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Introduction
Safety notices
Dear Customer,
General
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.
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 qualified engineer.
Product support
• 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 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
• 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.
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
• 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 sufficient trained and
experienced personnel on deck to ensure constant observation
and the continued safe conduct both of the vessel and the
hoisting operation.
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 certificates 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.
• 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, Lewmar 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.
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.
Ocean Electric Winches 34 - 77
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1.1 Identifying the manual convertible winch
• Fig. 1.1.1
1.3 Fitting a complete electric
• Test fit the winch to the Power Drive Base and Gearbox to
check the orientation and the necessary clearence needed
BEFORE DRILLING ANY HOLES.
Pre Ocean winches, i.e. fixed 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).
• Now
1.4 Positioning winch above deck
• Lewmar recommend that the rope enters onto the drum at an
angle of –5° to –10° 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.
• Ocean Wave Spring manual winches made between 1992 and
August 2000 are NOT fitted 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. fixed jaw Wave Grip winches, made
before 1992 are NOT convertible.
Always keep in mind the space available below the deck for the
motor gearbox.
Fig. 1.4.1
Winch Model
Description
Centre Stem Kit
Centre Stem Kit
Centre Stem Kit
Part Number
48040037
-5° to -10°
40
44
48
48044037
48048037
1.2 Preparing the manual winch
for conversion to electric
-5° to -10°
• 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.
• 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).
Fig. 1.4.2
Fig. 1.2.1
OUTPUT GEAR
2 SPEED / 3 SPEED WINCHES
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• Use the template provided as a guide to position the winch on
the deck.
Fig. 1.5.3
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
• 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, fit 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.
1.5 Positioning winch ancillaries below deck
NOTE: The positioning of the motor
gearbox must be checked prior to cutting
for deck/hull and bulkhead clearance.
1.6 Fitting a convertible electric winch 34-65
NOTE: Illustrations are based on a model 50 winch.
• The motor gearbox can be rotated in 90° steps, Fig. 1.5.1.
• Place the winch in position to ensure correct fit once the holes
have been drilled/cut (Fig. 1.6.1).
Fig. 1.5.1
Fig. 1.6.1
• Unscrew the top cap (Fig. 1.6.2).
• The motor rotation is factory set for fitting as Fig. 1.5.2.
Fig. 1.6.2
Fig. 1.5.2
NOTE: The motor can be fitted as Fig. 1.5.3.
Contact Lewmar for correct fitting of electrical connections.
If the motor is unitentionally fitted 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.
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• 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-fitting the drum
Fig. 1.6.4
• 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
• Remove all screws holding centre stem to base (Fig. 1.6.5).
Using a flat bladed screwdriver in the drainage slots, lever off
centre stem assembly clear of the two dowel pins.
Fig. 1.6.5
• 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
• 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.
Ocean Electric Winches 34 - 77
7
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• Refit 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.
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.
Fig. 1.6.9
• 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 ‘T’ dimension (see Sec. 9). Optional
extension kits are available to special order. Contact your
nearest Lewmar office.
Fig. 1.9.1
• Replace the drum, collets, feeder arm in correct feeder position
and screw on the top cap.
1.7 Fitting 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.
15
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.
Fig. 1.9.2
NOTE: Deck fastenings are not supplied.
Fig. 1.8.1
+(x)
mm/inch=
Winch
34/40
Fastening
5 x M6 (1/4” W)
5 x M8 (5/16” W)
6 x M8 (5/16” W)
5 x M10 (3/8” W)
5 x M10 (3/8” W)
6 x M10 (3/8” W)
X mm (min.)
X inch (min.)
30
33
33
36
38
31
11/4
15/16
15/16
17/16
11/2
44/48
50/54
58
64/65
66/68 & 77
11/4
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2. Electrical wiring installation
GB
Fig. 2.1.1
3
2
1
4
5
System
Voltage
(V)
Cross
sectional
area
Cable
size
(US Only)
Distance
Power supply to winch
Battery size
12
12
12
24
24
24
Up to 10 m (33 ft)
10 to 15 m (33 to 49 ft)
15 to 20 m (49 to 66 ft)
Up to 7 m (23 ft)
50 mm2
70 mm2
95 mm2
25 mm2
35 mm2
50 mm2
1/Ø
2/Ø
3/Ø
3
Up to 300
Amp/hrs
7 to 10 m (23 to 33 ft)
10 to 13 m (33 to 43 ft)
2
1/Ø
2.1 Typical electrical layout
2.2 Main spindle rotation
NOTE: This is not a wiring diagram.
