"service manual"
Contents
1. Ocean Electric Winches 23 Modas 4C 77 ISI Sed 8 8 3 Parts list 66 77 9 Dimensions ZN El ioe AA ded n El is o Q co TT IT Qptiond extension kits to increese T are avilable to special order Contact your nearest Larner office if required G9 9 8 ODO OO 9 S S C9 S o Model E E F L IV N S T R V X 40 735 154 189 4 95 4 237 38 1 9c 33 5 15 7C 112 E 44 87 174 215 5 103 5 238 5 42 130 5 64 4 18 72 5 112 E 4 Z 18 228 C 108 5 238 5 44 5 130 5 64 4 18 72 5 112 c 5C 105 209 258 126 29C 48 5 138 5 59 5 182 8c 11 u 2 Speed versions showrydketailed S 54 10 209 270 135 29C 48 5 138 5 59 5 182 8c 112 qr 5 11 234 286 3 138 29C 52 138 5 59 5 182 8c 112 Hem Description Qty 66 2 TP 2 SEES 118 234 291 1418 29C 52 9 138 5 59 5 182 ac 112 1 Push Red Aserrly a 18000181 18000486 E 6 14 282 302 2 142 1 29C 144 67 5 188 5 8c 112 J 66 3 14 294 34 17C 29C 144 87 5 191 1 8c mao s SEO Lies eve 77 17 294 348 174 29C 144 37 5 191 1 8C 112 O Ring 1 B2532 B2532 77 2 178 294 348 174 29C 147 87 5 191 1 8c 112 4 Bust 1 15000184 15000184 5 Spring Aig 1 B9941 B9941 Optiond extension kits to increeee T are available to special order Contact your nearest Lanner office if required Drive Doc J 15300688 15300575 Mode2. e UV a E m min Line Speed o o a o o1 Line Speed m min o Line Speed m min 20 Model 54 Electric 12 amp 24 Volts Cutout 1350 kg NS ANS 2 A N ors 24 Volts 12 Volts 600 800 1000 1200 1400 1600 Load kg Model 58 Electric 12 amp 24 Volts Cutout 1450 kg NS ae 24 yos 24 Volts 12 Volts 200 400 600 800 1000 1200 1400 1600 Load kg Mode 64 Electric 12 amp 24 Volts 400 Cutout 1580 k D A not 300 250 E 2 NOUS 24 Volt s 12 Volts 200 400 600 800 1000 1200 1400 1600 Load kg Model 66 3 Electric 24 Volts Cutout 1814 Kg 200 400 600 800 1000 1200 1400 1600 1800 1900 Load kg Ocean Electric Winches Modas 4C 77 Model 77 3 Electric 24 Volts 160 Cutout 2721 kg 140 120 T 100 x 1000 1500 2000 2500 3000 Load kg 5 Safe working loads 5 1 Optimum rope diameters Model Rope S mmi Rope in 4C 81D 12 4e tc 1 7 44 amp 4E 8to14 he De 50 amp 54 81016 5 Ac to 5 e 58 62 amp 64 8to 1 Yog ig 6 10 to 2C z g c A a 77 121022 MAP te ye 5 2 Maximum winch load values Model Mepdimum Load Maimam Load ko Ibs AC 795 175C 44 113 250C 48 1247 275C 5C 136 300C 54 1474 325C 5E 1587 350C 64 170C 375C 6 2727 600C 77 340 750C S Maimam safe working loads are recommended to be NOT MORE than the those detailed above This provides an accept
3. E B r L IV N S T R M x 7 Sed 1 B2592 B2592 40 ZI 6 14e 74 35 348 64 9 5 4 20375 37 g 15 1 6 e 23 4 4 3 e E Thrust Sleeve 1 45002154 45002154 o 4A 3 ne 6 6 8 Z e 4 ie 9 25 64 1 5 e 5 Ve 2U u 71 3 2 55 64 4 3 g c Sprinc 1 15300486 1530048 P AE 3 He 7 ey 9 Z e 41 a 9 Z ga 1E 5 S ca 2 Wez 73 5 255 64 4 3 e c 10 Hollow Dowd 1 4500214C 4500214C pe 5C 41 g 81 4 10 1 g 4 Be 11 7 3 1A 57 1 25 7g 31 e 4 3 g 11 Bust J 15000566 15000565 D 54 4 1 e 81 3 10 5 5 3 g 1 Yig 1A E 25 4e We 31 e 4 3 e c Screw 4 BO68 BO68 2 SE 4 9 1 4 11 1 4 51 2 11 7e 2 he She 2 She 7a 3 fe 4 g 12 2 E i E a Hali coil 4 B2423 B2422 S 64 4 Je 9 1 4 1177 5 1 11 he 2 he 5 he 2 he 7 g 31 g 4 Je 1 Roller Beerinc J 15010007 15010007 E 6 5 he 11 e 11 Pe 59 16 11 Je 57 16 2 he 7 fe 31 g 4 Z e 14 Thrust Wher 1500328 1500328 Sins Lip eg Sic NE 5 ae 2 e UE 3 e 4 fe 15 Connecting Sheft 1 4500215 4500215 a he Ole T Sie 3e 7 1s A e 77 3 7 11 13 V 7 alu 57 DY 7 3 31 4 7 16 Adaptor J 45000944 45000944 lt ss 2E E 17 Key 1 15003287 15003287 Motor Geerbox 12 V 1 48000077 48000077 1E Motor Geerbox 24 V 1 4800007 4800007 1 Power Bese 1 4500094C 4500204C 2C Main Spinde Hec Hyd 1 45000947 45002180 24 Ocean Electric Winches Ocean Electric Winches 25 Modes 4C 77 Haben Sie Fragen zum Thema Einfach ein Email an Modes4C 77 service sailtec de oder 040 8229940 anrufen v 10 Total weigh
