Lewmar PRO Series Owners Installation, Operation & Basic Servicing Manual

GB

a

r.

com

GB

3

P

ro-Series & Pro-Fish Windlass

GB

C

ontents

I

ntroduction

4

Pro

d

uct support 4

Important information about this manual 4

C

E A

pp

rovals 4

S

afet

y

notices

4

Ge

n

e

r

al

4

F

i

tt

i

ng 4

Electrical 4

E

l

ectromagnetic compati

b

i

l

ity 4

1

. In

s

tallation 5

1

.1 Gypsy suita

b

i

l

ity 5

1

.2 Package contents 5

1

.3 Additional re

q

uirements 5

1.

4

Accesso

ri

es

5

1

.5

S

pec

iﬁ

cat

i

ons 5

1

.6 Fitting the windlass to the deck 5/6

2

. E

l

ectr

i

ca

l

w

i

r

i

ng

i

nsta

ll

at

i

on

7

2

.1 Electrical cable selection

7

2

.2 Wirin

g

7

2.3

M

odel

700

- 12 V

8

2

.4 Model 1000 - 12 V

9

3

.

O

perat

i

ng your w

i

n

dl

ass 10

3.1 Safety ﬁ rst 10

3.

2

Use

o

f

clutch

o

n Pr

o

-

Se

ri

es

1

0

3.3

Use

o

f

clutch

o

n Pr

o

-Fi

sh

1

0

3.4 Letting go under gravit

y

10

3.5 Lettin

g

o un

d

er

p

ower 10

3.6 C

h

ange Pro-Fis

h

to power

d

own mo

d

e 10

3.7 L

y

ing to anchor safel

y

10

3.8 Haulin

g

in 10

3.9 Manua

l

recovery 10

3.10

O

perat

i

ng t

i

ps 10

3.11 Joining rope to chain 10

B10490 Issue 1. Pro-Series & Pro-Fish Windlass.

4. Maintenance 1

1

4

.

1

Ge

n

e

r

al

r

eco

mm

e

n

dat

i

o

n

s

11

5. D

i

smant

li

n

g

proce

d

ure 1

1

5.1 G

y

ps

y

replacement (Pro-Series) 1

1

5.2 G

y

ps

y

replacement (Pro-Fish) 1

1

5.3 Contro

l

arm rep

l

acement 1

1

5.4 Gypsy drive shaft replacemen

t

&

lubrication service 1

1

5.5 E

l

ectric motor re

pl

acement 12

5.6

Pr

o

-Fi

sh

co

nv

e

r

s

i

o

n 1

2

6. Part

s

li

s

t 12

6

.1 Exploded diagram & Parts list 12/1

3

6

.2 Service kits 1

3

7. Troubleshooting 13

7.1 Anc

h

or ro

d

e pays out in

d

epen

d

ent

l

y

whil

e

win

d

l

ass

i

s

n

ot

in

use

14

7.2 Anchor rode pa

y

s out independentl

y

w

h

i

l

e win

dl

ass is not in use

(

Pro-Fis

h)

14

7.3 E

l

ectrica

l

trou

bl

es

h

ooting 14

8. Lewmar

li

m

i

te

d

warranty 15

To the best of our knowled

g

e, the information in this manual

was correct w

h

en it went to press. However, Lewmar canno

t

accept

l

ia

b

i

l

ity for any inaccuracies or omissions it may contain.

In a

dd

ition, our po

l

icy of continuous pro

d

uct improvement ma

y

c

h

ange speciﬁ cations wit

h

out notice. As a resu

l

t, Lewmar canno

t

accept liability for any differences between the product and the

m

a

n

ua

l

.

This manual forms

p

art of the

p

roduct and MUST BE RETAINED

alon

g

with, OR incor

p

orated into, the Owner’s Manual for the vessel

to

whi

c

h th

e

win

d

l

ass

i

s

ﬁ tt

ed.

4

P

ro-Series & Pro-Fish Windlass

I

ntro

d

uction

Im

p

ortant

i

n

f

ormat

i

on a

b

out t

hi

s manua

l

Th

roug

h

out t

h

is manua

l

, you wi

ll

see safety an

d

pro

d

uct

d

amage

w

arnings. You must fo

ll

ow t

h

ese warnings carefu

ll

y to avoi

d

p

ossi

bl

e injury or

d

amage.

T

he type of warnings, what they look like, and how they are used

i

n this manual are ex

p

lained as follows:

Dear

C

ustomer

,

T

h

an

k

you for c

h

oosing Lewmar win

dl

ass. Lewmar pro

d

ucts are

world renowned for their qualit

y

, technical innovation and proven

performance. With a Lewmar windlass

y

ou will be provided with

man

y

ears of outstanding service

.

P

roduct support

Lewmar products are supported b

y

a worldwide network of

distributors and Authorised Service Representatives. If

y

ou

encounter an

y

difﬁ culties with this product, please contact

y

our

national distributor, or

y

our local Lewmar dealer. Details are

avai

l

a

bl

e at

:

www.lewmar.com

App

roval

s

For CE a

pp

roval certiﬁ cates contact Lewmar.

G

enera

l

Please read before installin

g

and operatin

g

your

Windla

ss.

Classiﬁ cation Societies and Lewmar re

q

uire that a vessel a

t

anc

h

or must

h

ave its ro

d

e

h

e

ld

b

y a c

h

ain stopper or equiva

l

ent

strong point at a

ll

times!

At a

ll

times it is t

h

e responsi

b

i

l

ity of t

h

e

b

oat user to ensure

t

h

at t

h

e anc

h

or an

d

ro

d

e are proper

l

y stowe

d

for t

h

e prevai

l

ing

sea conditions. This is particularl

y

important with high-speed

powerboats, because an anchor accidentall

y

deplo

y

ing while

under wa

y

can cause considerable damage. An anchor windlass

is mounted in the most ex

p

osed

p

osition on a vessel and is thus

sub

j

ect to severe atmospheric attack resulting in a possibilit

y

o

f

corrosion in excess of t

h

at ex

p

erience

d

wit

h

most ot

h

er items of

d

ec

k

equipment. As t

h

e win

dl

ass may on

l

y

b

e use

d

infrequent

l

y,

t

h

e ris

k

of corrosion is furt

h

er increase

d

. It is essentia

l

t

h

at t

h

e

win

dl

ass is regu

l

ar

l

y examine

d

, operate

d

an

d

given any necessar

y

maintenance

.

P

l

ease ensure t

h

at

y

ou t

h

oroug

hly

un

d

erstan

d

t

h

e operation

and safet

y

requirements of the windlass before commencing

the installation. Onl

y

persons who are completel

y

familiar with

the controls and those who have been full

y

made aware of the

co

rr

ect

use

o

f

t

h

e

win

d

l

ass

s

h

ou

l

d

be

a

ll

o

w

ed

to

use

i

t.

If

t

h

e

r

e

i

s

any

d

ou

b

t of

h

ow to insta

ll

or operate t

h

is unit p

l

ease see

k

a

d

vice

from a suita

bl

y qua

l

iﬁ e

d

engineer

.

•

Win

dl

asses use

d

incorrect

l

y cou

ld

cause

h

arm to equipmen

t

o

r

c

r

ew

.

•

Win

dl

asses s

h

ou

ld

b

e use

d

wit

h

care an

d

treate

d

wit

h

res

p

ect

.

•

Sailing, like man

y

other sports can be hazardous. Even the

correct selection, maintenance and use of

p

ro

p

er e

q

ui

p

men

t

cannot eliminate the potential for danger, serious in

j

ur

y

o

r

deat

h

.

•

Lewmar win

dl

asses are

d

esigne

d

an

d

supp

l

ie

d

for anc

h

or

contro

l

in marine app

l

ications an

d

are to

b

e use

d

in conjunction

wit

h

any ot

h

er use.

•

It is t

h

e unavoi

d

a

bl

e responsi

b

i

l

ity of t

h

e owner or master or

ot

h

er responsi

bl

e party to assess t

h

e ris

k

of any operation on

the vessel

.

S

afet

y

notices

W

arn

i

ng

!

Thi

s

i

s a warn

i

ng aga

i

nst anyt

hi

ng w

hi

c

h

may cause

i

n

j

ury to peop

l

e

i

f the warnin

g

is i

g

nored. You are informed about what you must

or must not do in order to reduce the risk of in

j

ury to yourself and

o

th

e

r

s

.

S

afet

y

S

y

mbo

l

When

y

ou see the safet

y

s

y

mbol it means: “Do not...”; “Do not do

this”; or “Do not let this ha

pp

en”

.

