1. Introduction
This manual provides comprehensive instructions for the installation and maintenance of the Lewmar 559003 Black Box Thruster Controller Upgrade Kit. This kit is designed to facilitate the replacement of previous generation thruster controllers with newer models, ensuring compatibility and seamless integration within your marine thruster system.
The Lewmar 559003 Black Box is engineered for easy fitting, allowing the use of existing boat wiring in many cases, and is built to comply with strict industry standards for superior quality and reliability.
2. Safety Information
Always prioritize safety during installation and maintenance. Failure to follow these instructions could result in damage to the product, vessel, or personal injury.
- Ensure the vessel's power supply is disconnected before beginning any electrical work.
- Consult a qualified marine electrician if you are unsure about any part of the installation process.
- Wear appropriate personal protective equipment (PPE) such as gloves and eye protection.
- Verify all connections are secure and properly insulated to prevent short circuits and corrosion.
- Keep the installation area clean and free of obstructions.
3. Package Contents
The Lewmar 559003 Black Box Thruster Controller Upgrade Kit includes the following components:
- Lewmar 559003 Black Box unit with integrated wiring harness and connectors.
Figure 1: The Lewmar 559003 Black Box unit. This image displays the compact rectangular black box, approximately 2 inches by 1 inch, connected to a network of multi-colored wires (red, black, blue, purple) and various white plastic connectors. A metal ring terminal is visible at one end of the wiring harness, and a yellow crimp connector is at another, indicating connections for power and control signals.
4. Installation
The Lewmar 559003 Black Box is designed as an upgrade kit for replacing previous generation thruster controllers. It needs to be installed next to the existing controller location.
4.1. Pre-Installation Checks
- Confirm the vessel's power is off at the main breaker.
- Identify the location of the previous generation thruster controller.
- Ensure sufficient space is available for mounting the new Black Box unit next to the controller.
- Inspect existing wiring for any signs of damage or corrosion.
4.2. Wiring Connection
- Carefully disconnect the wiring from the previous generation thruster controller, noting each connection.
- Connect the Lewmar 559003 Black Box wiring harness to the appropriate terminals on the new thruster controller. The kit is designed for easy fitting, and existing boat wiring can often be reused.
- Ensure all connections are firm and correctly seated. Refer to the specific wiring diagram provided with your new thruster controller for precise connection points.
- Secure any loose wiring to prevent strain or abrasion.
4.3. Mounting
Mount the Lewmar 559003 Black Box securely next to the thruster controller using appropriate fasteners (not included, as mounting surfaces vary). Ensure the unit is protected from excessive moisture and physical damage.
5. Operation
The Lewmar 559003 Black Box functions as an interface or upgrade component for your thruster controller. It does not have user-operable controls itself. Once installed, the thruster system will operate as normal via your vessel's thruster control panel, now utilizing the upgraded controller facilitated by the Black Box.
Refer to the instruction manual for your specific thruster control panel for operational details.
6. Maintenance
The Lewmar 559003 Black Box is designed for minimal maintenance. Regular inspection is recommended to ensure optimal performance and longevity.
- Annual Inspection: Annually inspect all wiring and connections for signs of corrosion, wear, or damage.
- Cleaning: Keep the unit and surrounding area clean and dry. Use a soft, dry cloth to wipe down the exterior. Avoid using harsh chemicals or abrasive cleaners.
- Connection Integrity: Periodically check that all electrical connections remain tight and secure.
7. Troubleshooting
If you experience issues with your thruster system after installing the Lewmar 559003 Black Box, consider the following troubleshooting steps:
- No Power to Thruster:
- Check the main power supply to the thruster system and ensure all breakers are engaged.
- Verify all connections to the Black Box and thruster controller are secure and free from corrosion.
- Erratic Thruster Operation:
- Ensure all wiring connections are correct according to the thruster controller's manual.
- Inspect for any loose or damaged wires that could cause intermittent signals.
- System Not Responding:
- Confirm the Black Box is properly installed next to the controller as specified.
- If issues persist, contact Lewmar customer support or a qualified marine technician.
8. Specifications
| Manufacturer | Lewmar |
| Brand | Lewmar |
| Model | 559003: Black Box |
| Item Model Number | 559003 |
| Manufacturer Part Number | 559003 |
| Item Weight | 5.1 ounces |
| Package Dimensions | 5.51 x 5.28 x 1.5 inches |
| ASIN | B0BCKZKSNT |
| Date First Available | August 31, 2022 |
9. Warranty and Support
For warranty information, technical support, or service inquiries regarding your Lewmar 559003 Black Box, please contact Lewmar customer service directly. Details can typically be found on the official Lewmar website or through your authorized Lewmar dealer.
When contacting support, please have your product model number (559003) and any relevant purchase information available.
