Lewmar TT Series Quick start guide

TT Electric Thruster
110-140TT 2.0
Owner’s Installations, Operation & servicing manual

2
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 qualifi ed 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 thrusters must be located in a dry environment.
 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.
 WARNING!
2- Safety Notice
1- Introduction
Dear Customer,
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.
GB

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 3
 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 fittted.
 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.
3- Installation
The actual position of the Thruster will depend on the internal & external construction of the Motor Boat or Sail-
ing Yacht. For optimal performance the Thruster should be mounted within the following:
 As far forward as possible (Fig 3.1.1 / lever effect).
 1 x Ø below the waterline to prevent air being sucked into the tunnel. (Fig. 3.1.2 / 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 = Tunnel Diameter
3.1 Choosing the location
 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.
To the best of our knowledge, the information in this manual was correct when it went to press. However, Lew-
mar 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.
Ø
Optimum area
Min 100mm (4”)
Min 0.75 x Ø
Fig 3.1.1 Fig 3.1.2

4
GB
3.2 Preparing the hole for the tube
TT Thruster can be fitted new or as a replacement for
an existing thruster. Tunnel dimensions listed on the
following table.
NOTE: Check mounting holes on the saw template
 The recommended tunnel is designed to fit a
Lewmar saddle, take the weight of the Thruster
and the torque of the motor.
 Fig 3.1.3 - 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. Fig 3.1.3
Fig 3.2.1
Fig 3.2.3
Fig 3.2.2
When you are satisfied the best location for the
Thruster unit has been found within the parameters
available proceed as follows.
 Fig 3.2.1 - 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.
 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.
THRUSTER MODEL
(kW)
INSIDE DIAMETER WALL THICKNESS
mm inch mm inch
110 (1.5) 110 4 ⁵/₁₆ 5.0 ³/₁₆
140 (2.0) 140 5 ½ 4.0-5.0 ⁵/₃₂ - ³/₁₆
 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.
r = 0.1 Ø

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 5
3.3 Preparing for fitting the thruster
Fig 3.3.1
Fig 3.3.2
Fig 3.3.3 Fig 3.3.4
The Thruster can be installed at any angle within 90°
from vertical.
 Choose position of thruster, ensuring internal room for motor and controls and that the propeller is easily
reached from outside.
NOTE: Fig 3.3.2. - Normal install is to Port
 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.
 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.
 Electric motors must be supported if installed
more than 30° from vertical (Fig 3.3.1).
600 mm
(24”) Max

6
3.5 Propeller assembly
GB
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.
 Check the hub gasket is in place.
 Fig 3.5.1 - Assemble propeller as shown: nyloc nut
onto propeller shaft.
Note: Tighten each bolt alternately a number of
times to full torque.
NOTE: Poor exterior tunnel surface could cause
leakage and noise. Apply sealant to this area as
required (Fig. 3.4.2).
 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. 3.4.2).
NOTE: Tighten to full torque within 10 minutes.
3.4 Installing hub unit and saddle
 Check the propeller has been assembled in the
correct order.
Fig 3.5.2 - Tighten hub/saddle bolts to
 5 Nm (3.7 lbs.) for 110
 9 Nm (6.6 lbs.ft) for 140
Check that propeller is centred and free turning
(within 10 minutes of applying Blue Loctite® 243).
 Antifoul propeller if desired.
DO NOT allow propeller to touch tunnel.
110TT140TT
Fig 3.4.1 Fig 3.4.2
Fig 3.5.2
Fig 3.5.1
Fig 3.5.3

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 7
Tighten propeller nut to
 6Nm (4.4 lbs.ft) for 110
 10 Nm (7.4 lbs.ft) for 140
A length of wood placed between propeller blade and
tunnel will stop movement.
DO NOT overtighten propeller nuts.
DO NOT REMOVE the drive pin plastic retainer
tie on the motor drive shaft.
3.6 Electric motor unit support
3.7 Installing electric motor unit
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.
 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) . Apply Blue Loctite® 243 to
all bolts.
Illustrations based on 140TT saddle.
 Align motor drive pin inline with slot in shaft.
Apply grease to hub shaft.
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
 Saddle and motor are firmly seated on the tube.
3.8 Final checks
Fig 3.5.4
Fig 3.7.1 Fig 3.7.2
Fig 3.6

8
Thermal
Switch
FUSE
BATTERY
SWITCH
BATTERY
Motor
CONTROL BOX
COVER
REMOVED
+VE
Red
Fuse 3 A
5 x 20 mm
Grey
Black
Black
To Controls
Blue
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.
GB
 To satisfy International standards, a suitably sized battery switch
should be fitted to the thruster +VE supply. It should be switched
off whilst the thruster is not in use or the boat is unoccupied.
Lewmar recommend this as best practice for safe installations.
4- Electrical wiring installation
4.1 Typical electrical layout
LOOM WIRING
Red +VE
Blue Thrust port switch
Grey Thrust starboard switch
Black -VE
Positive Switching
Fuse Torgue settings
8mm: 12.5 Nm (9.2lbf) 12mm:
21.5 Nm (15.9lbf)