1. Position the recommended circuit breaker close to the battery.
See wiring diagrams Sec. 3.
2. Route 2 cables (see size table above) from battery to the
control box.
• Check correct main spindle rotation when fitted and
operated.
Fig. 2.2.1
3. Attach motor cables to control box (see wiring diagram) using
recommended cable sizes.
4. Position the control box near the winch ( 1 metre) in a dry
area for watertight security and accessible for maintenance.
5. Position deck switches in view of winch. Route wire and attach
to control box (see wiring diagram).
Winch
1st Gear
2nd Gear
3rd Gear
2 Speed
66−77
3 Speed
66−77
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3.1 E Series Electric
34-48, 12V or 24V
Fig. 3.1.1 Single direction contactor in box with thermal cutout.
12 V (18000301) or 24 V (18000302). Also see Section 3.7.
• This simple installation of a power drive
unit, motor and switch gear controls the
winch by a single direction contactor,
which can be a Contactor housed in a
waterproof box (Fig 3.1.1), or a stand
alone Nylon encased unit (Fig 3.1.2).
• The motor thermal trip is connected to
monitor motor temperature while the
Lewmar safety electric deck switch can
be easily wired.
Battery – VE
1
Grey
Not Used
Battery
Electric Switch Kit
69000018
Thermal
Cutout
4
D1
A2
2
Isolator/Safety
Switch
D2
• Manual override facility is still
available for backup, or as a means of
experiencing traditional sailing.
• Two plus one speed comes as standard
control which gives two speed manual
drive (handle) plus one speed electric
drive.
Contactor
12 V - 18000301
24 V - 18000302
Circuit
Breaker
3
Motor +VE
Battery +VE
Fig. 3.1.2 Contactor
Motor +VE
12 V (0052505) or 24 V (0052506)
0V/Motor A2
Electric
Battery +VE
Switch Kit
69000018
Blue
Black
3 Amp
Slow Blow Fuse
Grey
Not Used
Customer Supplied
Thermal
Cutout
Fig. 3.2.1 12 V or 24 V Control box with overload protection. Also see Section 3.7.
Sensing 34-48, 12 V or 24 V
Air Deck
Switch Kit
69000022
• This installation controls the winch by
Lewmar’s unique Overload Protection
Control Box (Fig 3.2.1), this allows the
winch to be operated up to the Safe
Working Load for winch size.
PCB
Electric Switch Kit
69000016
Two-way
3A Terminal Block
Fuse
2
Black
• Other features as Section 3.1
Blue
Grey
Not Used
Sub Box
Total voltage drop MUST NOT exceed
5% of supply over completed cabling
installation. Check all connections
for water tight security. Lewmar
recommends an isolator to be fitted in
the circuit in an accessible position as
close as possible to the supply.
1
Battery –VE
Control Box
Battery
Thermal
Cutout
4
Connect the power supply cables
to the battery last when the winch
installation has been completed
and checked for correct installation.
Incorrect connection of motor cables
may damage the unit.
3
Isolator/Safety
Switch
D1
Motor –VE
A2
Motor + VE
Circuit
Breaker
D2
Battery +VE
NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS
Negative earth MUST be used.
The deck switch wires MUST be fitted as shown on wiring diagrams.
Connect all low power wiring (deck switches, motor cutout etc.) before fitting high power
cables to controller.
Cable boots are supplied for all high power cable connections, follow guidelines Fig. 2.1.1
for cable sizing.
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3.3 ELS Electric Load
Fig. 3.3.1 12 V or 24 V Control box with overload protection. Also see Section 3.7.
Sensing 50-65, 12 V or 24 V
GB
Air Deck
Switch Kit
69000022
• This installation controls the winch by
Lewmar’s unique Overload Protection
Control Box (Fig 3.3.1), this allows the
winch to be operated up to the Safe
Working Load for winch size.
PCB
Electric Switch Kit
69000016
Two-way
3A Terminal Block
Fuse
2
Black
Blue
• Other features as Section 3.1
Grey
Not Used
Sub Box
Total voltage drop MUST NOT exceed
5% of supply over completed cabling
installation. Check all connections
for water tight security. Lewmar
recommends an isolator to be fitted in
the circuit in an accessible position as
close as possible to the supply.
