Lewmar 34 77 User Manual To The E9bb4393 54a5 4132 B497 Bfa0dfa58845

User Manual: Lewmar 34-77 to the manual

Open the PDF directly: View PDF .
Page Count: 22

Download
Open PDF In Browser	View PDF

www.lewmar.com

Contents

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

Introduction

Product support

Important information about this manual

EMC Recommended guidelines

CE Approvals

Safety notices

General

Fitting

4. Performance diagrams

5. Safe working loads

5.1 Optimum rope diameters

5.2 Maximum winch load values

6. Operating your winch

7. Ser vicing your winch

Electrical

8. Parts list

1. Installation

8.1 Winch notes

1.1 Identifying manual convertible winch

8.2 Models 34-65

1.2 Preparing manual winch for conversion

8.3 Models 66-77

1.3 Fitting a complete electric winch from new

9. Dimensions

1.4 Positioning winch above deck

10. Total weight

1.5 Positioning winch ancillaries below deck

1.6 Fitting a convertible electric winch 34-65

11. Electric convertible model range

1.7 Fitting a convertible electric winch 66 -77

1.8 Fastenings

1.9 Winch motor gearbox couplings

2. Electrical wiring installation

2.1 Typical electrical layout

2.2 Correct main spindle rotation

3. Electrical connections

11.1 Winches 34-77

19/20

11.2 Circuit breakers

11.3 NEW Electric deck switch

12. Fault finding

13. Lewmar limited warranty

3.1 E Series Electric 34-48

3.2 ELS Electric Load Sensing 34-48

3.3 ELS Electric Load Sensing 50-65

3.4 ELS Electric Load Sensing 2/3 speed 66-77

3.5 EVC Electric Variable Control 34-48

3.6 EVC Electric Variable Control 50-65

3.7 NEW Electric deck switch

Ocean Electric Winches 34 - 77

Introduction

Safety notices

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.

General

Product support
Lewmar products are supported by a worldwide network of
distributors and Authorised Ser vice 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

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

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.
• 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 sufficient trained and
experienced personnel on deck to ensure constant observation
and the continued safe conduct both of the vessel and the
hoisting operation.

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.

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

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.

1. Installation
PRE 1992

1992 AUG 2000

40/44/48 AUGUST 2000

Wavegrip Winch

Ocean
Wavespring Manual

Convertible
Manual

1.1 Identifying the manual convertible winch
• Fig. 1.1.1
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).
• 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.

Convertible Manual
with Power Drive Unit

Complete Electric
Convertible Winch

1.3 Fitting a complete electric
winch from new
• Test fit 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 –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.
Always keep in mind the space available below the deck for the
motor gearbox.
Fig. 1.4.1

Winch Model

Description

Part Number

Centre Stem Kit

48040037

Centre Stem Kit

48044037

Centre Stem Kit

48048037

-5° to -10°

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).
E
N
LI

Fig. 1.4.2

Y
TR
EN

Fig. 1.2.1

LO
AD
OUTPUT GEAR
2 SPEED / 3 SPEED WINCHES

Ocean Electric Winches 34 - 77

• 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. 1.5.3

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.

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.

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

• The motor gearbox can be rotated in 90° steps, Fig. 1.5.1.
Fig. 1.5.1

NOTE: Illustrations are based on a model 50 winch.
• Place the winch in position to ensure correct fit once the holes
have been drilled/cut (Fig. 1.6.1).
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. 1.5.2

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.

Ocean Electric Winches 34 - 77

Fig. 1.6.2

• Remove feeder arm and collets (Fig. 1.6.3).

Fig. 1.6.6

Fig. 1.6.3

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

• 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.
Fig. 1.6.9

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 ‘ 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.

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) mm /inch =

Winch

X mm (min.)

X inch (min.)

