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.