1
Battery –VE
Control Box
Motor –VE
Battery
F2
A1
Thermal
Cutout
3
F1
Connect the power supply cables
to the battery last when the winch
installation has been completed
and checked for correct installation.
Incorrect connection of motor cables
may damage the unit.
Isolator/Safety
Switch
4
A2
Circuit
Breaker
Motor +VE
Battery +VE
Fig. 3.4.1a 2 Speed winch electrical connections
Fig. 3.4.1b 3 Speed winch electrical connections
F2
F1
F1
F2
Fig. 3.4.1 2/3 Speed 12 V or 24 V control box with overload protection. Also see Section 3.7.
3.4 ELS Electric Load
Sensing 2/3 speed controller
66/68-77, 12 V or 24 V
Electric Switch Kit
69000016
2
• This installation controls the winch by
Lewmar’s unique Overload Protection
& Autoshift Control Box (Fig. 3.4.1).
This allows the winch to be started in
1st and if reaches the Safe Working
Load, for the winch size and gear, will
automatically shift the winch into 2nd
gear for complete load control.
Sub Box
Black
Blue
Grey
Not Used
Air Deck
Switch Kit
69000022
In the case of a 3 speed winch (Fig.
3.4.1b) the switch must be re-selected
to achieve 3rd gear.
1
Battery –VE
Battery
Thermal
Cutout
Total voltage drop MUST NOT exceed
5% of supply over completed cabling
installation. Check all connections
for water tight security. Lewmar
recommends an isolator to be fitted in
the circuit in an accessible position as
close as possible to the supply.
F1
A1
3
F2
Isolator/Safety
Switch
4
Control Box
Circuit
Breaker
Motor – VE
A2
Battery +VE
Connect the power supply cables
to the battery last when the winch
installation has been completed
and checked for correct installation.
may damage the unit.
NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS
Negative earth MUST be used.
The deck switch wires MUST be fitted as shown on wiring diagrams.
Connect all low power wiring (deck switches, motor cutout etc.) before fitting high power
cables to controller.
Cable boots are supplied for all high power cable connections, follow guidelines Fig. 2.1.1
for cable sizing.
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3.5 EVC Electric Variable
Control. Standard controller
single speed winches
Fig. 3.5.1
Two-way
Terminal Block
SW 1
Electric Switch Kit
69000018
SW 2
Electric Switch Kit
69000018
Also see Section 3.7.
2
Grey
Not Used
Grey
Not Used
34-48, 12V & 24 V
Black
Blue
Black
• The EVC winch controller is a variable
speed motor controller which can drive
the winch in 3 different ways:
1. SW 1 drives the winch at full speed.
3 Amp
Fuse
2. SW 2 drives the winch at a set speed
determined by adjustable dial marked
(SP) on the control box. On supply the
dial is preset by Lewmar to drive the
winch at 60% of full speed.
(Optional)
Vario Control
1
Battery –VE
Thermal
Cutout
Battery
3. If optional Vario Control is fitted
then the winch will drive at a speed
determined by adjustment of the Vario
Control when deck switch (SW 2) is
engaged.
• The EVC controller uses current
sensing to halt the operation of the
winch when the winch has reached its
Maximum Safe Working Load.
• The EVC controller features a Ramp/
Soft Start to control the winch start
up, adjustment of dial RA will vary the
start period between 0.5 - 5 seconds.
The dial is preset by Lewmar for a start
period of 1 second.
• In order to adjust the speed (SP)
and Ramp (RA) dials, unscrew the
plug screws, on top of the controller
4 full turns and retract the plug/
screw assembly. Use an electrical
slotted (2.5mm Max.) screwdriver to
adjust the internal dial to the desired
setting.
EVC
Control Box
Isolator/Safety
Switch
D1
A2
BAT–
MOT+
BAT+
MOT–
Circuit
Breaker
D2
3
4
Battery +VE
Motor – VE
Motor +VE
Two-way
Terminal Block
SW 1
SW 2
Fig. 3.6.1
Also see Section 3.7.
Electric Switch Kit
Electric Switch Kit
69000018
69000018
2
Grey
Not Used
Grey
Not Used
Black
Blue
Black
3 Amp
Fuse
(Optional)
Vario Control
1
Battery –VE
Battery
F2
Thermal
Cutout
F1
3.6 EVC Electric Variable
Control. Standard & high
power controller single speed
winches 50-65, 12 V & 24 V
speed motor controller which can drive
the winch in 3 different ways:
EVC
Control Box
A1
A2
Isolator/Safety
Switch
BAT–
MOT+
BAT+
MOT–
Circuit
Breaker
4
3
Battery +VE
Motor +VE
Motor – VE
NOTE: Standard EVC used
on 50−65 24 V. High power
EVC used on 50−65 12 V.