•

L

ewmar recommen

d

s t

h

e use of appropriate Persona

l

P

rotective E

q

ui

p

ment an

d

h

an

d

s free communication

e

quipment b

y

an

y

person going aloft, and onl

y

then where

t

he person going aloft is properl

y

trained in the use of that

eq

ui

p

ment and where there remain sufﬁ cient trained and

e

x

p

erienced

p

ersonnel on deck to ensure constant observation

a

n

d

t

h

e continue

d

safe con

d

uct

b

ot

h

of t

h

e vesse

l

an

d

t

h

e

h

oisting operation.

Fittin

g

•

This e

q

ui

p

ment must be installed and o

p

erated in accordance

w

i

t

h

t

h

e

in

st

r

uct

i

o

n

s

co

n

ta

in

ed

in

t

hi

s

m

a

n

ua

l

.

F

a

il

u

r

e

to

do

s

o could result in poor product performance, personal in

j

ur

y

a

nd/or damage to

y

our boat.

•

Consult the boat manufacturer if

y

ou have an

y

doubt about

th

e strengt

h

or suita

b

i

l

ity of t

h

e mounting

l

ocation

.

E

l

ect

ri

ca

l

•

Ma

k

e sure you

h

ave switc

h

e

d

off t

h

e power

b

efore you start

i

nsta

ll

ing t

h

is pro

d

uct.

•

If in doubt about installin

g

electrical e

q

ui

p

ment

p

lease seek

a

dvice from a suitabl

y

qualiﬁ ed electrical engineer

.

El

ectromagnet

i

c compat

ibili

t

y

•

It is essentia

l

t

h

at t

h

is pro

d

uct

d

oes not cause any

el

ectromagnetic

d

istur

b

ance to any ot

h

er e

l

ectrica

l

or

el

ectronic equipment insta

ll

e

d

in t

h

e vesse

l

. T

h

is wi

ll

b

e

a

c

h

ieve

d

if t

h

e win

dl

ass is connecte

d

to t

h

e same

b

attery as

t

he vessel’s starter motor and not to the service batter

y

to

w

hich other e

q

ui

p

ment is connected. In addition, the run of

t

he wiring, from the batter

y

to the windlass, should be kept

a

s far a

p

art from the other wirin

g

on the vessel as

p

ossible.

F

or instance, if the main wirin

g

loom is to starboard, ﬁ t the

w

in

dl

ass wiring to port.

It s

h

ou

ld

b

e note

d

t

h

at t

h

ere is no evi

d

ence to in

d

icate t

h

at

w

in

dl

ass insta

ll

ations

d

o cause magnetic interference

b

ut t

h

e

i

nsta

ll

er is a

d

vise

d

to carry out c

h

ec

k

s w

h

en t

h

e insta

ll

ation

i

s comp

l

ete.

5

P

ro-Series & Pro-Fish Windlass

GB

1

. Insta

ll

atio

n

1

.1 G

yp

s

y

suitabilit

y

Gypsies ﬁ tte

d

to t

h

e Pro-Series range of win

dl

asses are i

d

ea

ll

y

suite

d

to

h

an

dl

ing our factory ma

d

e Rope

/

C

h

ain com

b

ination

rodes, which consist of rope spliced to a chain tail.

Ropes use

d

must

b

e win

dl

ass gra

d

e, me

d

ium

l

ay ny

l

on. Ropes

from

d

ifferent manufacturers

h

ave wi

d

e variations in stretc

h

an

d

consistenc

y

in diameter. Therefore, rope and chain from other

manufacturers ma

y

require some experimentation to determine

the o

p

timum size.

Should

y

ou have difﬁ cult

y

in matching a g

y

ps

y

to

y

our chain

please consult

y

our local agent or our international network of

L

e

wm

a

r

d

i

st

ri

buto

r

s

w

o

rl

d

wi

de.

1

.2 Packa

g

e content

s

• Win

dl

ass

• Inte

ll

igent Mounting Stu

d

s, Was

h

ers an

d

Nuts

• A

ll

-in-

o

n

e

In

stallat

i

o

n Wr

e

n

ch

&

Clutch

L

e

v

e

r

• B

ase

Gas

k

et

Sea

l

• Safet

y

Instructions

• Mountin

g

Tem

p

late

• In

st

r

uct

i

o

n B

oo

kl

et

• Warrant

y

Registration Card

• Breaker

/

Isolator

• Control Switch (Pro-Series 700 onl

y

)

• Guar

d

e

d

Roc

k

er Switc

h

(

Pro-Series 1000 on

l

y

)

• Contactor

(

Pro-Series 1000 on

l

y

)

1

.3 Additional requirement

s

Eac

h

insta

ll

ation requires:

Windla

ss

in

s

tallation

The followin

g

tools:

• 10 mm

(

3

/

8

”)

Drill.

• 75 mm

(

3”

)

Hole saw.

• An a

pp

ro

p

riate marine sealant.

W

i

r

i

n

g

i

nsta

ll

at

i

on

T

h

e fo

ll

owing too

l

s:

• Crimping p

l

iers

/

wire stripper.

• Suita

bl

e e

l

ectrica

l

ca

bl

e an

d

crimp termina

l

s.

M

ode

l Gy

p

s

y

C

hain Ro

pe

7

00

R

C0762

7

mm

(

1

/

4

”

)

H

i

g

h Test G-4 ISO

1

2

mm or

1

/

2

”

3

stran

d

m

edium la

y

or

8

plait n

y

lo

n

7

00

R

C067

0

6 mm

(

NON USA

)

1

2 mm

(

NON USA

)

1

000

R

C085

0

8

mm (

5

/

1

6

”)

H

igh Test G-4 ISO

1

4-1

6

mm or

9

/

1

6

”

-

5

/

8

”

3

strand medium la

y

o

r

8

plait n

y

lo

n

1.4 Accessorie

s

Use on

l

y Lewmar parts an

d

accessories to ensure top performance

an

d

e

l

iminate t

h

e ris

k

of voi

d

ing your warranty. For rep

l

acemen

t

parts, p

l

ease see t

h

e Parts section or visit your nearest

d

ea

l

er o

r

the Lewmar website

.

1.5 S

p

eciﬁ cation

s

Model 7

00

Maximum

p

ul

l

3

20 k

g

(

700 lb

)

Maximum line s

p

ee

d

3

2 m/min

(

105 ft/min

)

T

y

pical working load

80

k

g

(

175 lb

)

Normal line s

p

ee

d

2

7 m/min

(88

f

t/min

)

B

oat siz

e

u

p

to 10.7 m

(3

5 ft

)

Model

1000

Maximum

p

ul

l

454 k

g

(

1000 lb

)

Maximum line s

p

ee

d

3

2 m/min

(

105 ft/min

)

12 V

T

y

pical working load

1

14 k

g

(

250 lb

)

Normal line s

p

ee

d

2

7 m/min

(

88 ft/min

)

12

V

B

o

a

t

s

iz

e

u

p

to 1

3

.7 m

(

45 ft

)

1.6 F

i

tt

i

ng t

h

e w

i

n

dl

ass to t

h

e

d

ec

k

• If t

h

e

d

ec

k

is not ﬂ at, a suita

bl

e mounting pa

d

may

b

e require

d

to ta

k

e up cam

b

er or s

h

eer

.

Dec

k

s t

h

at are t

h

in, or of foam or

b

a

l

sa

l

aminate construction,

wi

ll

require reinforcement in or

d

er to sprea

d

t

h

e

l

oa

d

s t

h

a

t

will be a

pp

lied to the deck while the windlass is in use.

The standard 8 mm

(

5

/

16

”

) threaded mountin

g

studs su

pp

lied

suit deck and

p

ackin

g

thickness of u

p

to 76 mm (3”). These

are ade

q

uate for most installations.

Fi

g

.

1

.

6

.

1

• Place the windlass on the deck and decide u

p

on a

p

osition for

it with reference to the vessel’s bow roller (Fi

g

. 1.6.2) and the

chain locker below. Rode lead from the roller should ideall

y

be fed horizontall

y

back to the top of the g

y

ps

y

and along its

center

l

ine

(

Fig. 1.6.3

)

.

T

h

ere must

b

e sufﬁ cient vertica

l

fa

ll

for t

h

e c

h

ain or rope,

even wit

h

a fu

ll

l

oc

k

er, to

d

raw t

h

e ro

d

e from t

h

e gypsy w

h

en

h

au

l

ing in

.

• Pro-

S

eries & Pro-Fish Manual

All references re

g

ardin

g

installation and wirin

g

e

tc. of Pro-Series a

pp

l

y

to the e

q

uivalent

P

ro-Fish model

(

700 or 1000

).

6

P

ro-Series & Pro-Fish Windlass

DO NOT use a

p

ermanent adhesive/sealant, e.

g

., 5200 to the base

of the windlass, any mountin

g

p

ad or around the studs

.

12” (300 mm) min.