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 9
 Terminals must be correctly clamped to motor
studs. Use a pair of spanners - the one nearest
motor to stop rotation of the stud.
 Spanner size is 13 mm. Tighten the bolts to 20 Nm
(15 lbs.ft).
 Battery crank capacity should be at least 1.5 times the thruster current.
 Main power cables should be run from the batteries and must have an inline fuse fitted.
NOTE: Cable length is total from battery to thruster and back.
 The cables should be terminated with a ring terminal corresponding to the motor studs, 8 mm (5/16”).
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 units.
 Ensure the insulating boots, supplied with the unit, are correctly fitted.
4.2 Electric motor terminal connections
4.3 Battery cable connections
4.4 Recommended cable sizes
DO NOT overtighten electric motor
terminal nuts.
TT Model Current
(A) Max cable length (meters) Cable size (mm C.S.A)
110 1.5 kW-12V 215 12 50
140 2.0 kW-12 V 270 14 70
Fig 4.2
 Correct installation. Supplied cable boots are used
and no bare wires exposed (Fig 4.3.1).
 Live wire exposed! (Fig. 4.3.2). Correct the cable
installation to match (Fig 4.3.1).
 Terminal or motor is damaged. Contact Lewmar
Limited (Fig 4.3.3).
 Crimp inverted and is touching motor! (Fig 4.3.4).
Correct the cable installation to match as (Fig 4.3.1).
NOTE: If very large cables are used discard sup-
plied boots and fit appropriate sized ones.
 Incorrect installation of battery cables or dam-
age to connection studs may result in a short to
the thruster body. Use the examples opposite to
check for a correct installation on both +V and -V
battery connections.
Boot
Fig 4.3.1
Boot
Fig 4.3.2
Boot
Fig 4.3.3
Boot
Fig 4.3.4

10
Test 1. Fig.4.5.1
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 at-
tached to the assembly and check as before.
Test 2. Fig 4.5.2
With the batter y 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.
4.5 Electrolytic test
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.
ΩΩ
V
 Refer to the cutting template opposite, use a
50mm (2”) hole saw and a 3mm drill for mounting
screws
 Mount on a clean flat surface
 Connect panel wiring loom to the plug and play
thruster control loom
4.6 Installing control panel
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.
Operation of electrical unit
 Ensure batteries are fully charged before switching
on the main power.
 Before operating the thruster, check that the water
is free from swimmers, divers or debris and make
sure you are not close to other vessels.
4.7 Final checks
Check the power is OFF  The thruster must not be operated unless it is
in water.
Fig 4.5.1
Fig 4.5.2
Fig 4.6
50mm (2”)
53mm (2 ¹/₁₆”)
53mm (2 ¹/₁₆”)
GB

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 11
 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.
5- Operating your thruster
The thruster can be operated using the Lewmar simple
joystick (Part No. 589094) or any water proof momen-
tary two direction switch with a 5 amp rating.
 Switch ON the battery switch.
 To turn on the panel, press and release the ON/OFF
button (fig.5.1). This will cause the LED to illuminate
indicating the panel is ON
 Move the joystick in the desired direction to operate
the Thruster (fig.5.2)
 To turn off the panel, press and release the ON/OFF
button. This will cause the LED to turn off indicating
the panel is off.
DO NOT frequently move port to starboard on
the joystick in quick succession as this could
damage the electric motor.
Fig 5.1
Fig 5.2

12
6- Servicing your thruster
7- Specifications
At the annual boat service:
 Remove any debris from tunnel, propeller and hub.
 If the propeller is damaged or heavily contaminated,
replace it, best to be safe.
 Apply grease to exposed thruster seal and shaft.
 If hub is removed the tunnel gasket must be
replaced.
 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.
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.
 Propeller: Single 5 blade
 Suitable fuse holder:
Standard - 589006 or T2- 589013
Thrusters are more likely to attract ‘debris’, so it is necessary to regularly check the tunnel.
6.1 Service schedule
6.2 Changing drive pin
Cut cable tie on sha (if fitted) Tap in new pin and secure with new
plastic cable tie
Punch out pin parts
PART NO MODEL VOLTAGE POWER GEARBOX
MATERIAL
TUNNEL THRUST WEIGHT FUSE
V kW hp (mm) kgf lbs Kg lbs
591101 110TT1.5 12 1.5 2.0 Composite 110 28 62 10 22 200A- 589012
591482 140TT2.0 12 2.0 2.7 Composite 140 37 81 13 29 200A- 589012
Fig 6.2.1 Fig 6.2.2 Fig 6.2.3
GB