34/40

5 x M6 ( /4” W)

11/4

44/48

5 x M8 (5/16” W)

15/16

50/54

6 x M8 ( /16” W)

15/16

5 x M10 (3/8” W)

17/16

64/65

5 x M10 (3/8” W)

11/2

11/4

66/68 & 77

Fastening

6 x M10 ( /8” W)

Ocean Electric Winches 34 - 77

Fig. 1.9.2

2. Electrical wiring installation

GB
Fig. 2.1.1

3
2

System
Voltage
(V)
12
12

Distance
Power supply to winch
Up to 10 m (33 ft)
10 to 15 m (33 to 49 ft)

Cross
sectional
area

Cable
size
(US Only)

50 mm2

1/Ø

2/Ø

70 mm

15 to 20 m (49 to 66 ft)

95 mm

3/Ø

Up to 7 m (23 ft)

25 mm2

7 to 10 m (23 to 33 ft)

35 mm2

10 to 13 m (33 to 43 ft)

50 mm

Battery size

Up to 300
Amp/hrs

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.
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).

• Check correct main spindle rotation when fitted and
operated.
Fig. 2.2.1

Winch

1st Gear

2nd Gear

3rd Gear

2 Speed
66−77
3 Speed
66−77

Ocean Electric Winches 34 - 77

3. Electrical connections
12 V (18000301) or 24 V (18000302). Also see Section 3.7.
Battery – VE

Blue

D1
A2

Contactor
12 V - 18000301
24 V - 18000302

Slow Blow Fuse
Customer Supplied

Thermal
Cutout

Grey
Not Used

Electric Switch Kit
69000018

Battery

Black

• 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.
• Manual over ride 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.

Fig. 3.1.1 Single direction contactor in box with thermal cutout.

3 Amp

3.1 E Series Electric
34-48, 12 V or 24 V

Isolator/Safety
Switch

Circuit
Breaker

Motor +VE

Battery +VE

Fig. 3.1.2 Contactor

Motor +VE

12 V (0052505) or 24 V (0052506)

0 V/Motor A2

Battery +VE

Electric
Switch Kit
69000018

Blue
3 Amp

Grey
Not Used

Black
Slow Blow Fuse
Customer Supplied

3.2 ELS Electric Load
Sensing 34-48, 12 V or 24 V
• 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.
• Other features as Section 3.1
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.
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.

Thermal
Cutout

Fig. 3.2.1 12 V or 24 V Control box with overload protection. Also see Section 3.7.
Air Deck
Switch Kit
69000022

PCB
3A
Fuse

Two-way
Terminal Block

Electric Switch Kit
69000016

Black
Blue
Sub Box

Grey
Not Used

Battery –VE
Control Box

Battery

Thermal
Cutout

D1
Motor –VE

Motor + VE

Isolator/Safety
Switch

Circuit
Breaker

Battery +VE

NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS
n Negative earth MUST be used.
o The deck switch wires MUST be fitted as shown on wiring diagrams.
p Connect all low power wiring (deck switches, motor cutout etc.) before fitting high power
cables to controller.
q Cable boots are supplied for all high power cable connections, follow guidelines Fig. 2.1.1
for cable sizing.

Ocean Electric Winches 34 - 77

3.3 ELS Electric Load
Sensing 50-65, 12 V or 24 V
• 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.
• Other features as Section 3.1

Fig. 3.3.1 12 V or 24 V Control box with overload protection. Also see Section 3.7.

PCB
3A
Fuse

Two-way
Terminal Block

Electric Switch Kit
69000016

Black
Blue
Sub Box

Grey
Not Used

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.
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.

Air Deck
Switch Kit
69000022

Battery –VE
Control Box

Motor –VE

Battery

Thermal
Cutout

Isolator/Safety
Switch

Circuit
Breaker

Motor +VE

Battery +VE

Fig. 3.4.1b 3 Speed winch electrical connections

Fig. 3.4.1a 2 Speed winch electrical connections

F2
F1
3.4 ELS Electric Load
Sensing 2/3 speed controller
66/68-77, 12 V or 24 V

F1
F2

Fig. 3.4.1 2/3 Speed 12 V or 24 V control box with overload protection. Also see Section 3.7.