Fi

g

. 1.6.2

ro

)

m

m01(

"

8

/3

=

A

l

li

rD

)

m

6

7

(

"

3

=

B

waS

e

l

oH

)mm0

1

(

"

8

/3 =

A

l

i

rD

)

m

6

7

(

"3

=

B

w

a

S

e

lo

H

ssaldniW

enilt

u

O

e

s

a

B

taM

s

sa

l

dn

i

W

en

ilt

u

O

esa

B

t

a

M

en

o

ci

l

i

S

t

n

al

ae

S

• Usin

g

a 10 mm (

3

/

8

”)

diameter drill, make the three holes

for the mountin

g

studs and two for the motor wires. With

a

76 mm

(

3”

)

diameter hole saw, make the hole for the rode to

p

ass throu

g

h. When all the holes have been made, remove the

template. To help avoid water absorption b

y

the deck, appl

y

an appropriate marine sea

l

ant to t

h

e fres

hl

y cut

h

o

l

e e

d

ges.

e

l

c

r

i

C

ret

u

O

=

B

Øm

6

7

(

"

3m)

=

CØ)

m

m5

2

(

"

1

e

vi

t

a

n

r

e

t

l

A

el

oH

e

r

i

W

u

O

=

Be

lc

r

i

C

re

t

Øm6

7

(

"

3)

m

=

CØ)

m

m5

2

(

"1

e

v

i

t

a

n

r

e

t

l

A

e

l

oH e

r

iW

Fig. 1.6.4

F

• P

l

ace t

h

e mounting temp

l

ate on t

h

e

d

ec

k

or mounting pa

d

in

the desired

p

osition for the windlass and hold it in

p

lace usin

g

adhesive ta

p

e

.

• NOTE: Check the

s

cale of the

tem

p

late matches the winch.

F

ig.

1

.

6

.5

• Fu

ll

y screw t

h

e t

h

ree mounting stu

d

s into t

h

e

b

ase of t

h

e

windlass. This can be done, quite simpl

y

, using the multi-tool

wrench su

pp

lied. Screw the studs into the base ﬁ n

g

er ti

g

ht,

with the ﬂ ats towards the base (Fi

g

1.6.5).

•

Next, using t

h

e wrenc

h

on t

h

e ﬂ ats, tig

h

ten t

h

e stu

d

s unti

l

t

hey bottom out in their holes. Do this to each of the studs in

tu

rn

.

F

i

g

. 1.6.

6

As a ru

l

e of t

h

um

b

, if t

h

e ﬂ ats on t

h

e stu

d

s are visi

bl

e

b

e

l

ow

d

eck, the deck and/or any packing is likely to be too thin to

o

ffer ade

q

uate su

pp

ort when the windlass is under load.

•

NOTE: If usin

g

silicone or other rubber y type sealant,

i

t is advisable to allow curin

g

of the sealant before

ﬁ

nal ti

g

htenin

g

of the mountin

g

nuts. Trim the studs

b

ac

k

to 6 mm

(

1

/

4

/

”)

b

e

l

ow t

h

e

f

u

ll

y t

i

g

h

tene

d

nuts.

DO NOT

g

et CAULK or SEALANT under the GEAR TRAIN COVER

(

17

)

as it makes it difﬁ cult to remove. Secure the windlass ﬁ rmly

to the deck

f

rom below, using the nuts and washers supplied

.

Fig.

1

.

6

.3

•

P

l

ace t

h

e

b

ase mat in position on t

h

e

d

ec

k

, optiona

ll

y, app

l

y

a

suita

bl

e sea

l

ant.

F

i

g

. 1.6.

7

P

ro-Series & Pro-Fish Windlass

GB

2

. E

l

ectrica

l

wirin

g

insta

ll

atio

n

2

.1 E

l

ectr

i

c ca

bl

e se

l

ect

i

o

n

To ac

h

ieve t

h

e

b

est performance an

d

to safeguar

d

your e

l

ectrica

l

system it is essentia

l

t

h

at any e

l

ectrica

l

win

dl

ass

b

e ﬁ tte

d

wit

h

sufﬁ cient

l

y

l

arge

d

iameter ca

bl

e to cope wit

h

t

h

e current

d

raw

imposed upon it and to keep the voltage drop within acceptable

limits. In an

y

circumstance voltage drop due entirel

y

to cable

r

es

i

sta

n

ce

s

h

ou

l

d

n

ot

e

x

ceed

1

0%.

The followin

g

table

g

ives recommended cable sizes. The

recommendations are based on total len

g

th of cable re

q

uired,

from t

h

e

b

attery, fo

ll

owing t

h

e route of t

h

e ca

bl

es.

• Tota

l

engt

h

o

f

ca

bl

e run

i

s

f

rom t

h

e

b

attery to t

h

e

wi

n

dl

ass, an

d

f

rom t

h

e w

i

n

dl

ass

b

ac

k

to t

h

e

b

attery

.

Model 7

00

cable selection

V

o

lt

s

C

able Length

S

ize

m

f

t

mm

2

AW

G

12

0

- 1

2

0

- 4

0

1

0

8

1

2

.

5

- 1

8

41 -

60

1

0

6

1

8

.

5

- 2

4

6

1 -

80

1

5

6

M

ode

l 1000

cab

l

e

se

l

ec

ti

on

V

o

l

t

s

Cable Len

g

t

h

S

iz

e

m

f

t

mm

2

A

W

G

12

0

- 1

5

0 - 50

1

6

4

15.5 - 2

1

5

1 - 7

0

25

2

1.5 -

3

0.

5

7

1 - 10

0

35

2

• In Mu

l

ti Station insta

ll

ations 14 AWG wire

(

1.5 mm² cross

s

ectional area, 21/0.30 PVC covered) is used to connect the

s

witches to the reversin

g

control box.

2.2 W

i

r

i

n

g

P

l

an t

h

e insta

ll

ation to suit t

h

e contro

l

s an

d

give t

h

e operator a fu

ll

view of t

h

e win

dl

ass. T

h

e wiring system s

h

ou

ld

b

e of t

h

e two ca

bl

e

fu

ll

y insu

l

ate

d

return type, w

h

ic

h

avoi

d

s possi

bl

e e

l

ectro

l

ytic

corrosion problems. We recommend the use of type III stranded,

tinned co

pp

er wire with co

pp

er crim

p

terminals. Most modern

installations are negative return (negative ground) but polarit

y

should be checked. If necessar

y

add a grounding strap between

the mountin

g

studs and an earthin

g

p

oint.

In a Mo

d

e

l

1000 insta

ll

ation, t

h

e contactor must

b

e site

d

in a

d

ry

l

ocation

.

If a contactor is insta

ll

e

d

in an anc

h

or

l

oc

k

er it is expose

d

to

h

ars

h

conditions it is not designed to withstand. Furthermore this type

of installation will void

y

our warrant

y.

Overload

p

rotection, in the form of the circuit breaker/isolato

r

su

pp

lied, must be built into the windlass wirin

g

circuit. This

p

rotects the wirin

g

and

p

revents undue dama

g

e to the windlass

motor, in the event of its being stalled b

y

an excessive load in

serv

i

ce

.

It is a

d

visa

bl

e to site t

h

e circuit

b

rea

k

er

/

iso

l

ator in a

d

ry,

rea

d

i

l

y accessi

bl

e p

l

ace. T

h

e Brea

k

er

/

Iso

l

ator supp

l

ie

d

mus

t

b

e manua

ll

y reset s

h

ou

ld

an over

l

oa

d

occur t

h

at causes it to trip

to t

h

e off position

.

• NOTE: Crim

p

terminals should be used on all wire

ends wherever possible for

g

ood electrical contacts.

If

y

ou are not sure

y

ou understand these guidelines, see

k

p

rofessional hel

p.

2.3 Control Switch Installation

Fo

ll

ow t

h

e mounting instructions supp

l

ie

d

wit

h

t

h

e switc

h

.

Remem

b

er, in a Mu

l

ti Station insta

ll

ation a

ll

switc

h

es must

b

e

wire

d

in a para

ll

e

l

circuit

.

DO NOT confuse cable Len

g

th with the len

g

th of the vessel!

DO

N

O

T install the contactor in the anchor locker

.

8

P

ro-Series & Pro-Fish Windlass

C

h

oice of ca

bl

e t

h

ic

k

ness

d

epen

d

s on tota

l

ca

bl

e

l

engt

h

:

A

+ B + C + D + E

=

Battery to windlass, windlass to battery

.

BATTERY

12 VOLT

+

C

D

E

B

A

Rear View on

Toggle Switch

0052519

50A Breaker/Isolator

68000348 - 12 V

F

ig.

2

.3.