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 13
ITEM PART NO
110TT
PART NO
140TT2.0 DESCRIPTION
1 582003 581029 Motor Assembly
2 553034 553034 Cover
3B12526 B12526 Solenoid
559070 559070 Solenoid loom
4 552004 551052 Mounting Saddle
5 552005 551035 Tunnel gasket
6 582001 581001 Hub assembly
7 589451 589151 Propeller and washer
8 589453 589150 Propeller fixing kit
9 589452 589152 Installation fixing kit
10 559107 559018 Drive pin
ITEM PART NO DESCRIPTION
1 589094 Joystick
2589021 2m Control cable & Connectors
589016 7m Control cable & Connectors
589017 10m Control cable & Connectors
589018 14m Control cable & Connectors
589019 18m Control cable & Connectors
3 589206 Y connector for dual controls
4 589006 Fuse Holder
5 589013 T2 Fuse Holder
6 589012 200A ANL Type Fuse
7 589096 Motor Support Bracket kit
8- Parts list
1
9
4
5
6
8
7
3
2
10
9
1
3
2
10
9
9
4
5
6
7
8
1
4
5
3
2
6 7
110TT Exploded view
140TT2.0 Exploded view
Accessories

14
GB
9- Dimensions
10- Fault finding
Thrust in wrong direction? Change contactor wires on motor solenoid (See section 4.1).
Fuse keeps blowing?  Wrong fuse fitted - check rating and replace.
 Propeller restricted or jammed causing excessive load on
motor - check and clear. Check that propeller washer is fitted
see Section 3.5.
Control panel does not illuminate? Check
 Battery is connected.
 Main switch ON, check fuse.
 Control loom connections.
 Long operation has tripped thermal switch. Wait 20 minutes
for motor to cool and reset.
 DO NOT attempt to cool motor by any other means.
Control panel illuminates but no thrust?  Are batteries charged?
 Check main motor connections are tight.
Poor thrust or thrust in one direction only?  Batteries not large enough or charged, cables not
recommended size.Voltage at motor when running should be a
minimum 10 V for 12 V and 21 V for 24 V units.
 Blockage in tunnel/propeller jammed with debris, switch off
main power, inspect and clear.
 Propeller washers fitted wrong. See Section 3.5
 Check motor brush springs are located properly, brushes
should have good contact with the commutator.
Motor turns but no drive?  DO NOT continue to run thruster.
 Shear pin broken, remove 4 motor bolts, see Sec. 6.2, drive out
old pin and replace with new pin.
 Propeller blades broken. Replace with new.
Thruster noisy and vibrating?  Check propeller is not touching the tunnel wall.
 Check hub height is correct, see section 9.
A
B
C
D
MODEL A B C D
110TT 123 4  261 10 ¼ 110 4 ⅓ 67 2 ⅝
140TT2.0 123 4  305 12 140 5 ½ 73 2 ⅞
Illustration based on
the 140TT2.0 model

Lewmar Thruster 110TT and 140TT 2.0 Manual ref B10417 iss.2 | 15
11- Warranty
Lewmar warrants that in normal private pleasure boat
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 fail-
ure, or any resulting loss or damage that 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 accor-
dance 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.
g. Abuse
iv Product subject to a warranty claim must be returned
to the Lewmar outlet that supplied the product for
examination unless otherwise approved by Lewmar in
writing.
v This warranty does not cover any incidental costs
incurred for the investigation, removal, carriage, trans-
port or installation of product.
vi Service by anyone other than authorized Lewmar rep-
resentatives shall void this warranty unless it accords
with Lewmar guidelines and standards of workman-
ship.
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 profes-
sional 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
• Hatch & Portlight weather seals
• Products used in “Grand Prix” racing applications
• Products used in commercial or charter applications
• Anchor rodes
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 fit-
ness 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 lim-
ited to a period of one year from the date of purchase
by the end user. Some states and countries do not al-
low 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 that supplied the product or to Lewmar
Limited at Southmoor Lane, Havant, Hampshire PO9
1JJ, England.
E SEVERANCE CLAUSE
If any clause of this warranty is held by any court or
other competent authority to be invalid or unenforce-
able 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 ap-
plicable 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 accor-
dance 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 Ma-
rine House, Thorpe Lea Road, Egham, England, TW20
8BF
Limited Warranty and Key Terms of Supply by Lewmar

© Copyright 2018 Lewmar Ltd. All rights reserved.
www.lewmar.com
B10417 iss.2
UK & International Distribution
Lewmar / Navtec
Southmoor Lane
Havant
Hampshire
PO9 1JJ
England
Tel: [phone]
Fax: [phone]
Email: [e-mail]
USA
Lewmar / Navtec
351 New Whitfield Street
Guilford, CT
06437
USA
Tel: [phone]
Fax: [phone]
Email: [email protected]