4. ELS Control Box 12 V EVC Cona Box 24 V EVC Conrod Box 48077205 Alloy Deck Unit 4807720 Chon Deck Unit 77 3 4807720 St Stea Deck Unit 4807720 Al Chrorre Deck Unit 28 Ocean Electric Winches Models 4C 77 Circuit Circuit Breaker Moodie Voltage Breaker Part Number 12V 9c 6800034 40 24V AC 68000542 12V 11C 6800035C 44 24V 5C 68000348 12V 12C 6800023 48 24V 7C 6800024C 12V 15C 6800035 50 24V 9C 6800034 12V 250 FUSE 58900 54 24V 9C 6800034 12V 325 FUSE 58900 5E 24V 11C 6800035C 12V 325 FUSE 58900 64 24V 11C 6800035C 12V 11C 6800035C 6 24V 5C 6800034 12V 11C 6800035C 72 24V 5C 68000348 Order fuse holder 589006 with fuse indicated 12 Fault finding J v Does the winch operate electrically J v X omen tect Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen Winch handle loded in Winches 66 77 only J v J v J v J v J v J v Ocean Electric Winches Modas 4C 77 29 LIMITED WARRANTY and KEY TERMS OF SUPPLY BY LEWMAR Lewmar warrants that in normal usage and with proper maintenance its products will conform with their specification for a period of three years from the date of purchase by the end user subject to the conditions limitations and exceptions listed below Any product which proves to be defective in normal usage during that thr
5. by a single direction contactor which can be a Contactor housed in a waterproof box Fig 3 11 or a stand alone Nylon encased unit Fig 3 12 The motor thermal trip is connected to monitor motor temperature while the Lewmar safety electric deck switch can be easily wired Manual override facility is still available for backup or as a means of experiencing traditional sailing Two plus one speed comes as standard control which gives two speed manual drive handle plus one speed electric drive O L Negative earth MUST be used 2 The deck switch wires MUST be fitted as shown on Wiring diagrams Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen 3 1 E Series Electric 40 48 12V or 24V Slow Blow Fuse Customer Supplied Fig 3 12 Contactor 12 V 0052505 or 24 V 0052506 NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS 3 Connect all low power wiring deck switches motor cutout etc before fitting high power cables to controller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing Ocean Electric Winches 13 Modas 4C 77 Uu ez o T2 Q Qo e ez o o o b Q o Lu mM 3 2 ELS Electric Load Sensing 40 48 12 V or 24 V Fig 3 21 12 V or 24 V Control box with overload protection This installation controls the winch by Lewrnar s unique Overload Protection Control Box Fig 3 21 this allo
6. B2303 Issue 6 Ocean Electric Winches Models 40 77 Owners Installation Operation amp Basic Servicing Manual SAILTEC www lewmar com Contents B2303 Issue 6 Ocean electric winches models 40 77 For sizes over 77 please contact Lewmar for details Introduction 4 3 Electrical connections 13 Product support 4 3 1E Series Electric 40 48 13 Important information about this manual 4 3 2 ELS Electric Load Sensing 40 48 14 EM C Recommended guidelines 4 3 3 ELS Electric Load Sensing 50 64 15 CE Approvals 4 3 4 ELS Electric Load Sensing 2 3 speed 66 77 16 Safety notices 5 3 5 EVC Electric Variable Control 40 48 17 General 5 3 6 EVC Electric Variable Control 50 64 18 Fitting 5 4 Performance diagrams 19 20 Electrical 5 5 Safe working loads 21 1 Installation 6 5 1 Optimum rope diameters 21 1 1 Identifying manual convertible winch 6 5 2 Maximum winch load values 21 1 2 Preparing manual winch for conversion 6 6 Operating your winch 21 1 3 Fitting a complete electric winch from new 6 7 Servicing your winch 22 1 4 Positioning winch above deck 7 8 Parts list 22 1 5 Positioning winch ancillaries below deck 8 8 1 Winch notes 22 1 6 Fitting a convertible electric winch 40 64 9 10 8 2 Models 40 64 23 1 7 Fitting a convertible electric winch 66 77 11 8 3 Models 66 77 24 1 8 Fastenings 11 9 Dimensions 25 1 9 VVinch motor gearbox couplings 11 10 Tota
7. able safety margin for dynarnic load surges in exdrerre sea conditions 6 Operating your winch e Ocean Winches 40 64 are single speed powered winches amp manual 2 speed these winches employ an overide ratchet gearing for safety when winching manually e Ocean Winches 66 77 are 2 or 3 speed powered and manually operated they will not drive electrically while the winch lock in handle is in the drive socket 1 Adjust the feeder arm so that the rope tails into a secure area away from the incoming line 2 There must be at least 3 turns of rope around the winch before being passed across the feeder arm in to the wavespring self tailing jaws Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen 3 Use the winch handle or electric switch to operate the winch Remove handie after use NEVER hold the incoming rope to the winch while the winch is operated Only control the rope leaving the winch 4 Pay outline as per manual winch ALWAYS switch off the winch at the circuit lbreaker isolator after sailing or when leaving the boat to prevert accidental operation Ocean Electric Winches 21 Modas 4C 77 7 servicing your winch o TURN THE POWER OFF at the circuit breaker isolator before any maintenance servicing is Carried out Winches need regular maintenance damage and premature wear can result MONTHLY Hose down w