1

M

o

d

e

l

M

oto

r

B

reaker

/

Isolato

r

C

ontactor

700

12

V 50 A (68000348

)

-

1000

1

2 V 70 A (68000240

)

005

2

5

31

2.3 Mo

d

e

l

700 - 12 V

A + B +

C

+ D + E

=

12 V

up

to 12 m

(

40 ft

)

1

2.5 to 18 m

(

41 to 60 ft

)

18.5 to 24 m

(

61 to 80 ft

)

US

E

1

0 m

m

2

(

8 AW

G)

10 mm

2

(

6 AW

G)

16 mm

2

(

6 AW

G)

9

P

ro-Series & Pro-Fish Windlass

GB

2

.4 Mo

d

e

l

1000 - 12

V

CIRCUIT

BREAKER/ISOLATOR

BATTERY

GUARDED

ROCKER

SWITCH

68000593

Fuse

3 A

CONTACTOR

0052531 - 12 V

68000240 - 70 A, 12 V

E

A

B

D

C

Shared

Down

Up

DOWN UP

DECK

FOOT SWITCH

SET

68000598 Black

68000597 White

HAND

HELD

CONTROL

68000599

+

R

Fi

g

. 2.4.1

A

+ B +

C

+ D + E =

12 V

U

p

to 15 m

(

50 ft

)

15.5 to 21 m

(

51 to 70 ft

)

21.5 to

3

0.5 m

(

71 to 100 ft

)

US

E16 mm

2

(

4 AW

G)

25 mm

2

(

2 AW

G)

3

5 m

m

2

(

2 AW

G)

1

0

P

ro-Series & Pro-Fish Windlass

As a pru

d

ent act of seamans

h

ip, anc

h

or recovery operations

re

q

uire the undivided attention of ski

pp

er and crew to

p

reven

t

personal in

j

ur

y

or damage to the vessel.

In a t

y

pical anchor recover

y

situation, the windlass will pass

throu

g

h a number of o

p

erational

p

hases.

3.1 Safet

y

ﬁ rs

t

To avoi

d

persona

l

injuries ensure t

h

at

l

im

b

s, ﬁ ngers an

d

c

l

ot

h

ing

are

k

ept c

l

ear of t

h

e anc

h

or ro

d

e an

d

win

dl

ass

d

uring operation.

A

l

ways ensure t

h

at t

h

ere are no swimmers or

d

ivers near

b

y w

h

en

d

ropping your anc

h

or

.

3.2 U

s

e of clutch on Pro-Serie

s

To ti

g

hten the clutch - usin

g

the Installation Tool & Clutch Leve

r

su

pp

lied, rotate the clutch nut (1) clockwise, this will

g

ri

p

the

gypsy, effective

l

y

l

oc

k

ing it to t

h

e win

dl

ass gear train.

To s

l

ac

k

en t

h

e c

l

utc

h

- turn t

h

e nut antic

l

oc

k

wise, t

h

is wi

ll

free

t

h

e gypsy a

ll

owing it to turn in

d

epen

d

ent

l

y of t

h

e win

dl

ass gear

train. A

l

ways remove t

h

e

h

an

dl

e after use.

3.3 U

s

e of clutch on Pro-Fi

s

h freefall

Pr

ess

D

O

WN

butto

n f

o

r 2

seco

n

ds

u

n

t

il

t

h

e

a

n

c

h

o

r i

s

u

n

de

r

freefall. (Note: Pressin

g

the DOWN button for 5+ seconds will

result in a lon

g

er clutch re-en

g

a

g

ement time durin

g

the next UP

comman

d)

. If using a rope

/

c

h

ain ro

d

e, motor astern to create

t

h

e

d

esire

d

scope

.

Once scope

h

as

b

een create

d

press t

h

e UP

b

utton continuous

l

y

unti

l

freefa

ll

stops. It norma

ll

y ta

k

es severa

l

secon

d

s to fu

ll

y

re-engage t

h

e interna

l

c

l

utc

h

mec

h

anism,

l

oc

k

ing t

h

e win

dl

ass.

Fai

l

ure to

d

o t

h

is cou

ld

resu

l

t in rope

/

c

h

ain creeping out. Press

the UP button continuousl

y

to recover the anchor

.

3.4 Letting go under gravit

y

Insert t

h

e c

l

utc

h

l

ever into t

h

e c

l

utc

h

nut

(

1

)

an

d

turn it c

l

oc

k

wise

to ensure t

h

at t

h

e c

l

utc

h

is tig

h

t. Re

l

ease any in

d

epen

d

ent anc

h

o

r

l

oc

k

s. If it is safe to

d

o so, pu

ll

b

ac

k

on t

h

e c

l

utc

h

l

ever unti

l

t

h

e

anchor and rode begin to pa

y

out. Control the rate of descent o

f

the anchor b

y

pushing the clutch lever forwards. When sufﬁ cien

t

rode has been paid out, full

y

tighten the clutch nut once again.

3.5 Lett

i

ng go un

d

er power

Re

l

ease any in

d

epen

d

ent anc

h

or

l

oc

k

s. If it is safe to

d

o so,

l

et

go un

d

er power

b

y operating a

d

own contro

l

. Re

l

ease t

h

e contro

l

w

h

en sufﬁ cient ro

d

e

h

as

b

een pai

d

out.

3.6

Ch

ange Pro-F

i

s

h

to power

d

own mo

d

e

Lock the Pro-Fish Plun

g

er (38) in, usin

g

the Sto

pp

er (41). The unit will

now function as a stan

d

ar

d

Pro-Series

.

3.7 Lying to anchor safel

y

Vesse

l

s at anc

h

or wi

ll

snu

b

on t

h

e ro

d

e an

d

t

h

is can cause s

l

ippage or

apply excessive loads to the windlass.

For maximum safety and to prevent damage, the windlass must not be

l

e

f

t

to

ta

k

e

t

h

e

n

t

ir

e

f

o

r

ce

fr

o

m

t

h

e

a

n

c

h

o

r r

ode

whil

e

at

a

n

c

h

o

r

.

Th

e

rode should be made fast directl

y

to a bollard, sampson post or cleat.

3

.8 Hau

li

ng

in

U

ntie t

h

e

b

ri

dl

e or rep

l

ace t

h

e ro

d

e in t

h

e gypsy. If it is safe to

d

o

s

o, operate an ‘Up’ contro

l

. Having retrieve

d

t

h

e anc

h

or, ensure it

i

s in

d

epen

d

ent

l

y secure

d

to prevent its acci

d

enta

l

re

l

ease.

3

.9 Manua

l

recovery

I

nsert a standard 12 mm

(

1

/

2

”

)

drive ratchet into the socket

o

n the end of the Driveshaft (30). Usin

g

the ratchet, turn the

d

riv

es

h

a

f

t

c

l

oc

kwi

se.

3

.10 Operating tips

Wh

en anc

h

oring, it is

b

est to power t

h

e ro

d

e out, a

ll

owing t

h

e

v

esse

l

to ta

k

e up stern way

b

efore fu

ll

scope is

l

et out. T

h

is

h

e

l

ps

p

revent the rode from becoming tangled on top of

y

our anchor

o

n

t

h

e

seabed.

T

o aid anchor recover

y

, we recommend that the vessel’s engine

b

e used to assist b

y

moving the vessel towards the anchor. We

d

o not recommend that the vessel be motored over and be

y

ond

th

e anc

h

or, as t

h

is can cause t

h

e ro

d

e to

d

amage your topsi

d

es.

A

s t

h

e anc

h

or approac

h

es t

h

e stem

h

ea

d

, t

h

e

l

ast few feet of

r

o

d

e s

h

ou

ld

b

e inc

h

e

d

in

b

y ju

d

icious use of contro

l

s to avoi

d

amage to t

h

e vesse

l

. Having retrieve

d

t

h

e anc

h

or, ensure it is

i

ndependentl

y

secured to prevent accidental release. It is strongl

y

a

dvised to use an anchor safet

y

strap (Part No. 66840011), or a

c

hain sto

pp

er (Part No. 2417301).

W

hen mooring stern to, at a suitable distance from the

j

ett

y

,

d

eplo

y

the anchor to prevent the bow from swinging. Gentl

y

pa

y

o

ut t

h

e ro

d

e un

d

er t

h

e inﬂ uence of t

h

e stern way of t

h

e vesse

l

a

s it approac

h

es t

h

e jetty. Ma

k

e fast your vesse

l

wit

h

warps from

th

e stern.

3

.11 Joinin

g

rope to chain

W

hen s

p

licin

g

ro

p

e to chain, select a len

g

th of chain that will

a

void having the splice positioned in the g

y

ps

y

when the anchor

c

omes over the stemhead. Furthermore, ensure that the s

p

lice

i

s no ti

g

hter than the ro

p

e. A hard s

p

lice is not desired.