• The EVC controller features a Ramp/
Soft Start to control the winch start
up, adjustment of dial RA will vary the
start period between 0.5 - 5 seconds.
The dial is preset by Lewmar for a start
period of 1 second.
• In order to adjust the speed (SP)
and Ramp (RA) dials, unscrew the
plug screws, on top of the controller
4 full turns and retract the plug/
screw assembly. Use an electrical
slotted (2.5mm Max.) screwdriver to
adjust the internal dial to the desired
setting.
1. SW 1 drives the winch at full speed.
2. SW 2 drives the winch at a set speed
determined by adjustable dial marked
(SP) on the control box. On supply the
dial is preset by Lewmar to drive the
winch at 60% of full speed.
3. If optional Vario Control is fitted
then the winch will drive at a speed
determined by adjustment of the Vario
Control when deck switch (SW 2) is
engaged.
NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS
Negative earth MUST be used.
The deck switch wires MUST be fitted as shown on wiring diagrams.
Connect all low power wiring (deck switches, motor cutout etc.) before fitting high power
cables to controller.
Cable boots are supplied for all high power cable connections, follow guidelines Fig. 2.1.1
for cable sizing.
• The EVC controller uses current
sensing to halt the operation of the
winch when the winch has reached its
Maximum Safe Working Load.
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3.7 NEW Electric deck switch
• The new electric deck switch can be ordered unlit (69000018)
or lit (69000350/48000170).
Fig. 3.7.1
GB
Unlit
Electric Switch
69000345
Lit
Electric Switch
69000350/48000170
NOTE: In lit option the wires should be connected
separate to the electric winch control box, to avoid
any possibility of a signal upsetting/interfering
with the control box circuit. Use a general lighting
circuit and fused at the ship’s main circuit panel.
Red
White
Red
White
White
5 A
Max.
5 A
Max.
Black
White
Black –VE
Red +VE
Black
LED
4. Performance diagrams
The following graphs show line speed and amperage draw relative
to the load applied. Each control box is set to cut out at the SWL
which is 50% of the breaking load.
Model 34-40 Electric 12 Volts
Model 48 Electric 12 & 24 Volts
Model 64-65 Electric 12 & 24 Volts
Cutout (500 kg)
Cutout (1000 kg)
Cutout (1580 kg)
Load (kg)
Load (kg)
Load (kg)
Model 40 Electric 24 Volts
Model 50 Electric 12 & 24 Volts
Model 66/68-3 Electric 24 Volts
Cutout (500 kg)
Cutout (1250 kg)
Cutout (1814 kg)
Load (kg)
Load (kg)
Load (kg)
Model 44 Electric 12 Volts
Cutout (800 kg)
Cutout (2721 kg)
Cutout (1350 kg)
Load (kg)
Load (kg)
Load (kg)
Model 44 Electric 24 Volts
Model 58 Electric 12 & 24 Volts
Cutout (800 kg)
Cutout (1450 kg)
Load (kg)
Load (kg)
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5. Safe working loads
5.1 Optimum rope diameters
5.2 Maximum winch load values
Model
30/40
44
Maximum Load (kg) Maximum Load (lbs)
Model
34/40
Rope Ø (mm)
8 to 12
Rope Ø (in)
5/16” to 1/2
5/16” to 9/16
5/16” to 5/8
5/16” to 11/16
3/8” to 3/4
795
1750
2500
2750
3000
3250
3500
3750
6000
7500
1136
1247
1363
1474
1587
1700
2727
3409
44/48
8 to 14
48
50/54
8 to 16
50
58 & 64/65
66/68
8 to 18
54
10 to 20
12 to 22
77
1/2” to 7/8
58
64/65
66/68
77
Maximum safe working loads are recommended to be NOT MORE
than the those detailed above. This provides an acceptable safety
margin for dynamic load surges in extreme sea conditions.
6. Operating your winch
Fig. 6.0.1
• Ocean Winches 34−65 are single speed powered winches &
manual 2 speed, these winches employ an overide ratchet
gearing for safety when winching manually.
• Ocean Winches 66−77 are 2 or 3 speed powered and manually
operated, they will not drive electrically while the winch lock-in
handle is in the drive socket.
