Lewmar 34-77 User Manual

GB

www.lewmar. com

Contents

GB

B2303 Issue 6. Ocean electric winches models 34-77. For sizes over 77 please contact Lewmar for details.

Introduction		4
	Product support	4
	Important information about this manual	4
	EMC Recommended guidelines	4
	CE Approvals	4

Safety notices		4
	General	4
	Fitting	4
	Electrical	4

1. Installation			5
1.1		Identifying manual convertible winch	5
1.2		Preparing manual winch for conversion	5
1.3		Fitting a complete electric winch from new	5
1.4		Positioning winch above deck	5
1.5		Positioning winch ancillaries below deck	6
1.6		Fitting a convertible electric winch 34-65	6
1.7		Fitting a convertible electric winch 66 -77	8
1.8		Fastenings	8
1.9		Winch motor gearbox couplings	8

2.	Electrical wiring installation		9
	2.1	Typical electrical layout	9
	2.2	Correct main spindle rotation	9
3.	Electrical connections		10
	3.1	E Series Electric 34-48	10
	3.2	ELS Electric Load Sensing 34-48	10
	3.3	ELS Electric Load Sensing 50-65	11
	3.4	ELS Electric Load Sensing 2/3 speed 66-77	11
	3.5	EVC Electric Variable Control 34-48	12
	3.6	EVC Electric Variable Control 50-65	12
	3.7	NEW Electric deck switch	13

4.	Performance diagrams	13
5.	Safe working loads	14
	5.1 Optimum rope diameters	14
	5.2 Maximum winch load values	14
6.	Operating your winch	14
7.	Servicing your winch	15
8.	Parts list	16
	8.1 Winch notes	16
	8.2 Models 34-65	16
	8.3 Models 66-77	17
9.	Dimensions	18
10. Total weight		19
11. Electric convertible model range		19
	11.1 Winches 34-77	19/20
	11.2 Circuit breakers	20
	11.3 NEW Electric deck switch	20
12. Fault Þnding		21
13. Lewmar limited warranty		22

Ocean Electric Winches 34 - 77

3

Introduction

Dear Customer,

Thank you for choosing Lewmar Electric Ocean Winches. Lewmar products are world renowned for their quality, technical innovation and proven performance. With a Lewmar winch you will be provided with many years of outstanding service. We wish you happy sailing.

Product support

Lewmar products are supported by a worldwide network of distributors and Authorised Service Representatives. If you encounter any difÞculties with this product, please contact your national distributor, or your local Lewmar dealer. Details are available at:

www.lewmar.com

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:

Warning!

This is a warning against anything which may cause injury to people 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”.

Approvals

For CE approval certiÞcates contact Lewmar.

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 winch is fitted.

Safety notices

General

Please ensure that you thoroughly understand the operation and safety requirements of the winch 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 winch 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 qualiÞed engineer.

¥Winches used incorrectly could cause harm to equipment or crew

¥Winches should be used with care and treated with respect.

¥Sailing, like many other sports can be hazardous. Even the correct selection, maintenance and use of proper equipment cannot eliminate the potential for danger, serious injury or death.

¥Lewmar winches are designed and supplied for line control in marine applications and are to be used in conjunction with appropriate clutches, cleats and other manual controls and stoppers.

¥It is the unavoidable responsibility of the owner or master or other responsible party to assess the risk of any operation on the vessel.

¥Under no circumstances should any self tailing winch be used in self tailing mode for any lifting operation; rather suitable and adequate manual tailing should be arranged with proper means of manually cleating or stopping the hoist.

¥Every winch should be installed with adequate means of manually cleating or stopping the loaded ropes.

¥Lewmar recommends the use of appropriate Personal Protective Equipment and hands free communication equipment by any person going aloft, and only then where the person going aloft is properly trained in the use of that equipment and where there remain sufÞcient trained and experienced personnel on deck to ensure constant observation and the continued safe conduct both of the vessel and the hoisting operation.

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.

¥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 qualiÞed electrical engineer.

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 speciÞcations without notice. As a result, Lewmar cannot accept liability for any differences between the product and the manual.

4 Ocean Electric Winches 34 - 77

1. Installation

GB

Convertible	Convertible Manual	Complete
Manual	with Power Drive Unit	Convertible

1.1Identifying the manual convertible winch

¥Fig. 1.1.1

Pre Ocean winches, i.e. Þxed jaw Wave Grip winches, made before 1992 are NOT convertible.

Convertible manual winches made in August 2000 will be date marked H/00 on the centre stem, (H = August; 00 = year 2000). They also carry a blue sticker on the screw-on top-cap showing a winch handle and a hand operating an electric deck switch. These winches can be converted by adding the Power Drive Base (B) unit and the required Motor Gearbox (C), Control Box and Switch-gear (12 V or 24 V).

¥Ocean Wave Spring manual winches made between 1992 and August 2000 are NOT Þtted with the necessary centre stem to convert to powered operation. A Centre Stem Kit (A) is available to convert the early Ocean Wave Spring winches from (1992 to July 2000). The part numbers are listed below. Pre Ocean Winches, i.e. Þxed jaw Wave Grip winches, made before 1992 are NOT convertible.

Winch Model					Description			Part Number
40				Centre Stem Kit			48040037
					Centre Stem Kit
	44								48044037
48				Centre Stem Kit			48048037

1.2 Preparing the manual winch for conversion to electric

¥Remove the winch from the deck (if already installed) and remove the Centre Plate, which is located on the underside of the Centre Stem, by using a soft hammer and punch (Fig. 1.2.1).

¥Remove any sharp edges and clean, to remove all old bedding/ sealing compounds from the underside of the Centre Stem.