8. ads are countersunk and correctly and replace base plate cover Fig 1 68 Refit the centre stem assembly taking care to hold the gear stack in position as before Fig 1 69 Rotating the gears will facilitate re engagement of the pawls and ratchet tracks Replace the drum collets feeder arm in correct feeder position and screw on the top cap 1 7 Fitting a convertible electric winch 66 77 For winches 66 77 simply remove the winch drum and access to mounting holes is available through holes in the base of the centre stem 1 8 Fastenings Fix the winch to the deck using CSK Head Stainless Steel Washers Locknuts e Forthecorrect bolt length refer to Fig 1 81 and table NOTE Deck fastenings are not supplied ab Lhe SR es x mm inch 5 xM6 4 VV 5 xMB 5 4 V 6 xM8 E 3 VV 5 xM10 g VV 5 x M10 e VV 6xM10 g VV H X we RH 1 9 Winch motor gearbox coupling M echanical coupling of the horizontal drive unit and reduction gearbox to the winch should be mounted as Fig 1 91 40 64 and Fig 1 92 66 77 with instructions of previous pages e The horizontal drive unit assembly should be bolted from below decks Use threadlock on item No 15 see Sec 8 2 e If athick deck or increased motor gearbox distance from deck demands a greater T dimension see Sec 9 Optional extension kits are available to special order Contact your nearest Lewmar
9. ctrical connections A Total voltage drop MUST NOT exceed 5 of supply over completed cabling installation Check all connections for water tight security Levarar recommends an isolator to be fithed in the circuit in an accessible position as Close as possible to the supply Gomectthe power supply cables to the battery lasi when the winch installation has been con pleted and checked for correct installation Incorrect connection of motor cables may damage the unit Fig 3 41b 3 Speed winch electrical connections Fig 3 41 2 3 Speed 12 V or 24 V control box with overload protection Electric Switch Kit NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS 3 Connect all low power wiring deck switches 1 L Negative earth MUST be usedl 2 The deck switch wires MUST be fitted as shown on wiring diagrams Ocean Electric Winches Modds 4C 77 motor cubout etc before fitting high power cables to controller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing 3 5 EVC Electric Variable Control Standard controller single speed winches 40 48 12 V amp 24 V The EVC winch controller is a variable speed motor controller which can drive the winch in 3 different ways SW 1 drives the winch at full speed SW 2 drives the winch at a set speed determined by adjustable dial marked SP on the control box On supply the dial is preset by Lewmar to drive t
10. eck switches motor cutout etc before fitting high power cables to controller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing 4 Performance diagrams The following graphs show line speed and amperage draw relative to the load applied Each control box is set to cut out at the SWL which is 50 of the breaking load Line Speed m min Line Speed m min o Model 40 Electric 12 Volts Cutout 500 kg K xD ost Ling S Dee 100 200 300 400 500 600 Load kg Model 40 Electric 24 Volts Cutout 500 kg 300 400 500 Load kg Model 44 Electric 24 Volts Cutout 800 kg M NOS x C Line Speeq 400 600 Load kg Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen Line Speed m min Line Speed m min N Cc Line Speed m min o Model 44 Electric 24 Volts Cutout 800 kg jM V M ie tine SPeeg 400 600 Load kg Model 48 Electric 12 amp 24 Volts 300 Cutout 1000 kg 250 XS 29 200 E 1506 z g ows 5 O x 100 24 Volts 7 2 5 lis m 50 0 600 800 1000 1200 Load kg Model 50 Electric 12 amp 24 Volts Cutout 1250 kg de gt 24y pANdR lts 12 Volts 200 400 600 800 1000 1200 1400 1600 Load kg Ocean Electric Winches 19 Modas 4C 77 vn E BS O L Ke Q 8