• 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.
In the case of a 3 speed winch (Fig.
3.4.1b) the switch must be re-selected
to achieve 3rd gear.

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.

Sub Box
Black
Blue
Grey
Not Used

Air Deck
Switch Kit
69000022

Battery –VE

Battery
Motor –VE

Thermal
Cutout

F1
F2

4
Control Box

Isolator/Safety
Switch

Electric Switch Kit
69000016

Motor – VE

Circuit
Breaker

Battery +VE

Ocean Electric Winches 34 - 77

Two-way
Terminal Block

Also see Section 3.7.

SW 1
Electric Switch Kit
69000018

SW 2
Electric Switch Kit
69000018
Grey
Not Used

Grey
Not Used

Black

Blue

3 Amp
Fuse
(Optional)
Vario Control

Battery –VE

Thermal
Cutout

Battery

EVC
Control Box

BAT–
MOT–

MOT+

Isolator/Safety
Switch

D1
A2

BAT+

Circuit
Breaker

Battery +VE
Motor – VE
Motor +VE

Two-way
Terminal Block

Fig. 3.6.1

SW 1
Electric Switch Kit
69000018

Also see Section 3.7.

SW 2
Electric Switch Kit
69000018
Grey
Not Used

Grey
Not Used

Black

1 2 3 4 5 6 7 8

• 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.
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.
• The EVC controller uses cur rent
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.

Fig. 3.5.1

1 2 3 4 5 6 7 8

3.5 EVC Electric Variable
Control. Standard controller
single speed winches
34-48, 12 V & 24 V

Black

Blue

3 Amp
Fuse
(Optional)
Vario Control

Battery –VE

Battery
F2

3.6 EVC Electric Variable
Control. Standard & high
power controller single speed
winches 50-65, 12 V & 24 V
• The EVC winch controller is a variable
speed motor controller which can drive
the winch in 3 different ways:
NOTE: Standard EVC used
on 50−65 24 V. High power
EVC used on 50−65 12 V.
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.
• The EVC controller uses cur rent
sensing to halt the operation of the
winch when the winch has reached its
Maximum Safe Working Load.

Ocean Electric Winches 34 - 77

EVC
Control Box

BAT–
MOT–

MOT+

Thermal
Cutout

F1
Isolator/Safety
Switch

BAT+

Circuit
Breaker

Battery +VE
Motor +VE
Motor – VE

• 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.

3.7 NEW Electric deck switch

Fig. 3.7.1
Unlit
Electric Switch
69000345

• The new electric deck switch can be ordered unlit (69000018)
or lit (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.

5A
Max.

Lit
Electric Switch
69000350/48000170

Red

White

Black

White

5A
Max.

Red
Black

White
White
Black –VE

LED

Red +VE

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

Load (kg)

Model 50 Electric 12 & 24 Volts

Model 40 Electric 24 Volts
Cutout (500 kg)

Current (Amp)

Line Speed (m/min)

Cutout (1580 kg)

Current (Amp)

Line Speed (m/min)

Cutout (1000 kg)

Current (Amp)

Line Speed (m/min)

Cutout (500 kg)

Model 66/68-3 Electric 24 Volts

Cutout (1250 kg)

Current (Amp)

Line Speed (m/min)

Current (Amp)

Line Speed (m/min)

Current (Amp)

Line Speed (m/min)

Cutout (1814 kg)

Load (kg)

Model 44 Electric 12 Volts

Model 54 Electric 12 & 24 Volts

Model 77-3 Electric 24 Volts

Load (kg)

Model 44 Electric 24 Volts

Current (Amp)

Line Speed (m/min)

Current (Amp)

Line Speed (m/min)

Load (kg)