NEVER hold the incoming rope to the winch while the winch is
operated. Only control the rope leaving the winch.
4. Pay out line as per manual winch.
1. Adjust the feeder arm so that the rope tails into a secure area
away from the incoming line.
2. There must be at least 3 turns of rope around the winch before
being passed across the feeder arm in to the wavespring self
tailing jaws.
ALWAYS switch off the winch at the circuit breaker/isolator after
sailing or when leaving the boat to prevent accidental operation.
3. Use the winch handle or electric switch to operate the
winch.
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7. Servicing your winch
GB
Fig. 7.0.1
Oil
TURN THE POWER OFF at the circuit breaker/isolator before
any maintenance/servicing is carried out. Winches need regular
maintenance to operate at peak efficiency otherwise permanent
damage and premature wear can result.
Electric motors become hot during and for some time after
use. These units have an oil filled gearbox. DO NOT remove the
motor.
1. MONTHLY
• For
10” B 2196 and “Custom Winch Service Manual Volume 8”
B2312 (77-144/2) or download from:
Hose down with fresh water then lightly oil and grease as per
illustration taking care not to get any grease in the pawls as
they will stick in operation.
2. TWO OR THREE TIMES DURING
ACTIVE SAILING SEASON
Strip, clean, check and relubricate.
OF NEW SEASON
Strip, clean, thoroughly check for damage, lubricate and
reassemble as detailed in the service manual.
Check condition of motor gearbox. In the event of corrosion,
clean and repaint motor with marine grade oil based enamel
paint.
Ocean Electric Winches 34 - 77
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8. Parts list
• On winches 50 to 65 the 2 lower bearings have been replaced
by item 45003103 (Plain Bearing). These items ARE
interchangeable.
8.1 Winch model notes
NOTE: For winches before February 1995.
• Plain bearing 45000248 has replaced the bearings and spacer,
these items ARE NOT interchangeable. Contact your Lewmar
Dealer.
NOTE: Manual winches cannot be converted into
electric versions by adding parts listed here.
8.2 Parts list 34-65
Fig. 8.2.1
4
3
5
4
1
2
6
7
8
10
9
12
13
11
16
14
15
Item Description
Qty
1
1
1
4
4
3
1
1
1
1
1
2
1
1
4
4
1
5
5
6
6
5
34
40
48
50
54
58
64/65
45000860
45000744
45000842
15000301
1260/7
1
2
3
Centre Stem
45000265
45000258
45000288
15000094
1260/7
45000237
45000241
45000242
15000094
1260/7
45000337
45000344
45000342
15000094
1260/7
45000437
45000444
45000342
15000094
1260/7
45000560
45000544
45000542
15000301
1260/7
45000660
45000744
45000642
15000301
1260/7
45000760
45000744
45000742
15000301
1260/7
Gear Spindle
Rachet Pawl Gear
Pawl
4
Spring
5
6
7
8
9
Bearing
15000378
45000357
15003287
45000359
45000229
45000264
45000235
B6234
15000378
45000357
15003287
45000359
45000229
45000228
45000235
B6234
15000398
45000357
15003287
45000358
45000329
45000328
45000235
B6234
15000398
45000357
15003287
45000358
45000429
45000428
45000235
B6234
15000017
45000543
15003287
45000248
45000529
45000528
45000581
B6235
15000017
45000543
15003287
45000248
45000529
45000528
45000581
B6235
15000017
45000543
15003287
45000248
45000759
45000758
45000581
B6235
15000017
45000543
15003287
45000248
45000759
45000758
45000581
B6235
Drive Shaft
Key
Plain Bearing
Base Plate Cover
Base Plate
10
Dowel
Shaft Seal
11
12
13
14
15
Insulation Shim
HEX Bolt M8x25
Washer M8
45000257
B0173
45000257
B0173
45000257
B0173
45000257
B0173
45000257
B0173
45000257
B0173
45000257
B0173
45000257
B0173
B1207
B1207
B1207
B1207
B1207
B1207
B1207
B1207
Plate
45000350
B0678
45000350
B0678
45000350
B0678
45000350
B0678
45000350
B0678
45000350
B0678
45000350
B0678
45000350
B0678
SKT HD screw M6 x 12
CSK HD screw M6 x 16
CSK HD screw M8 x 16
CSK HD screw M8 x 25
CSK HD screw M10 x 25
B0524
B0524
-
-
B0536
B0536
16
-
-
-
-
B0812
B0812
-
-
-
-
B0567
B0567
Ocean Electric Winches 34 - 77
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8.3 Parts list 66-77
GB
Fig. 8.3.1
1
2
19
20
3
4
5
6
18
7
8
9
10
11
12
13
14
15
16
17
*2 Speed versions shown/detailed
Item Description
Qty
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
66/68-*2
18000181
15044613
B2532
77-*2
1
2
Push Rod Assembly
Spring
18000488
15044613
B2532
3
‘O’ Ring
4
Bush
15000184
B9941
15000184
B9941
5
Spring Clip
Drive Dog
6
15300688
B2593
15300575
B2593
7
Seal
8
Thrust Sleeve
Spring
45002154
15300489
45002140
15000569
B0686
45002154
15300489
45002140
15000569
B0686
9
10
11
Hollow Dowel
Bush
Screw
12
Heli-coil
B2423
B2423
13
14
15
16
17
Roller Bearing
Thrust Washer
Connecting Shaft
Adaptor
15010007
15003286
45002156
45000944
15003287
48000077
48000078
45000940
45000947
15010007
15003286
45002156
45000944
15003287
48000077
48000078
45002040
45002180
Key
Motor/Gearbox 12 V
Motor/Gearbox 24 V
Power Base
Main Spindle - Elec./Hyd.