11. ecurity Levarar recommends an isolator to be fithed in the circuit in an accessible position as Close as possible to the supply Connectthe power supply cables to the battery last when the winch installation has been con pleted and checked for correct installation Incorrect connection of motor cables may damage the unit NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS 3 Gonnect all low power wiring deck switches 1 Negative earth MUST be used 2 The deck switch wires MUST be fitted as shown on wiring diagrams Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen motor cutout etc before fitting high power cables to controller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing Ocean Electric Winches 15 Modas 4C 77 SUOLn29UuUuoO je591 3990 J 3 Uu ez o T2 Q Qo e ez o o o b Q 2 Lu e 3 4 ELS Electric Load Sensing 2 3 speed controller 66 7 12 V or 24 V This installation controls the winch by Lewrnar s unique Overload Protection amp Autoshift Control Box Fig 3 41 This allows the winch to be started in 1st and if reaches the Safe Working Load for the winch size and gear will automatically shift the winch into 2nd gear for complete load control In the case of a 3 speed winch Fig 3 41b the switch must be re selected to achieve 3rd gear Fig 3 41a 2 Speed winch ele
12. ee year period will be repaired or at Lewmar s option replaced by Lewmar A CONDITIONS AND LIMITATIONS i Lewmar s liability shall be limited to the repair or replacement of any parts of the product which are defective in materials or workmanship ii Responsibility for the selection of products appropriate for the use intended by the Buyer shall rest solely with the Buyer and Lewmar accepts no responsibility for any such selection iii Lewmar shall not be liable in any way for Product failure or any resulting loss or damage which arises from a useofaproductin an application for which it was not designed or intended corrosion ultra violet degradation or wear and tear c afailureto service or maintain the product in accordance with Lewmar s recommendations d faulty or deficient installation of the product unless conducted by Lewmar any modification or alteration of the product f conditions that exceed the product s performance specifications or safe working loads iv Product subject to a warranty claim must be returned to the Lewmar outlet which supplied the product for examination unless other wise agreed by Lewmar in writing v This warranty does not cover any incidental costs incurred for the investigation removal carriage transport or installation of product vi Service by anyone other than authorised Lewmar representatives shall void this warranty unless it accords with Lewmar guidelines and standards
13. es Grip winches made before 1992 are NOT convertable Convertible manual winches made in August 2000 will be date marked H 00 on the centre stem H August O0 year 2000 They also carry a blue sticker on the screw on top cap showing a winch handle and a hand operating an electric deck switch These winches can be converted by adding the Power Drive Base B unit and the required M otor Gearbox C Control Box and Switch gear 12 V or 24 V Ocean Wave Spring manual winches made between 1992 and August 2000 are NOT fitted with the necessary centre stem to convert to powered operation A Centre Stem Kit A is availableto convertthe early Ocean Wave Spring winches from 1992 to July 2000 The part numbers are listed below Pre Ocean Winches i e fixed jaw Wave Grip winches made before 1992 are NOT convertable Winch Mode Description Part Number 4C Centre StemKkit 48040037 44 Centre Stem kit 48044037 4 Centre Stem kit 48048037 Modds 4C 77 is located on the underside of the Centre Stem by using a soft hammer and punch Fig 1 21 Remove any sharp edges and clean to remove all old bedding sealing compounds from the underside of the Centre Stem 1 3 Fitting a complete electric winch from new Test fit the winch to the Power Drive Base and Gearbox to check the orientation and the necessary clearence needed BEFORE DRILLING ANY HOLES Now follow sections 1 4 and 1 5 should be installed so that the ou
