Lewmar Swing Thruster — Product & Installation Manual

Before You Install

• The thruster must not be used at speeds above 6 knots, and must be retracted at that speed. Use it as a mooring aid only, and never close to swimmers.
• Install it so the hatch opens towards the normal water flow direction; otherwise the hatch, leg and actuator are overstressed.
• Never power the motor flange via the actuator without the motor bolted in place – the flange will crack.
• Limits of travel: when deploying, the actuator must reach its own internal "minimum extension" microswitch; when retracting, the electronics sense the current spike as the lid meets the hull and cut power.
• When deployed, the leg must not hit the edge of the hull – file the hull away for clearance if it does.
• Never cut the original cables or join them with anything other than the original plugs and sockets.
• Always fit a circuit breaker/isolator and switch the thruster off there when not in use. The manual is based on a GRP hull; for other hull materials consult an expert.

Hull Opening, Box and Hatch

Kit contents

*Not for model 250.

Hatch outline and dimension A

• Place the thruster as far forward as possible without the top of the box coming above the waterline. Drill a 3 mm reference hole from inside, as close as possible to the centre line, and mark the hatch outline around it on the outside.
• The mould is not included – it must be made on site to fit the shape of your hull.
• Cut the hole with a jigsaw at an angle of 40° to the hull.
• Fit the box with its inside aft edge a maximum of the flange width (10 mm) aft of the hole; trim the box so dimension A matches the table. Sand the outside of the box about 10 cm all round for adhesion; check the box sides are not concave (strut them out while glassing if they are).
• Hatch: the forward edge must sit at least 1 mm proud of the hull; the after edge and sides flush. The hatch must be no thicker than 5–7 mm where the tunnel ends bear on it. Do not apply final laminations until the hatch is fitted and clears the hull.
• Lamination: not less than 6 layers, tapered, starting with 1 × 300 gm mat then 5 × 600 gm. On the sides and rear, at least 100 mm up the box and over the coach bolt heads; on the front, up to just below the hinge.
• Brace: a stainless square washer is glassed in as the stop. Retract, check the hatch lies against the lip, then tighten the screw until its head touches the washer and lock the nut. On the model 250 the lip must be moulded by the installer/boatbuilder.
• Motor: check the shear pin on the motor enters the channel in the shaft (turn the motor slowly back and forth), then fit the bolts and washers.
• Flange-base version (for builders fitting in the same location repeatedly): a custom box bonded into a moulded hull recess, supplied complete with the hatch pre-fitted – contact Lewmar.

Electrics and Adjustment

• The panel must be installed in a dry location – its rear is not watertight.
• Electronics supply: Red +12/24V, Blue GND – connect direct to the battery via a 10A fuse, not to the motor power supply. Pink and Grey are not in use.
• Windlass control (only with the wireless remote option): White common plus, Brown and Yellow up/down.
• Dual system: to combine an existing Lewmar tunnel thruster with the Swing Thruster, remove the tunnel thruster's black box and install conversion box 58991011 in its place; the RMC joystick must then be used, as existing Lewmar controls are not compatible.
• If the boat moves the wrong way, swap the green and brown cables on the electric motor.

Adjustment (3.11)

• Tunnel height when deployed: slacken nut (1) on the forward edge of the fitting and tighten nyloc nut (2) on the after edge until the flow through the tunnel is clear of the hull; re-tighten nut (1).
• Move bracket (3) so side support bolt (4) is centred on its surface with the thruster fully deployed.
• Set bolt (4) for a 0.5–1mm gap to the side support bracket; the bolts must not press on the brackets when the thruster is not running.

Operation and Panel Settings

• Deploy: hold the on/off button for about two seconds; the green LED flashes, then shines steadily when ready. Hold on/off again to retract.
• Auto-retract (2 or 5 minutes after the last button press): with the panel off, press PT (or joystick to port) – 1 buzz = off, 2 buzzes = 2 minutes, 3 buzzes = 5 minutes.
• Deployed alarm interval: with the panel off, press SB (or joystick to starboard) – 1 buzz = 5 s, 2 buzzes = 15 s, 3 buzzes = 60 s.
• Overheating: a thermal switch cuts the motor and the green LED flashes rapidly; it resets automatically once cool. The thruster can still be retracted with on/off.
• Extra panels can be installed in parallel; both indicate alike. Accessories: wireless remote (needs an extra circuit board in the electronics box), joystick and lit foot switch (plug into the rear of the panel), and a water detector fitted just forward of the box that sounds a steady alarm on a leak.
• System voltage: 12/24 V. Control system fuse: 5 A.

List of Parts