Model 58 Electric 12 & 24 Volts

Cutout (800 kg)

Current (Amp)

Line Speed (m/min)

Cutout (1450 kg)

Current (Amp)

Line Speed (m/min)

Cutout (2721 kg)

Cutout (1350 kg)

Current (Amp)

Line Speed (m/min)

Cutout (800 kg)

Load (kg)
Load (kg)

Ocean Electric Winches 34 - 77

5. Safe working loads
5.1 Optimum rope diameters

5.2 Maximum winch load values
Rope Ø (in)

Model

Maximum Load (kg) Maximum Load (lbs)

Model

Rope Ø (mm)

34/40

8 to 12

/16” to 1/2”

30/40

795

1750

44/48

8 to 14

/16” to 9/16”

1136

2500

50/54

8 to 16

/16” to 5/8”

1247

2750

58 & 64/65

8 to 18

/16” to 11/16”

1363

3000

66/68

10 to 20

1474

3250

12 to 22

1587

3500

64/65

1700

3750

66/68

2727

6000

3409

7500

/8” to 3/4”
/2” to 7/8”

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.
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.
3. Use the winch handle or electric switch to operate the
winch.

Ocean Electric Winches 34 - 77

Remove handle after use.
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.
ALWAYS switch off the winch at the circuit breaker/isolator after
sailing or when leaving the boat to prevent accidental operation.

7. Servicing your winch

Fig. 7.0.1

Grease

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.
1. MONTHLY
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.

Electric motors become hot during and for some time after
use. These units have an oil filled gearbox. DO NOT remove the
motor.

• For more details ask for the free booklet and manual “How to
Service Your Winch” B 2304 “Winch Parts Manual Volume
10” B 2196 and “Custom Winch Service Manual Volume 8”
B2312 (77-144/2) or download from:
www.lewmar.com/winchser vice.

2. TWO OR THREE TIMES DURING
ACTIVE SAILING SEASON
Strip, clean, check and relubricate.
3. END OF SEASON OR BEGINNING
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

8. Parts list
• On winches 50 to 65 the 2 lower bearings have been replaced
by item 45003103 (Plain Bearing). These items ARE
interchangeable.
NOTE: Manual winches cannot be converted into
electric versions by adding parts listed here.

8.1 Winch model notes
NOTE: For winches before Februar y 1995.
• Plain bearing 45000248 has replaced the bearings and spacer,
these items ARE NOT interchangeable. Contact your Lewmar
Dealer.

8.2 Parts list 34-65
Fig. 8.2.1

4
3
4
5

2
7
8
10
9

12
13

11
16

14
15

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Description
Centre Stem
Gear Spindle
Rachet Pawl Gear
Pawl
Spring
Bearing
Drive Shaft
Key
Plain Bearing
Base Plate Cover
Base Plate
Dowel
Shaft Seal
Insulation Shim
HEX Bolt M8x25
Washer M8
Plate
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

Qty

64/65

1
1
1
4
4
3
1
1
1
1
1
2
1
1
4
4
1
5
5
6
6
5

45000265
45000258
45000288
15000094
1260/7
15000378
45000357
15003287
45000359
45000229
45000264
45000235
B6234
45000257
B0173
B1207
45000350
B0678
B0524
-

45000237
45000241
45000242
15000094
1260/7
15000378
45000357
15003287
45000359
45000229
45000228
45000235
B6234
45000257
B0173
B1207
45000350
B0678
B0524
-

45000337
45000344
45000342
15000094
1260/7
15000398
45000357
15003287
45000358
45000329
45000328
45000235
B6234
45000257
B0173
B1207
45000350
B0678
B0536
-

45000437
45000444
45000342
15000094
1260/7
15000398
45000357
15003287
45000358
45000429
45000428
45000235
B6234
45000257
B0173
B1207
45000350
B0678
B0536
-