18
19
20
Ocean Electric Winches 34 - 77 17
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9. Dimensions
Fig. 9.0.1
B
B
D
D
H
H
L
L
T*
N
T*
S
S
R
R
X
X
V
M
V
M
Model
D
B
H
L
M
237
238.5
238.5
290
290
290
290
290
290
290
290
N
38.1
42
S
T *
33.5
64.4
64.4
59.5
59.5
59.5
59.5
67.5
87.5
87.5
87.5
R
V
X
34/40
44
73.5
87
154
174
186
209
209
234
234
282
294
294
294
189.4
215.5
228.0
258
95.4
103.5
108.5
126
99
156
186
70
112
112
112
112
112
112
112
112
112
112
112
130.5
130.5
138.5
138.5
138.5
138.5
144
72.5
72.5
80
48
93
44.5
48.5
48.5
52.9
52.9
186
50
105
105
118
118
141
141
178
178
182
54
270.8
286.3
291.3
302.2
348
135.8
138.8
141.8
142.1
170
182
80
58
182
80
64/65
66/68
66-3
77
182
80
188.5
191.1
191.1
191.1
80
144
80
348
174
144
80
77-3
348
174
147
80
*Optional extension kits to increase ‘T’ are available to special order. Contact your nearest Lewmar office if required.
Model
34 & 40
44
D
2 7/8
B
6 1/16
H
L
M
9 5/16
N
S
3 7/8
T *
1 5/16
R
V
2 3/4
X
7 15
/
3 49
/
1 1/2
1 5/8
1 1/4
6 1/8
7 1/4
7 1/4
7 1/8
7 1/8
7 1/8
7 1/8
7 3/8
7 1/2
7 1/2
7 1/2
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
4 3/8
32
64
3 7/16
6 55
7 21
/
/
8 3/8
9 3/8
4 1/16
4 1/4
9 25
9 25
/
/
5 9/64
5 9/64
5 7/16
5 7/16
5 7/16
5 7/16
5 7/16
5 7/16
5 7/16
5 7/16
2 17
2 17
/
/
2 55
2 55
/
/
64
64
32
64
48
3 11
/
16
64
64
32
64
50
4 1/8
4 1/8
4 5/8
4 5/8
5 9/16
5 9/16
7
8 1/4
8 1/4
10 1/8
10 5/8
11 1/4
11 1/2
4 15
/
11 7/16
11 7/16
11 7/16
11 7/16
11 7/16
11 7/16
11 7/16
11 7/16
1 15
1 15
/
/
2 5/16
2 5/16
2 5/16
2 5/16
3 1/8
3 1/8
3 1/8
3 1/8
3 1/8
3 1/8
3 1/8
3 1/8
16
16
54
5 3/8
5 1/2
5 9/16
5 9/16
6 1/16
6 7/8
6 7/8
16
58
9 1/4
2 1/16
64/65
66/68
66-3
77
9 1/4
2 1/16
11 1/8
11 1/2
11 1/2
11 1/2
11 15
13 11
13 11
13 11
/
/
/
/
2 11
/
16
16
16
16
16
3 7/16
3 7/16
3 7/16
77-3
7
18 Ocean Electric Winches 34 - 77
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10. Total weight
GB
All
All
Chrome
(kg)
All
Bronze
(lbs)
St.