W

ith whipping twine or similar, seize

y

our rope 200 mm (8”) from

th

e rope’s en

d

an

d

un

l

ay t

h

e stran

d

s.

P

ass one stran

d

t

h

roug

h

t

h

e c

h

ain

l

in

k

from one si

d

e an

d

t

h

e ot

h

er

t

wo stran

d

s from t

h

e opposite si

d

e. Remove seizing an

d

comp

l

ete

a

b

ac

k

sp

l

ice in t

h

e norma

l

manner for four fu

ll

tuc

k

s.

W

it

h

a

h

ot

k

nife pare

d

own t

h

e t

h

ree stran

d

s

b

y one

h

a

l

f of t

h

eir

d

i

a

m

ete

r

a

n

d

co

n

t

in

ue

wi

th

t

w

o

f

u

r

the

r

tucks.

W

ith a hot knife, carefull

y

melt the ends back into the line.

B

ecause of wide variations in rope t

y

pe and construction some

e

xperimentation ma

y

be required.

W

hi

p

the line with

p

ermanent whi

pp

in

g

at the be

g

innin

g

of the

t

aper.

Th

e a

b

ove met

h

o

d

of joining is

d

esigne

d

to minimize c

h

afe

b

etween t

h

e rope an

d

c

h

ain

b

ut as a matter of pru

d

ent seamans

h

ip

th

e sp

l

ice s

h

ou

ld

b

e c

h

ec

k

e

d

regu

l

ar

l

y an

d

rema

d

e if t

h

ere is

a

ny evi

d

ence of wear.

F

i

g

. 3.

11

.

1

3

. Operating

y

our windlass

To ensure continuous freefall operation using rope

/

chain rode, it

is important that the rope is FREE

f

rom knots or hockles. To avoid

thi

s pro

bl

em we recommen

d

per

i

o

di

ca

ll

y pay

i

ng out t

h

e ro

d

e w

hil

st

motoring astern (in deep water) to unwind and knots or hockles

t

hat may be

p

resent

.

Isolate the windlass electrically and tie rode off to a secure ﬁ xin

g

p

oint

p

rior to carryin

g

out o

p

eration 3.6.

11

P

ro-Series & Pro-Fish Windlass

GB

4. Maintenanc

e

4

.1

G

enera

l

recommen

d

at

i

on

s

• After the ﬁ rst two or three anchor recoveries

,

check the

m

ountin

g

nuts to ensure that the windlass is still fastened

t

ightl

y

to

y

our deck, as it should now be bedded-in.

• Regu

l

ar

l

y was

h

d

own t

h

e exterior of your win

dl

ass wit

h

fres

h

w

a

t

er.

• Examine a

ll

e

l

ectrica

l

connections for possi

bl

e corrosion, c

l

ean

and lightl

y

grease as necessar

y.

• Anchor rode splice should be checked regularl

y

and remade

if there is an

y

evidence of wear

.

• The G

y

ps

y

should be examined on a regular basis, because i

t

is a high wear item. The G

y

ps

y

is designed for short scopes

of c

h

ain an

d

wi

ll

l

ast

l

onger if proper

l

y use

d

.

5. Dismantling procedures

5

.1 Gypsy replacement (Pro-Series

)

Remove t

h

e C

l

utc

h

Nut

(

1

)

, anti-c

l

oc

k

wise using t

h

e c

l

utc

h

operating

l

ever. Wit

hd

raw t

h

e Gypsy Cone

(

2

)

, carefu

ll

y set asi

d

e

t

h

e two Stain

l

ess Stee

l

Drive Pins

(

28

)

. Pu

ll

t

h

e Contro

l

Arm

(

8

)

into t

h

e uprig

h

t position. Remove t

h

e Screws

(

31

)

t

h

at retain

the Stri

pp

er (4) usin

g

a 4 mm (5

/

32”

)

Allen Wrench. Remove the

G

y

ps

y

assembl

y

. Remove the stripper from the G

y

ps

y

. To replace

the G

y

ps

y

, reverse the above procedure.

5

.2

G

ypsy rep

l

acement

(

Pro-F

i

s

h)

Remove t

h

e S

h

ou

ld

er Screw

(

45

)

antic

l

oc

k

wise using a 8 mm

(

5

/

1

6

”)

A

ll

en wrenc

h

. Remove t

h

e Was

h

er

(

46

)

from t

h

e centre

of t

h

e Pro-Fis

h

Drive Cap

(

36

)

. Loc

k

t

h

e Pro-Fis

h

P

l

unger

(

38

)

in, using t

h

e Stopper

(

41

)

. Remove t

h

e Pro-Fis

h

Drive

Ca

p

(36) anticlockwise. Remove Socket Head Ca

p

Screws (10)

anticlockwise, usin

g

a 4 mm (

5

/

32

”)

Allen wrench. Remove the

Pro-Fish Stopper Cam (37). Remove the G

y

ps

y

assembl

y

(3)

and Stri

pp

er (4) from the unit. Remove the Stri

pp

er (4) from

the G

y

ps

y

(3).

To replace the G

y

ps

y

, reverse the above procedure. Clean

t

h

rea

d

of S

h

ou

ld

er Screw

(

45

)

an

d

use Loctite® 638

(

66200160

)

(

Loctite® 2701 or 262 may a

l

so

b

e use

d)

on t

h

rea

d

uring re-

assem

bl

y. T i g

h

ten

b

o

l

t to 21 Nm

(

15.4

lb/

ft

)

an

d

a

ll

ow at

l

east

15 minutes for t

h

e Loctite® to cure

b

efore use.

5

.3

C

ontro

l

arm rep

l

acemen

t

To remove the Control Arm (8) rotate it to the vertical

p

osition.

Unscrew the Grub Screw (33) usin

g

a 2 mm (

5

/

64

”

)

Allen Wrench

b

y

3 mm (

1

/

8

”

)

. Allow the Control Arm to return to its normal

position. Wit

hd

raw t

h

e Contro

l

Arm Pivot

(

6

)

using a 4 mm

(

5

/

32

”)

A

ll

en wrenc

h

. T

h

e A

ll

en wrenc

h

s

h

ou

ld

b

e use

d

initia

ll

y

to pus

h

t

h

e Contro

l

Arm Pivot in towar

d

s t

h

e center

l

ine of t

h

e

win

dl

ass. On

d

oing t

h

is t

h

e Torsion Spring

(

7

)

wi

ll

ten

d

to turn

t

h

e Contro

l

Arm Pivot an

d

A

ll

en wrenc

h

c

l

oc

k

wise. A

ll

ow it

to travel clockwise as far as it can and, usin

g

some side force

on the wrench

,

withdraw the Pivot. Remove the Control Arm

,

Pivot Pin Washer (34) and Torsion S

p

rin

g

from the maincase.

Reverse this

p

rocedure to re

p

lace the Control Arm. Place the

Torsion Spring in t

h

e

h

o

l

e, ensuring t

h

at t

h

e outer tang is a

l

igne

d

para

ll

e

l

to t

h

e ri

d

ge on t

h

e maincase an

d

t

h

e

d

og

l

eg is para

ll

e

l

to t

h

e

d

ec

k

. P

l

ace t

h

e Pivot Pin Was

h

er in

b

oar

d

of t

h

e ﬂ ange

an

d

offer up t

h

e Contro

l

Arm suc

h

t

h

at it is pointing at t

h

e two

o’clock position. Pick up the Pivot Pin, align the groove on its

head also to the two o’clock

p

osition. Insert it throu

g

h the hole

on the maincase and en

g

a

g

e the s

p

rin

g

with its slot. Holdin

g

the Control Arm in

p

osition, use the Allen wrench to

p

ush the

Pivot Pin in. Then turn it anti-clockwise as far as it will

g

o. Usin

g

si

d

e force again, pu

ll

t

h

e wrenc

h

out unti

l

t

h

e

h

ea

d

of t

h

e Pivot

Pin sits s

l

ig

h

t

l

y prou

d

of t

h

e case. Rotate t

h

e contro

l

arm to t

h

e

vertica

l

an

d

, app

l

ying a spot of Loctite® 2701 t

h

rea

dl

oc

k

, fu

lly

re ti

g

hten the Grub Screw

.

5.4

Gyp

s

y

d

r

i

ve s

h

a

f

t re

pl

acement

&

l

u

b

r

i

cat

i

on serv

i

ce

• N

O

TE: Lu

b

r

i

cat

i

on an

d

i

nterna

l

parts w

ill

not

f

a

ll

out w

h

en t

h

e w

i

n

dl

ass

i

s

di

sassem

bl

e

d

.

