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INSTALLATION MANUAL

Drive selection data, mounting, draglink and tiller-lever geometry, course-computer wiring, post-installation checks and maintenance for the Lewmar Direct Drive autopilot drives (89300037 to 89300050) on boats with mechanical steering.

DocumentLewmar Direct Drive Autopilot Drive Installation Guide
FormatPDF · 32 pages · 0.3 MB
LanguageEnglish
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Lewmar Direct Drive Autopilot Drive — Installation Guide

Drive Specifications

Part No. Description Tiller lever length HP Volts No load speed (RPM, as printed "RMP") Max rudder torque ft lbs Max rudder torque MKG Average current Breaker motor Breaker clutch Weight kg / lb Guide to boat size
89300037 Direct 1/8hp 12v DL 166mm OL 10" 1/8 12 10 988 138 4A 16A 1.5A 8 / 17.6 Up to 11.6m (38')
89300038 Direct 1/8hp 12v DL 134mm OL 8" 1/8 12 10 988 138 4A 16A 1.5A 8 / 17.6 Up to 11.6m (38')
89300039 → Direct 1/4hp 12v DL 166mm OL 10" 1/4 12 10 1794 248 4A 16A 3A 9 / 19.8 Up to 16.75m (60')
89300040 → Direct 1/4hp 12v DL 134mm OL 8" 1/4 12 10 1794 248 4A 16A 3A 9 / 19.8 Up to 16.75m (60')
89300041 Direct 1/4hp 24v DL 166mm OL 10" 1/4 24 10 1794 248 2.5A 10A 2A 9 / 19.8 Up to 16.75m (60')
89300042 Direct 1/4hp 24v DL 134mm OL 8" 1/4 24 10 1794 248 4A (as printed) 10A 2A 9 / 19.8 Up to 16.75m (60')
89300043 Direct 1/4hp 2412v DL 166mm OL 10" 1/4 24/12 10 1794 248 2.5/4A 10A 3A 9 / 19.8 Up to 16.75m (60')
89300044 Direct 1/4hp 2412v DL 134mm OL 8" 1/4 24/12 10 1794 248 2.5/4A 10A 3A 9 / 19.8 Up to 16.75m (60')
89300045 Direct 1/2hp 24v DL 166mm OL 10" 1/2 24 10 3080 426 3.5A 16A 2A 10.5 / 23.1 Up to 24.4m (80')
89300046 Direct 1/2hp 24v DL 134mm OL 8" 1/2 24 10 3080 426 3.5A 16A 2A 10.5 / 23.1 Up to 24.4m (80')
89300047 Direct 1/2hp 2412v DL 166mm OL 10" 1/2 24/12 12 3080 426 3.5A 16A 3A 10.5 / 23.1 Up to 24.4m (80')
89300048 Direct 1/2hp 2412v DL 134mm OL 8" 1/2 24/12 12 3080 426 3.5A 16A 3A 10.5 / 23.1 Up to 24.4m (80')
89300049 Direct 1/2hp 24v DL 1/2 24 17 3080 426 3.5A 16A 2A 10.5 / 23.1 Up to 24.4m (80')
89300050 Direct 1/2hp 2412v DL 1/2 24/12 17 3080 426 3.5A 16A 3A 10.5 / 23.1 Up to 24.4m (80')

"DL" = draglink, "OL" = output lever (166 mm or 134 mm centres). The Maximum Output Torque columns are blank in the manual. 89300049 and 89300050 are listed without an output lever length.

Lewmar Direct Drive main parts: motor cable, clutch cable, gearbox and clutch, output lever, mounting holes

Preparation

  • In the box: Direct Drive, draglink, M8 securing bolts with washers and lock-nuts.
  • You also need a secondary tiller lever and lever pins: get them before you start.
  • The drive is not waterproof: mount it in a dry place clear of bilge water, accessible for service.
  • It produces considerable force: mount it on a substantial frame member (build a frame if needed), never on structure that supports cabins (noise and vibration).
  • It can be mounted in any attitude on a vertical or horizontal surface, facing either way; steering direction is corrected by reversing the motor polarity at the course computer.
  • Keep the drive and its cables at least 3ft (1m) from VHF equipment and cables, 7ft (2m) from SSB.

Mounting and Geometry

  • Fix the drive with M8 bolts, washers and lock-nuts; connect the draglink to the drive and to the tiller lever or quadrant.
  • The gearbox can be mounted flat or inverted, from 200mm to 2000mm from the rudderstock.
  • Figure A (Cobra or Mamba, extended primary tiller lever): work to the offset of 128mm ± 5mm; keep the drive body parallel to the tiller lever axis.
  • Figure B (independent secondary tiller): any angle and distance round the stock, drive parallel to the tiller lever; set the offset angle from distance L (table).
  • Figure C (under deck, linked to the Cobra pedestal output lever): use the shorter 134mm output lever for 1:1 geometry.
  • Figure D: as Figure A, but on a tiller quadrant.
  • The tiller lever must move 36° port and starboard.
(L) Distance between Direct Drive centre and rudder stock Offset angle Ø
200 – 225 25°
226 – 250 23°
251 – 300 20°
301 – 350 17°
351 – 400 14°
401 – 500 12°
501 – 750 10°
751 – 1000 8°
1000+ 5°

Connecting to the Course Computer

  • Switch the power off before making any connection.
  • Drive motor: two single-core black cables, twisted as a pair in sleeving. Clutch: two-core cable, brown (+) and blue (-).
  • Measure the total cable run to the course computer and size the motor cable from the table below; use at least 1.5mm2 (14 AWG) copper for the clutch.
  • Join with connectors or junction boxes of the correct rating, route following the EMC guidelines, then connect: clutch brown to +ve, blue to -ve; either motor core to either motor terminal (reverse later if the rudder moves the wrong way).

Post-Installation Checks

  • Drive secured to a substantial structure?
  • Tiller lever moves 36° port and starboard?
  • Most suitable drive output lever used?
  • Motor and clutch cables correctly routed and secure at the course computer?

Maintenance

  • Regularly check that all connections and mountings are secure.
  • Check the draglink connections.
  • Check the cables for wear or damage.

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