Steel
(lbs)
All
Chrome
(kg)
Chrome St. Steel
Alloy
(lbs)
Chrome
(lbs)
Model Alloy (kg) Bronze
(kg)
Model
(kg)
(kg)
34/40
44
19
23.3
26
21.2
25.8
30.1
35.7
37.2
40.6
43.7
49.7
20.7
25.8
29.4
34.8
36.4
39.8
42.9
48.8
54.8
53.3
57.3
20.5
25.5
28.6
34.7
35.6
38.1
40.1
46
21.2
25.8
30.1
35.7
37.2
40.6
43.7
49.7
55.7
62.3
64.3
34/40
44
41.9
51.4
46.7
56.8
66.4
78.7
82
45.6
56.8
45.2
56.2
63
46.7
56.8
66.3
78.7
82
48
48
57.3
64.8
50
30
50
66.15
67.4
76.7
76.5
78.5
84
54
30.6
33.4
35.7
42
54
80.2
58
58
73.6
89.5
96.3
109.3
80.2
89.5
96.3
109.3
122.5
137.7
141.5
64/65
66/68
66-3
77
64/65
66/68
66-3
77
78.7
94.6
88.4
101.2
114.4
116.6
121
92.4
107.3
120.6
121.7
126.1
48
52
105.6
108.5
112.9
49.3
51.3
53
77/3
55
77/3
11. Model range
11.1 Model range 34-77
Model
Part No.
48034255
48040255
48040256
48040258
48040259
48040260
48000116
48000117
48000301
or 0052505
48000302
or 0052506
48000081
48000082
48000138
48000139
48040055
48044255
48044256
48044258
48044259
48044260
48000116
48000117
Finish
Alloy
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Description
Model
Part No.
Finish
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Description
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
(Model 34) Deck Unit
(Model 40) Deck Unit
Deck Unit
48048255
48048256
48048258
48048259
48048260
48000116
48000117
18000301
or 0052505
18000302
or 0052506
48000085
48000086
48000142
48000143
48048055
48050200
48050201
48050204
48050203
48050202
48000075
48000076
N/A
Deck Unit
Deck Unit
Deck Unit
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V Motor/Gearbox
24 V Motor/Gearbox
48
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
34/40
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
Deck Unit
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
12 V Motor/Gearbox
24 V Motor/Gearbox
50
44
48000081
or 0052505
48000302
or 0052506
48000083
48000084
48000140
48000141
N/A
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
48000087
48000088
48000144
48000145
48050055
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Ocean Electric Winches 34 - 77
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Model
Part No.
48054200
48054201
48054204
48054203
48054202
48000075
48000076
N/A
Finish
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Description
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Model
77
Part No.
48077200
48077201
48077204
48077203
48077205
48077206
48077209
48077208
48000078
48000077
N/A
Finish
Alloy
Chrome
St. Steel
All Chrome
Alloy
Chrome
St. Steel
All Chrome
Description
Deck Unit
Deck Unit
Deck unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
77 -3
Speed
54
24 V Motor/Gearbox
12 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
N/A
48000089
48000090
48000146
48000147
48054055
48058200
48058201
48058204
48058203
48058202
48000075
48000076
N/A
77 &
77 -3
Speed
N/A
48000022
48000023
N/A
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Deck Unit
Deck Unit
Deck Unit
Deck Unit
N/A
11.2 Circuit breakers
Deck Unit
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
Circuit
Circuit Breaker
Part Number
Model
34/40
44
Voltage
Breaker
90
58
12 V
24 V
12 V
24 V
12 V
24 V
12 V
24 V
* 12 V
24 V
* 12 V
24 V
* 12 V
24 V
12 V
24 V
12 V
24 V
68000349
68000542
68000350
68000348
68000239
68000240
68000351
68000349
589008
N/A
40
48000091
48000092
48000148
48000149
48058055
48065200
48064200
48064201
48064204
48064203
48064202
48000075
48000076
N/A
110
50
120
48
70
Alloy
Alloy
Chrome
St. Steel
All Chrome
All Bronze
(Model 65) Deck Unit
(Model 64) Deck Unit
Deck Unit
150
50
90
250 FUSE
90
Deck Unit
Deck Unit
Deck Unit
54
68000349
589009
325 FUSE
110
58
68000350
589009
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Power Drive Kit
325 FUSE
110
64/65
64/65
66/68
77
68000350
68000350
68000348
68000350
68000348
N/A
110
48000093
48000094
48000150
48000151
48064055
48066200
48066201
48066204
48066203
48066202
48000077
48000078
N/A
50
110
50
*Order fuse holder 589006 with fuse indicated.