T

h

e gear train an

d

its

b

earings

h

ave

b

een

l

u

b

ricate

d

for you wit

h

SFG 100

g

rease an

d

s

h

ou

ld

not re

q

uire re

g

u

l

ar attention. SFG is

a white s

y

nthetic grease containing PTFE. Use grease of a simila

r

s

p

eciﬁ cation throu

g

hout. It is recommended that the external

Drive Shaft com

p

onents be stri

pp

ed, cleaned and re-

g

reased a

t

least annuall

y

. To do this, the G

y

ps

y

(3) and Stripper (4) should

b

e remove

d

as

d

etai

l

e

d

a

b

ove. To inspect t

h

e Maincase Wipe

r

Sea

l

(

29

)

for signs of wear t

h

e Mains

h

aft must

b

e remove

d

as

d

etai

l

e

d

b

e

l

ow. If t

h

e sea

l

is foun

d

to

b

e unservicea

bl

e, t

h

e

Gypsy Drive S

h

aft

(

30

)

wi

ll

h

ave to

b

e wit

hd

rawn an

d

t

h

e sea

l

re

p

laced. Remove the Gear train Cover (17) usin

g

a 4 mm (

5

/

32”)

All

e

n Wr

e

n

c

h

.

If there is sealant

p

resent, use a razor blade to cut throu

g

h it.

Withdraw the 1st Compound Gear Assembl

y

(16), taking care

not to

l

ose t

h

e Teﬂ on™ F

l

at Was

h

ers

(

14

)

. Remove t

h

e 2n

d

Compoun

d

Gear Assem

bl

y

(

22

)

.

• N

O

TE: Rotate t

hi

s gear assem

bl

y as you pu

ll

on

i

t, eventua

ll

y t

hi

s act

i

on w

ill

or

i

entate a

ﬂ

at on its washer and allow the assembly

to pass the Drive Shaft Gear

(

25

)

.

Remove the External Circli

p

(23) and withdraw the Drive Shaf

t

Gear (25). Gentl

y

tap the Drive Roller (27) through the Drive

S

h

a

f

t.

The Drive Shaft can now be withdrawn with or without the G

y

ps

y

Assem

bl

y attac

h

e

d

, provi

d

e

d

t

h

e Stripper is no

l

onger attac

h

e

d

to t

h

e Case. Remove t

h

e Sea

l

an

d

rep

l

ace it wit

h

a new one.

C

l

ean t

h

e strippe

d

own components in

k

erosene,

d

ry t

h

em an

d

inspect t

h

em for wear

.

To reassem

bl

e, reverse t

h

e a

b

ove proce

d

ure. Re

b

ui

ld

t

h

e

windlass applying generous amounts of grease.

Isolate the windlass electrically, before carryin

g

out any

ma

int

e

n

a

n

ce

w

o

rk.

DO NOT use a screwdriver or shar

p

ed

g

ed tool to

p

ry the Gear

t

rain Cover o

p

en

.

12

P

ro-Series & Pro-Fish Windlass

6.

P

a

r

ts

l

i

st

5.5 E

l

ectr

i

c motor re

pl

acemen

t

Disconnect t

h

e Motor Ca

bl

es from t

h

e vesse

l

’s wiring

l

oom.

Remove t

h

e Gear Train Cover

(

17

)

using a 4 mm

(

5

/

32

”)

A

ll

en

Wrench as detailed above. Remove the 1st Compound Gear

Assembl

y

(16) and Teﬂ on™ Flat Washers (14).

Usin

g

a 4 mm (

5

/

32

”)

Allen Wrench remove the Motor Screws

(

10

)

. Withdraw the motor from the Main Case. Note that silicone

is used to seal the holes in the case where the motor wires

p

ass

throu

g

h. Be careful not to stri

p

the insulation from the Moto

r

Wires w

h

en pu

ll

ing t

h

em t

h

roug

h

t

h

e Main Case.

Rep

l

ace t

h

e Motor

b

y reversing t

h

e a

b

ove proce

d

ure, using fres

h

si

l

icone to sea

l

t

h

e wire

h

o

l

es in t

h

e case. Use Loctite® 2701

t

h

rea

dl

oc

k

on t

h

e Motor Screws

.

5.6 Pro-Fi

s

h conver

s

ion

Pro-Series units from Serial Number ***0603***

(

March 2006

)

o

r

later, can easil

y

be converted to Pro-Fish units b

y

removing the

Clutch nut (1), G

y

ps

y

Cone (2), Drive Pins (28) & Screws (31)

an

d

ﬁ tting t

h

e Pro-ﬁ s

h

conversion

k

it

(

66000616

)

. Fu

ll

y ﬁ tting

instructions, too

l

s &

l

octite are inc

l

u

d

e

d

in t

h

e

k

it.

Isolate the windlass electricall

y!

I

tem

D

escr

ip

t

i

on

Q

t

y.

P

art

N

o

.

1

C

lutch Nu

t

1

66000098

2

G

y

ps

y

Cone

1

66000098

3

G

y

ps

y

RC 7 mm (

1

/

4

”

)

1

66000

11

0

3

a

Gypsy RC 8 mm (

5

/

16

”)

1

66000

1

01

3b

G

ypsy RC

5

/

16

”

G

4

1

66000

1

0

2

3

c

Gy

ps

y

RC 6 m

m

1

66000112

4

S

tri

pp

er Arm

1

66000096

5

M

aincas

e

1

N

/

A

6

Control Arm Pivot

1

66000097

7 Torsion Spring

1

66000097

8

Co

ntr

o

l Arm

1

660000

9

7

9

Do

w

el

1

/

4

”x1

1

/

4

”

3

66000

1

0

4

10

S

ocket HD

C

a

p

S

crew 10

-

2

4UN

C

x

3

/

4

”

5

66000616 or 66000617 or

66000096 or 66000104 or

6600010

7

11

M

otor Pinion

1

66000105 or 66000107

1

2

D

owel

,

6 x

3

0 m

m

1

66000

1

0

4 or

66000

1

0

7

1

3

S

p

irol Pin, 3 x 20 mm

1

66000

1

0

4 or

66000

1

0

5 or

66000

1

07

14 Te

ﬂ

on Flat Washer

2

66000

1

0

5

1

5

N

ee

dl

e

R

o

ll

er

B

ear

i

ng 2

66000

1

0

3

o

r

66000

1

05

1

6

1

st Compound

G

ea

r

1

66000

1

05

17

G

e

a

r Tr

a

in Cove

r

1

66000109

18

S

ocket HD

C

a

p

S

crew, 10

-

2

4UN

C

x 1

1

/

4

”

6

66000104 or 6600010

9

1

9

Wi

p

er

S

ea

l

1

66000

1

0

4 or

66000

1

09

20

Needle Roller Bearin

g

1

6600010

3

or 6600010

9

21

N

ee

dl

e

R

o

ll

er

B

ear

i

ng

1

66000

1

0

3

o

r

66000

1

09

22

2

nd Compound Gear Assembly

1

66000

1

05

o

r

66000

1

06

2

3

E

xternal Clip

1

66000

1

0

3

o

r

66000

1

0

4

o

r

66000

1

05

I

te

m

D

escr

ip

t

i

on

Q

t

y

.

P

art

N

o.

24

Roller Clutc

h

1

6600010

3

25

Mainshaft Gear

1

66000

1

05

26

N

ee

dl

e

R

o

ll

er

B

ear

i

n

g

1

66000

1

0

3

2

7 Dowel, 8 x 45 mm

1

66000

1

0

4

o

r

66000

1

05

28

Drive Pins, 5 x 10 mm

2

660000

9

8

o

r

66000

1

0

4

2

9 Wi

p

er

S

eal

1

6600010

4

3

0

Gy

ps

y

Drive Shaft

1

66000

1

05

3

1

S

ocket Head Ca

p

Screw, 10-

24UNC x

1

/

2

”

2

66000096

or

66000

1

0

4

32

Powertek Motor 1

2

V

1

66000

1

0

7

33

G

rub Screw

,

8-32 UNC

x

1

/

4

”

1

6600009

7

34

Pi

vot

Pi

n

Wash

e

r

1

660000

97

35

Rubber

G

rommet

s

2

66000

1

0

7

3

6 Pro-Fish Drive

C

a

p

1

6

6000616 or 66000620

3

7 Pro-Fish

S

to

pp

er

C

am

1

660006

1

6

or

660006

1

7

38

Pro-Fish Plunger

1

660006

1

6

or

66000620

39

P

ro-

Fi

s

h

Pl

unger

H

ous

i

ng

1

660006

1

6

o

r

66000620

40

P

ro-

Fi

s

h

Pl

unger

R

eta

i

n

i

ng

Pi

n

1

660006

1

6

o

r

660006

2

0

41

Pro-Fish Plunger Retaining

C

ap

1

660006

1

6

o

r

660006

2

0

42

Pro-Fish Plun

g

er

Sp

rin

g

1

6

6000616 or 66000620

43

Pro-Fish Retainin

g

Sp

rin

g

1

660006

1

6

or

66000620

44

G

rub Screw

,

8-32 UNC

x

3

/

1

6

”