45000560
45000544
45000542
15000301
1260/7
15000017
45000543
15003287
45000248
45000529
45000528
45000581
B6235
45000257
B0173
B1207
45000350
B0678
-

45000660
45000744
45000642
15000301
1260/7
15000017
45000543
15003287
45000248
45000529
45000528
45000581
B6235
45000257
B0173
B1207
45000350
B0678
-

45000760
45000744
45000742
15000301
1260/7
15000017
45000543
15003287
45000248
45000759
45000758
45000581
B6235
45000257
B0173
B1207
45000350
B0678
-

45000860
45000744
45000842
15000301
1260/7
15000017
45000543
15003287
45000248
45000759
45000758
45000581
B6235
45000257
B0173
B1207
45000350
B0678
-

B0812
-

B0567

Ocean Electric Winches 34 - 77

8.3 Parts list 66-77

Fig. 8.3.1

1
2
19
20
3
4

5
6

7
8
9
10
11
12
13
14
15
16
17

*2 Speed versions shown/detailed
Item

Description

Qty

66/68-*2

77-*2

Push Rod Assembly

18000181

18000488

Spring

15044613

‘O’ Ring

B2532

Bush

15000184

Spring Clip

B9941

Drive Dog

15300688

15300575

Seal

B2593

Thrust Sleeve

45002154

Spring

15300489

Hollow Dowel

45002140

Bush

15000569

Screw

B0686

Heli-coil

B2423

Roller Bearing

15010007

Thrust Washer

15003286

Connecting Shaft

45002156

Adaptor

45000944

Key

15003287

Motor/Gearbox 12 V

48000077

Motor/Gearbox 24 V

48000078

Power Base

45000940

45002040

Main Spindle - Elec./Hyd.

45000947

45002180

Ocean Electric Winches 34 - 77

9. Dimensions
Fig. 9.0.1

L
T*

S
X

X
V

Dimensions in mm

Model

34/40

73.5

154

189.4

95.4

237

38.1

33.5

156

112

174

215.5

103.5

238.5

130.5

64.4

186

72.5

112

186

228.0

108.5

238.5

44.5

130.5

64.4

186

72.5

112

105

209

258

126

290

48.5

138.5

59.5

182

112

105

209

270.8

135.8

290

48.5

138.5

59.5

182

112

118

234

286.3

138.8

290

52.9

138.5

59.5

182

112

64/65

118

234

291.3

141.8

290

52.9

138.5

59.5

182

112

66/68

141

282

302.2

142.1

290

144

67.5

188.5

112

66-3

141

294

348

170

290

144

87.5

191.1

112

178

294

348

174

290

144

87.5

191.1

112

77-3

178

294

348

174

290

147

87.5

191.1

112

Dimensions in inches

*Optional extension kits to increase ‘T’ are available to special order. Contact your nearest Lewmar office if required.