Alloy
Chrome
St. Steel
All Chrome
All Bronze
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Description
Part Number
68000345
Deck Unit
UNLIT - Electric deck switch open (Plastic)
LIT - Electric deck switch open (Plastic)
LIT - Electric deck switch open (Stainless Steel Lid)
Labels - Silver out of black (Sailing functions)
12 V Motor/Gearbox
24 V Motor/Gearbox
12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box
12 V ‘ELS’ Control Box
24 V ‘ELS’ Control Box
12 V ‘EVC’ Control Box
24 V ‘EVC’ Control Box
Deck Unit
66/68
Speed
69000350
48000170
69000349
N/A
Labels - Black out of silver (Sailing functions) use with 48000170
69000356
18000430
18000431
N/A
N/A
48066205
48066206
48066209
48066208
Alloy
Chrome
St. Steel
All Chrome
66/68
-3
Speed
Deck Unit
Deck Unit
Deck Unit
Ocean Electric Winches 34 - 77
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12. Fault finding
GB
Fig. 12.0.1
Check for correct assembly,
over use of grease? pawls
stuck. Clean, check for
broken pawl/springs,
regrease lightly.
Does the winch operate
manually?
Remove handle.
Check drive dog &
spring (items 6 & 7
parts list)
Ensure free
Winch handle locked in?
(Winches 66–77 only)
Does the winch operate
electrically?
operation.
Check terminal
connections.
Motor runs but winch
does not turn
Check battery
voltage.
Power at the battery?
Check polarity.
Adequate reserve
battery capacity?
Isolator switch/circuit
breaker on?
Switch on.
Change fuse
(3 Amp).
Check wiring.
Check fuse in control box.
NOTE: EVC does NOT
have a fuse.
Check circuit
diagram.
Check
Power at winch?
connections.
Clean & check cables
conductivity.
Check switch connection
in control box.
Reconnect.
Contact Lewmar
Check tube is
sealed, no leaks.
www.lewmar.com
Air hose correctly fitted?
Ocean Electric Winches 34 - 77
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13. Lewmar limited warranty
LIMITED WARRANTY and
KEY TERMS OF SUPPLY BY LEWMAR
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.
Lewmar warrants that in normal 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.
b
Lewmar grants no other warranties regarding the fitness 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 limited to a period of one year from the date
of purchase by the end user. Some states and countries do not allow
limitations on how long an implied warranty lasts, so this limitation
may not apply to you.
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.
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 which supplied the
product or to Lewmar at Southmoor Lane, Havant, Hampshire, England
PO9 1JJ.
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 failure, or any
resulting loss or damage which arises from:
E SEVERANCE CLAUSE
a
use of a product in an application for which it was not designed or
intended;
If any clause of this warranty is held by any court or other competent
authority to be invalid or unenforceable 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.
b. corrosion, ultra violet degradation or wear and tear;
c. a failure to service or maintain the product in accordance 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 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 applicable national law governing
the sale of Consumer Goods; this Warranty does not affect those
rights.
f. conditions that exceed the product’s performance specifications or
safe working loads.
iv Product subject to a warranty claim must be returned to the Lewmar
outlet which supplied the product for examination unless otherwise
agreed by Lewmar in writing.
v
This warranty does not cover any incidental costs incurred for the
investigation, removal, carriage, transport or installation of product.
G LAW
This warranty shall be governed by and read in accordance 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.
vi Service by anyone other than authorised Lewmar representatives
shall void this warranty unless it accords with Lewmar guidelines
and standards of workmanship.
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 professional advice as to their suitability.
Lewmar accepts no liability arising from such other use.
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.
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:
The British Marine Federation may be contacted at Marine House,
Thorpe Lea Road, Egham, England, TW20 8BF
•
•
•
•
•
Electric motors and associated electrical equipment
Electronic controls
Hydraulic pumps, valves and actuators
Weather seals
Products used in “Grand Prix” racing applications
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).
Ocean Electric Winches 34 - 77
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B2303
Produced by T. Connell UK (+44) 023 9263 9265 Ref:T1712/03/2006
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