1

660006

1

6

or

66000620

45

S

houlder

S

cre

w

1

660006

1

6

o

r

66000620

46

Pro-Fish Drive Cap Space

r

1

660006

1

6

o

r

660006

2

0

47*

Bas

e

Ma

t

1

66000

1

00

o

r

66000

1

08

4

8

a

*Mountin

g

S

tud, Washer & Nut

(

Im

p

erial

)

1

66000100

4

8b

*

Mountin

g

S

tud Washer and Nut

(

Metric

)

1

6600010

8

* Not shown on ex

p

loded drawin

g

6.1 Parts list ke

y

Pro-Series & Pro-Fish models 700 & 1000

13

P

ro-Series & Pro-Fish Windlass

GB

6.1.1 Parts lis

t

S

ervice Ki

t

D

escr

ip

t

i

o

n

I

tems Included

(Q

ty

)

66000096

P

ro-

S

eries

S

tri

pp

er Arm Kit 4

(

1

)

, 10

(

2

)

,

3

1

(

2

)

6600009

7 Control Arm Kit 6

(

1

)

, 7

(

1

)

, 8

(

1

)

,

33(

1

)

,

3

4

(

1

)

66000098

P

ro-Series Clutch Nut & Cone Kit 1(1),

2

(1),

28

(

2)

660000

99

C

lut

c

h L

e

v

e

r

C

lutch Lever (1)

66000

1

00

F

asten

i

n

g

Ki

t

(I

m

p

er

i

a

l)

47

(

1

)

, 48a

(

1

)

66000101

G

ypsy RC 8 mm (

5

/

16

”)

3a

(

1

)

66000

1

02

G

y

ps

y

RC 5

/

1

6

” G4

3

b

(

1

)

6600010

3

B

earin

g

s Ki

t

15

(

20, 20

(

1

)

, 21

(

1

)

, 2

3(

1

)

, 24

(

1

)

, 26

(

1

)

66000

1

04

P

ro-Series Seals and Screw Ki

t

10(5), 12(1), 1

3

(1), 18(6), 19(1), 2

3

(1), 9(

3

), 27(1), 28(2), 29(1),

3

1(2)

66000

1

05

Ge

a

r

s

a

nd

S

h

a

ft Kit 11(1), 13(1), 14(2), 15(2), 16(1), 22(1), 23(1), 25(1), 27(1), 30(1)

66000

1

06

Compound

G

ear Ki

t

22(1)

66000107

M

otor 12 V 11

(

1

)

, 32

(

1

)

, 10

(

3

)

, 12

(

1

)

, 13

(

1

)

, 35

(

2

)

6600010

8

F

astenin

g

Kit

(

Metric

)

47

(

1

)

, 48b

(

1

)

66000

1

09

Gear Train Cover Ki

t

17

(

1

)

, 1

8(6)

, 1

9(

1

)

,

20(

1

)

,

2

1

(

1

)

66000

11

0

G

y

ps

y

RC 7 mm (

1

/

4

”

)

3

(1)

66000

11

2

Gypsy RC 6 m

m

3c(1)

660006

1

6

P

ro-Fi

s

h Conver

s

ion Kit 36(1), 37(1), 38(1), 39(1), 40(1), 41(1), 42(1), 43(1), 44(1), 45(1), 46(1), 10(2

)

66000617

P

ro-Fish

S

to

pp

er Ki

t

37

(

1

)

, 10

(

2

)

66000620

P

ro-Fish Drive

C

ap Assembl

y

Kit

3

6

(

1

)

,

3

8

(

1

)

,

3

9

(

1

)

, 40

(

1

)

, 41

(

1

)

, 42

(

1

)

, 4

3(

1

)

, 44

(

1

)

, 45

(

1

)

, 46

(

1

)

6

.2 Pro-

S

erie

s

& Pro-Fi

s

h model

s

700 & 1000

s

ervice kit

s

14

P

ro-Series & Pro-Fish Windlass

7. Troubleshootin

g

7.1 A nchor rode

p

a

y

s out inde

p

endentl

y

while windla

ss

i

s

not in u

s

e

This problem is a result of not securing the anchor rode combined

with the Clutch Nut (1) bein

g

slack. Ti

g

hten the clutch nu

t

using the tool provided and alwa

y

s secure the anchor rode

independentl

y

of the windlass whenever it is not being deplo

y

ed

o

r r

eco

v

e

r

ed.

7.2 Anchor rode pays out independently

while windlass not in use (Pro-Fish

)

This

p

roblem is a result of not securin

g

the anchor rode combined

with the internal Clutch mechanism not being full

y

engaged.

Operate the UP button brieﬂ

y

to full

y

re-engage the internal

F

ailure to O

p

erate

(

Pro-Series 700 Only

)

Troubleshoot Chart: Reversin

g

To

gg

le Control Switch

(

Part No. 0052519

)

Is t

h

ere vo

l

tage at t

h

e input termina

l

(

positive

)

to t

h

e contro

l

s

wi

tc

h

?

I

f no voltage is present, the batter

y

isolation switch is OFF, the

b

reaker is tripped or a fuse has blown. The batter

y

ma

y

also

ha

v

e

bee

n

dead

o

r

d

i

sco

nn

ected.

YE

S

N

O

C

h

ec

k

vo

l

tage at t

h

e output termina

l

s of t

h

e contro

l

switc

h

wit

h

t

h

e switc

h

on forwar

d

t

h

en reverse.

Is t

h

ere vo

l

tage at eit

h

er output termina

l

for forwar

d

t

h

en

reverse.

?

Co

n

t

r

o

l

s

wi

tc

h i

s

de

f

ect

iv

e.

YE

S

N

O

Re

p

lace motor.

S

luggish

O

peration Troubleshoot

C

har

t

I

s

win

d

l

ass

o

v

e

rl

oaded?

E

ase t

h

e

l

oa

d

an

d

ensure t

h

e

b

attery is we

ll

c

h

arge

d

.

YE

S

N

O

Check the volta

g

e across the motor leads with the windlass

on.

(

Proper vo

l

tage is 13.5 V. Constant

l

ow vo

l

tage wi

ll

d

estro

y

t

h

e motor

)

.

Is t

h

e vo

l

tage

l

ow?

(

Be

l

ow 11.0 V on a 12 V system

)

.

Th

ere is a severe vo

l

tage

d

rop in t

h

e circuit.

Ch

ec

k

for un

d

ersize

d

ca

bl

es, poor connections or corro

d

e

d

c

onnections. A

l

so c

h

ec

k

for resistance across t

h

e

b

atter

y

i

solation switch or solenoid. (Feel them to see if the

y

are

h

eatin

g

u

p

).

YE

S

N

O

Is the volta

g

e correct? (Above 11.0 V and anchor is no

t

fouled

)

.

Th

e motor is

d

efective. Rep

l

ace t

h

e motor.

Y

E

S

Failure to

O

perate Troubleshoot

C

hart

I

s t

h

ere vo

l

tage at t

h

e input termina

l

s to t

h

e contactor an

d

s

witc

h(

es

)

?

Ch

ec

k

t

h

e circuit

b

rea

k

er

/

iso

l

ator switc

h

an

d

any fuses.

YE

S

N

O

Op

erate t

h

e switc

h

. Is t

h

ere vo

l

ta

g

e at t

h

e

p

ositive switc

h

termina

l

o

n t

h

e so

l

enoi

d

?

Th

e switc

h

(

or its wiring

)

, is

d

efective.

YE

S

N

O

K

eep the switch activated. Is there voltage at the main output

te

rmin

a

l

o

n

t

h

e

co

n

tacto

r

?

Ch

ec

k

t

h

e contactor coi

l

groun

d

circuit. If o

k

ay, rep

l

ace t

h

e

c

on

t

ac

t

or

.

YE

S

N

O

Ch

ec

k

t

h

e vo

l

tage at t

h

e motor. If vo

l

tage is present, t

h

e motor

i

s

d

efective. If you

h

ave any questions ca

ll

your nearest Lewmar

r

epresentat

i

ve.

cl

utc

h

mec

h

anism. A

l

ways secure t

h

e anc

h

or ro

d

e in

d

epen

d

ent

l

y

o

f the windlass whenever it is not being deplo

y

ed or recovered.

7

.3 E

l

ectr

i

ca

l

trou

bl

es

h

oot

i

ng

A

s with most electrical marine equipment the ma

j

orit

y

of problems

t

h

at

a

ri

se

a

r

e

l

ect

ri

ca

l in n

atu

r

e.