Model

34 & 40

2 7/8

6 1/16

7 155/32

3 499/64

9 5/16

1 1/2

3 7/8

1 5/16

6 1/8

2 3/4

4 3/8

3 7/16

6 555/64

8 3/8

4 1/16

9 255/64

1 5/8

5 9/64

2 17/32

7 1/4

2 555/64

4 3/8

3 11/16

7 21/64

9 3/8

4 1/4

9 255/64

1 1/4

5 9/64

2 17/32

7 1/4

2 555/64

4 3/8

4 /8

8 /4

10 /8

155

4 /16

11 /16

155

1 /16

5 /16

2 /16

7 /8

3 /8

4 3/8

4 1/8

8 1/4

10 5/8

5 3/8

11 7/16

1 155/16

5 7/16

2 5/16

7 1/8

3 1/8

4 3/8

4 5/8

9 1/4

11 1/4

5 1/2

11 7/16

2 1/16

5 7/16

2 5/16

7 1/8

3 1/8

4 3/8

64/65

4 /8

9 /4

11 /2

5 /16

11 /16

2 /16

5 /16

2 /16

7 /8

3 /8

4 3/8

66/68

5 9/16

11 1/8

11 155/16

5 9/16

11 7/16

5 7/16

2 11/16

7 3/8

3 1/8

4 3/8

66-3

5 9/16

11 1/2

13 11/16

6 1/16

11 7/16

5 7/16

3 7/16

7 1/2

3 1/8

4 3/8

11 /2

13 /16

6 /8

11 /16

5 /16

3 /16

7 /2

3 /8

4 3/8

77-3

11 1/2

13 11/16

6 7/8

11 7/16

5 7/16

3 7/16

7 1/2

3 1/8

4 3/8

Ocean Electric Winches 34 - 77

10. Total weight
Model

All
Alloy (kg) Bronze
(kg)

Chrome
(kg)

St. Steel
(kg)

All
Chrome
(kg)

Model

Alloy
(lbs)

All
Bronze
(lbs)

Chrome
(lbs)

St.
Steel
(lbs)

All
Chrome
(kg)

21.2

20.7

20.5

21.2

34/40

41.9

46.7

45.6

45.2

46.7

23.3

25.8

25.5

25.8

51.4

56.8

56.2

56.8

30.1

29.4

28.6

30.1

57.3

66.4

64.8

66.3

35.7

34.8

34.7

35.7

66.15

78.7

76.7

76.5

78.7

30.6

37.2

36.4

35.6

37.2

67.4

80.2

78.5

33.4

40.6

39.8

38.1

40.6

73.6

89.5

80.2

89.5

64/65

35.7

43.7

42.9

40.1

43.7

64/65

78.7

96.3

94.6

88.4

96.3

66/68

49.7

48.8

49.7

66/68

92.4

109.3

107.3

101.2

109.3

66-3

54.8

55.7

66-3

105.6

120.6

114.4

122.5

49.3

53.3

62.3

108.5

121.7

116.6

137.7

77/3

51.3

57.3

64.3

77/3

112.9

126.1

121

141.5

Weight in lbs

Weight in kg

34/40

11. Model range
11.1 Model range 34-77
Model

34/40

Part No.

Finish

Description

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
48000081
or 0052505
48000302
or 0052506
48000083
48000084
48000140
48000141

Alloy
Alloy
Chrome
St. Steel
All Chrome
All Bronze

(Model 34) Deck Unit
(Model 40) Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
12 V Motor/Gearbox
24 V Motor/Gearbox

Model

12 V ‘E’ Contactor Box
24 V ‘E’ Contactor Box

Alloy
Chrome
St. Steel
All Chrome
All Bronze

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
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

Part No.

Finish

Description

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
N/A
48000087
48000088
48000144
48000145
48050055

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

Alloy
Chrome
St. Steel
All Chrome
All Bronze

Ocean Electric Winches 34 - 77

Model

64/65

66/68
-2
Speed

66/68
-3
Speed

Part No.

Finish

Description

48054200
48054201
48054204
48054203
48054202
48000075
48000076
N/A
N/A
48000089
48000090
48000146
48000147
48054055
48058200
48058201
48058204
48058203
48058202
48000075
48000076
N/A
N/A
48000091
48000092
48000148
48000149
48058055
48065200
48064200
48064201
48064204
48064203
48064202
48000075
48000076
N/A
N/A
48000093
48000094
48000150
48000151
48064055
48066200
48066201
48066204
48066203
48066202
48000077
48000078
N/A
N/A
18000430
18000431
N/A
N/A
48066205
48066206
48066209
48066208

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
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
(Model 65) Deck Unit
(Model 64) 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
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
Deck Unit
Deck Unit
Deck Unit
Deck Unit

Alloy
Chrome
St. Steel
All Chrome
All Bronze

Alloy
Alloy
Chrome
St. Steel
All Chrome
All Bronze

Alloy
Chrome
St. Steel
All Chrome
All Bronze

Alloy
Chrome
St. Steel
All Chrome

Ocean Electric Winches 34 - 77

Model
77

77 -3
Speed

77 &
77 -3
Speed

Part No.