Fig. 1.2.1

1.3 Fitting a complete electric winch from new

¥Test Þt the winch to the Power Drive Base and Gearbox to check the orientation and the necessary clearence needed BEFORE DRILLING ANY HOLES.

¥Now follow sections 1.4 and 1.5.

1.4 Positioning winch above deck

¥Lewmar recommend that the rope enters onto the drum at an angle of Ð5¡ to Ð10¡ to the base axis of the winch. To achieve this angle it may be necessary to use a base wedge when installing the winch (Fig. 1.4.1). The winch must be mounted on an even surface.

Always keep in mind the space available below the deck for the motor gearbox.

Fig. 1.4.1

-5° to -10°

-5° to -10°

¥If practical, for best performance, the winch should be installed so that the output gear is situated in the optimum position in relation to the load (Fig. 1.4.2).

LINE	Fig. 1.4.2
ENTRY
	LOAD
	OUTPUT GEAR
	2 SPEED / 3 SPEED WINCHES

Ocean Electric Winches 34 - 77

5

¥Use the template provided as a guide to position the winch on the deck.

NOTE: Check the scale of the template matches the winch (Fig 1.4.3).

NOTE: Make sure there is room below deck for motor and sub box.

Fig. 1.4.3

1.5 Positioning winch ancillaries below deck

NOTE: The positioning of the motor gearbox must be checked prior to cutting for deck/hull and bulkhead clearance.

¥ The motor gearbox can be rotated in 90¡ steps, Fig. 1.5.1.

Fig. 1.5.1

¥ The motor rotation is factory set for Þtting as Fig. 1.5.2.

Fig. 1.5.2

NOTE: The motor can be Þtted as Fig. 1.5.3.

Contact Lewmar for correct Þtting of electrical connections. If the motor is unitentionally Þtted this way on a single speed winch it will not operate and make a clicking noise, on a 2 or 3 speed winch it will dramatically reduce performance.

Fig. 1.5.3

¥Check clearance below deck and accessibility then position the deck switches near and in view of the winch. Use the templates provided as a guide to cut/drill hole, Þt switch and seal.

NOTE: Air switch tubing must be twist and chafe free to the switch unit (sub box).

DO NOT cover the air bleed hole with sealant as this will stop air escaping and could result in winches self operating as the air expands with rising temperatures in the tube.

Once you have selected the position for the winch, motor gearbox and controls, double check everything and only then drill the holes in the deck.

1.6 Fitting a convertible electric winch 34-65

NOTE: Illustrations are based on a model 50 winch.

¥Place the winch in position to ensure correct Þt once the holes have been drilled/cut (Fig. 1.6.1).

Fig. 1.6.1

¥ Unscrew the top cap (Fig. 1.6.2).

Fig. 1.6.2

6 Ocean Electric Winches 34 - 77

¥ Remove feeder arm and collets (Fig. 1.6.3).						Fig. 1.6.6	GB
Fig. 1.6.3

¥Lift drum off (Fig. 1.6.4). Take care in re-Þtting the drum washer with bevel on underside.

Fig. 1.6.4

¥Remove all screws holding centre stem to base (Fig. 1.6.5). Using a ßat bladed screwdriver in the drainage slots, lever off centre stem assembly clear of the two dowel pins.

Fig. 1.6.5

¥Take care to hold the gear stack in position as shown (Fig. 1.6.6). (If pawl gear falls away... note shoulder face is down). Take care that pawls and pawl springs are kept in place, while rebuilding/placing the centre stem onto the base.

¥Remove the base plate cover. Lift the base and bed down with a light coating of sealing compound to prevent leaks (Fig 1.6.7).

NOTE: Do not use excessive sealant.

Fig. 1.6.7

44~64

¥Consult the fastening guide in section 1.8 for bolt type and length. Bolt the base plate to the deck ensuring that all fastening heads are countersunk and correctly and replace base plate cover (Fig 1.6.8).

Fig. 1.6.8

Ocean Electric Winches 34 - 77

7

¥ReÞt the centre stem assembly, taking care to hold the gear stack in position as before (Fig 1.6.9). Rotating the gears will facilitate re-engagement of the pawls, and ratchet tracks.

Fig. 1.6.9

¥Replace the drum, collets, feeder arm in correct feeder position and screw on the top cap.

1.7Fitting a convertible electric winch 66-77

For winches 66-77, simply remove the winch drum and access to mounting holes is available through holes in the base of the centre stem.

1.8 Fastenings

Fix the winch to the deck using CSK Head, Stainless Steel Washers/Locknuts.

¥For the correct bolt length refer to Fig. 1.8.1 and table.

NOTE: Deck fastenings are not supplied.

Fig. 1.8.1

+ ( x ) m m / i n c h =

Winch	Fastening					X mm (min.)	X inch (min.)
34/40	5 x M6 ( /4 ” W)					30	/4
44/48	5 x M8 (5/	16		” W)		33	5/	16
50/54	6 x M8 (5/	16		” W)		33	5/	16
58	5 x M10 (3/		8	” W)		36	7/	16
64/65	5 x M10 (3/			8	” W)	38	/		2
66/68 & 77	6 x M10 (3/		8	” W)		31	/		4

1.9 Winch/motor gearbox coupling

Mechanical coupling of the horizontal drive unit and reduction gearbox to the winch should be mounted as Fig 1.9.1 (34−65) and Fig. 1.9.2 (66−77) with instructions of previous pages.

¥The horizontal drive unit assembly should be bolted from below decks. Use threadlock on item No.15 (see Sec. 8.2).

¥If a thick deck or increased motor/gearbox distance from deck demands a greater ÔTÕ dimension (see Sec. 9). Optional extension kits are available to special order. Contact your nearest Lewmar ofÞce.

Fig. 1.9.1

15

Fig. 1.9.2

8 Ocean Electric Winches 34 - 77