulic TT Thruster 140 - 300
10
1
12
5
6
9
8
4
3
2
7
11
12
13
Item Part No. Description kW Volts
1
583026 Motor Assembly 3.0 12
583027 Motor Assembly 3.0 24
583032 Motor Assembly 4.0 12
583033 Motor Assembly 4.0 24
583028 Motor Assembly 5.0 12
583029 Motor Assembly 5.0 24
583030 Motor Assembly 6.0 12
583031 Motor Assembly 6.0 24
6.3 Model 185TT/H 3.0 to
6.0 kW 12 & 24 V
Item Part No. Description kW Volts
2
553034 Cover 3.0 12-24
553036 Cover 4.0/5.0 12-24
555034 Cover 6.0 12
3559003 Black Box All All
559020 Black Box 6.0 12
4
B11126 Solenoid 3.0 12
B11127 Solenoid 3.0 24
B11128 Solenoid 4.0/5.0 12
B11129 Solenoid 4.0/5.0/6.0 24
B11130 Solenoid 6.0 12
5 553071 Mounting Saddle All All
6 553035 Tunnel Gasket All All
7583001 Hub - 2.2 Ratio 3.0 12-24
583003 Hub - 1.5 Ratio 4.0-6.0 12-24
8 589351 Propeller All All
9 589350 Anode Kit All All
10 559017 Drive pin All All
11 589352 Installation Fixings Kit 3.0 12.24
589355 Installation Fixings Kit 4.0-6.0 12-24
Hydraulic Only
12 583040 Hydraulic Motor Assembly 5.0 cc/rev
583041 Hydraulic Motor Assembly 6.0 cc/rev
13 589352 Installation Fixings Kit All All