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
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
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
m
6
7
(
"
3
=
B
waS
e
l
oH
)mm0
1
(
"
8
/3 =
A
l
l
i
rD
)
m
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
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
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
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
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
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
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
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
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
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
© Copyright 2006 Lewmar Ltd. All rights reserved.
B10490
W
W
W
L
EWMARCO
M
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-
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-
6
-
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-
8
-
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-
10
-
11
-
12
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15
Lewmar PRO Series Owners Installation, Operation & Basic Servicing Manual
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