Finish

Description

48077200
48077201
48077204
48077203
48077205
48077206
48077209
48077208
48000078
48000077
N/A
N/A
48000022
48000023
N/A
N/A

Alloy
Chrome
St. Steel
All Chrome
Alloy
Chrome
St. Steel
All Chrome

Deck Unit
Deck Unit
Deck unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
Deck Unit
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

11.2 Circuit breakers
Model
34/40
44
48
50
54
58
64/65
66/68
77

Voltage

Circuit
Breaker

Circuit Breaker
Part Number

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

90
40
110
50
120
70
150
90
250 FUSE
90
325 FUSE
110
325 FUSE
110
110
50
110
50

68000349
68000542
68000350
68000348
68000239
68000240
68000351
68000349
589008
68000349
589009
68000350
589009
68000350
68000350
68000348
68000350
68000348

*Order fuse holder 589006 with fuse indicated.

11.3 NEW Electric deck switch
Description
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)
Labels - Black out of silver (Sailing functions) use with 48000170

Part Number
68000345
69000350
48000170
69000349
69000356

12. Fault ﬁnding

Fig. 12.0.1

Does the winch operate
manually?

Does the winch operate
electrically?

Check polarity.

Motor runs but winch
does not turn

Check for correct assembly,
over use of grease? pawls
stuck. Clean, check for
broken pawl/springs,
regrease lightly.

Winch handle locked in?
(Winches 66–77 only)

Remove handle.
Check drive dog &
spring (items 6 & 7
parts list)
Ensure free
operation.

Power at the battery?

Check terminal
connections.
Check battery
voltage.
Adequate reserve
battery capacity?

Isolator switch/circuit
breaker on?

Switch on.

Check fuse in control box.

Change fuse
(3 Amp).
Check wiring.
NOTE: EVC does NOT
have a fuse.

Power at winch?

Check circuit
diagram.
Check
connections.
Clean & check cables
conductivity.

Check switch connection
in control box.

Reconnect.

Air hose correctly fitted?

Check tube is
sealed, no leaks.

Contact Lewmar
www.lewmar.com

Ocean Electric Winches 34 - 77

13. Lewmar limited warranty
LIMITED WARRANTY and
KEY TERMS OF SUPPLY BY LEWMAR
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.
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.
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:
a use of a product in an application for which it was not designed or
intended;
b. corrosion, ultra violet degradation or wear and tear;
c. a failure to ser vice 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. 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.
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.
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:
• 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

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.
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.
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.
E SEVERANCE CLAUSE
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.
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.
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.
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.
The British Marine Federation may be contacted at Marine House,
Thorpe Lea Road, Egham, England, TW20 8BF

WWWLEWMARCOM

B2303

Produced by T. Connell UK (+44) 023 9263 9265 Ref:T1712/03/2006

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.5
Linearized                      : Yes
Page Count                      : 22
Has XFA                         : No
XMP Toolkit                     : XMP toolkit 2.9.1-14, framework 1.6
About                           : uuid:deb54978-1de3-4cda-bff6-18eec1fe7d2f
Producer                        : Acrobat Distiller 6.0.1 (Windows)
Create Date                     : 2006:07:19 10:55:35+01:00
Modify Date                     : 2006:07:19 10:57:05+01:00
Metadata Date                   : 2006:07:19 10:57:05+01:00
Document ID                     : uuid:118aa478-f295-400a-9e89-4ce4f5537ac5
Format                          : application/pdf
Title                           : untitled

EXIF Metadata provided by EXIF.tools

Lewmar 34 77 User Manual To The E9bb4393 54a5 4132 B497 Bfa0dfa58845

Navigation menu

Versions of this User Manual:

Views

Navigation