Th

e

r

e

f

o

r

e

i

t

i

s

esse

n

t

i

a

l

t

h

at

th

e proper vo

l

tage

b

e maintaine

d

. T

h

e proper vo

l

tage on a 12

v

o

l

t system is 13.5 vo

l

ts.

(

Constant

l

ow vo

l

tage wi

ll

d

estroy t

h

e

m

otor

)

. Ensure t

h

at e

l

ectrica

l

ca

bl

e size is

l

arge enoug

h

to

h

an

dl

e

th

e current

d

raw impose

d

upon it an

d

to

k

eep t

h

e vo

l

tage

d

rop

w

ithin acceptable limits. In any circumstance voltage drop due

e

ntirel

y

to cable resistance should not exceed 10%.

F

ollow the charts to troubleshoot the

p

roblem.

15

P

ro-Series & Pro-Fish Windlass

GB

8. Lewmar limited warrant

y

LIMITED WARRANTY an

d

KEY TERMS OF SUPPLY BY LEWM

A

R

Lewmar warrants that in normal usage and with proper maintenance its

products will conform with their speciﬁ cation for a period of ﬁ ve

y

ears

f

rom the date of purchase b

y

the end user, sub

j

ect to the conditions,

l

imitations and exceptions listed below. An

y

product, which proves to be

defective in normal usage during that ﬁ ve-

y

ear period, will be repaired

o

r, at Lewmar’s option, replaced b

y

Lewmar

.

A

CO

NDITI

O

N

S

AND LIMITATI

O

N

S

i

Lewmar’s

l

ia

b

i

l

ity s

h

a

ll

b

e

l

imite

d

to t

h

e repair or rep

l

acemen

t

o

f any parts of t

h

e pro

d

uct w

h

ic

h

are

d

efective in materia

l

s o

r

w

or

k

mans

h

ip

.

i

i Responsibilit

y

for the selection of products appropriate for the use

intended b

y

the Bu

y

er shall rest solel

y

with the Bu

y

er and Lewma

r

accepts no responsibilit

y

for an

y

such selection.

i

ii Lewmar s

h

a

ll

not

b

e

l

ia

bl

e in any way for Pro

d

uct fai

l

ure, or an

y

r

esu

l

ting

l

oss or

d

amage w

h

ic

h

arises from

:

a use of a

p

roduct in an a

pp

lication for which it was not desi

g

ned o

r

intended

;

b

. corrosion, u

l

tra vio

l

et

d

egra

d

ation or wear an

d

tear;

c

. a failure to service or maintain the

p

roduct in accordance with

Lewmar’s recommendations

;

d

. fau

l

ty or

d

eﬁ cient insta

ll

ation of t

h

e pro

d

uct

(

un

l

ess con

d

ucte

d

by

Lewmar

)

;

e. an

y

modiﬁ cation or alteration of the product;

f

. con

d

itions t

h

at excee

d

t

h

e pro

d

uct’s performance speciﬁ cations o

r

safe wor

k

ing

l

oa

d

s.

i

v Product sub

j

ect to a warrant

y

claim must be returned to the Lewma

r

o

utlet which su

pp

lied the

p

roduct for examination unless otherwise

agreed b

y

Lewmar in writing

.

v

T

h

is warranty

d

oes not cover any inci

d

enta

l

costs incurre

d

for t

h

e

investigation, remova

l

, carriage, transport or insta

ll

ation of pro

d

uct.

v

i Service b

y

an

y

one other than authorised Lewmar representatives

shall void this warrant

y

unless it accords with Lewmar guidelines

and standards of workmanshi

p.

v

ii Lewmar’s pro

d

ucts are inten

d

e

d

for use on

l

y in t

h

e marine

environment. Buyers inten

d

ing to use t

h

em for any ot

h

er purpose

s

h

ou

ld

see

k

in

d

epen

d

ent professiona

l

a

d

vice as to t

h

eir suita

b

i

l

ity.

Lewmar accepts no

l

ia

b

i

l

ity arising from suc

h

ot

h

er use

.

B

EX

C

EPTI

O

N

S

C

over under this Warrant

y

is limited to a period of one

y

ear from the date

o

f purchase b

y

the end user in the case of an

y

of the following products

o

r

p

arts of

p

roducts:

•

E

l

ectric motors an

d

associate

d

e

l

ectrica

l

equipmen

t

•

Electronic controls

•

H

y

draulic pumps, valves and actuators

•

W

eathe

r

seals

•

Products used in “Grand Prix” racing application

s

C

LIABILITY

i

Lewmar’s

l

ia

b

i

l

ity un

d

er t

h

is warranty s

h

a

ll

b

e to t

h

e exc

l

usion o

f

a

ll

ot

h

er warranties or

l

ia

b

i

l

ities

(

to t

h

e extent permitte

d

b

y

l

aw

)

. In

p

articu

l

ar

(b

ut wit

h

out

l

imitation

):

a Lewmar shall not be liable for

:

•

Any

l

oss of anticipate

d

turnover or proﬁ t or in

d

irect, consequentia

l

o

r economic

l

oss

;

•

Damages, costs or expenses pa

y

able to an

y

third part

y

;

•

Any

d

amage to yac

h

ts or equipment

;

•

Death or personal In

j

ur

y

(unless caused b

y

Lewmar’s negligence)

.

S

ome states and countries do not allow the exclusion or limitation of

incidental or conse

q

uential dama

g

es, so the above limitation or exclusion

ma

y

not appl

y

to

y

ou

.

b

Lewmar grants no ot

h

er warranties regar

d

ing t

h

e ﬁ tness for purpose,

u

se, nature or satisfactory qua

l

ity of t

h

e pro

d

ucts

.

ii Where applicable law does not permit a statutor

y

or implied warrant

y

to be excluded, then such warrant

y

, if permitted b

y

that state or

countr

y

’s law, shall be limited to a period of one

y

ear from the date

of purchase b

y

the end user. Some states and countries do not allow

limitations on how long an implied warrant

y

lasts, so this limitation

m

a

y

not appl

y

to

y

ou.

D

PROCEDUR

E

N

otice of a c

l

aim for service un

d

er t

h

is warranty s

h

a

ll

b

e ma

d

e prompt

l

y

a

n

d

in writing

b

y t

h

e en

d

user to t

h

e Lewmar out

l

et w

h

ic

h

supp

l

ie

d

t

h

e

p

ro

d

uct or to Lewmar at Sout

h

moor Lane, Havant, Hamps

h

ire, Eng

l

an

d

PO

9 1JJ.

E

S

EVER

A

N

C

E

C

L

AUSE

I

f any c

l

ause of t

h

is warranty is

h

e

ld

b

y any court or ot

h

er competent

a

ut

h

ority to

b

e inva

l

i

d

or unenforcea

bl

e in w

h

o

l

e or in part, t

h

e va

l

i

d

ity

of t

h

e remaining c

l

auses of t

h

is warranty an

d

t

h

e remain

d

er of t

h

e c

l

ause

in

q

uestion s

h

a

ll

not

b

e affecte

d.

F

OTHER RIGHT

S

T

his warrant

y

gives

y

ou speciﬁ c legal rights, and

y

ou ma

y

also have other

legal rights, which var

y

, from state to state and countr

y

to countr

y

.

I

n t

h

e case of Euro

p

ean States a Consumer customer

(

as

d

efine

d

nationa

ll

y

)

h

as

l

ega

l

rig

h

ts un

d

er t

h

e app

l

ica

bl

e nationa

l

aw governing

t

h

e sa

l

e of Consumer Goo

d

s; t

h

is Warranty

d

oes not affect t

h

ose

ri

gh

ts.

G

L

A

W

T

his warrant

y

shall be governed b

y

and read in accordance with the laws

of England or the state or countr

y

in which the ﬁ rst end user is domiciled

a

t the time of purchase of the product

.

H DI

S

P

U

TE

S

A

ny

d

ispute arising un

d

er t

h

is warranty may, at t

h

e option of t

h

e en

d

-user,

b

e referre

d

to a

l

ternative

d

is

p

ute reso

l

ution un

d

er t

h

e ru

l

es of t

h

e Britis

h

M

arine Fe

d

eration or to t

h

e Courts of t

h

e State w

h

ose

l

aw s

h

a

ll

g

overn

t

h

e warranty or to t

h

e Courts of Eng

l

an

d

an

d

Wa

l

es.

Th

e Britis

h

Marine Fe

d

eration may

b

e contacte

d

at Marine House,

Th

or

p

e Lea Roa

d

, E

gh

am, En

gl

an

d

, TW20 8BF

Produced by T. Connell UK (+44) 023 9263 9265 Ref:T1954/05/2006

B10490

W

W

L

EWMARCO

M

Lewmar PRO Series Owners Installation, Operation & Basic Servicing Manual

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