14. he winch at 60700f full speed If optional Vario Control is fitted then the winch will drive at a soeed determined by adjustment of the Vario Control when deck switch SW 2 is engaged L Negative earth MUST be used 2 The deck switch wires MUST be fitted as shown on wiring diagrams Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen The EVC controller uses current sensing to halt the operation of the winch when the winch has reached its M aximum Safe Working Load TheEVC controller features a Ramp Soft Start to control the winch start up adjustment of dial RA will vary the start period between 0 5 5 seconds The dial is preset by Lewrnar for a start period of 1 second In order to adjust the speed SP and Ramp RA dials unscrew the plug screws on top of the controller 4full turns and retract the plug screw assembly Use an electrical slotted 2 5mm M ax screwdriver to adjust the internal dial to the desired setting SVV1 sw2 Hectric Switch Kit 69000018 Electric Switch Kit 69000018 motor cutout etc before fitting high power cables to controller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing Ocean Electric Winches 17 Models 4C 77 SUOLn29Uuuo je91 3990 J 4 Uu ez o T2 Q Qo e ez o o 6 b Q 2 Lu mM The EVC winch controller is a variable speed motor c
15. ith fresh water then lightly oil and grease as per illustration taking care not to get any grease in the pawls as they will stick in operation TWO OR THREE TIMES DURING ACTIVE SAILING SEASON Strip clean check and relubricate END OF SEASON OR BEGINNING OF NEW SEASON Strip clean thoroughly check for damage lubricate and reassemble as detailed in the ser vice manual Check condition of motor gearbox In the event of corrosion clean and repaint motor with marine grade oil based enamel paint Hectic motors become hot during and for some time after use These units have an oil filec gearbox DO NOT remove the motor For more details ask for the free booklet and manual How to Service Your Winch B 2304 Winch Parts Manual Volume 10 B 2196 and Custom Winch Service Manual Volume 8 B2312 77 144 2 or download from www lewmar com winchser vice Parts list 8 1 Winch model notes 1 For winches after February 1995 Items 7 9 amp 10 are replaced by items 13 45000248 Bearing sleeve These items are not interchangeable On winches 50 to 64 the 2 lower bearings have been replaced by item 5a 45003103 Plain Bearing These items are interchangeable A Manual winches cannot be converted nip electric versions by adding parts listed here Ocean Electric Winches Modas 4C 77 o 10 11 1 Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 a
16. l weight 26 E peg EC la du Ecuitconer blemoddrengs 27 2 1 Typical electrical layout 12 111 Winches 40 77 27 28 2 2 Correct main spindle rotation 12 Ti circtbreskers 28 12 Fault finding 29 13 Lewmar limited warranty 30 Ocean Electric Winches 3 Haben Sie Fragen zum Thema Einfach ein Email an Modes4C 77 service sailtec de oder 040 8229940 anrufen Introduction Dear Customer Thank you for chosing Lewmar Electric Ocean Winches Lewmar products are world renowned for their quality technical innovation and proven performance With a Lewmar winch you will be provided with many years of outstanding service We wish you happy sailing Product support Lewmar products are supported by a worldwide network of distributors and Authorised Service Representatives If you encounter any difficulties with this product please contact your national distributor or your local Lewmar dealer Details are avaiable at www lewmar com Important information about this manual Throughout this manual you will see safety and product damage warnings You must follow these warnings carefully to avoid possible injury or damage The type of warnings what they look like and how they are used in this manual are explained as follows Warming This is a waming against anything which may cause injury to people if the wanting is ignored Youare informed about what you mistor muet not do in order to reduce the risk of injury to yourse
17. ll and others Safety Symbol Q When you see the safety symbol it means Do not Do nct do this or Do nct let this happen C Approvals For CE approval certificates contact Lewmar 4 Ocean Electric Winches Modes 4C 77 To the best of our knowledge the information in this manual was correct when it went to press However Lewmar cannot accept liability for any inaccuracies or omissions it may contain In addition our policy of continuous product improvement may change specifications without notice As a result Lewmar cannot accept liability for any differences between the product and the manual Safety notices A General Please ensure that you thoroughly understand the operation and safety requirements of the winch before commencing the installation Only persons who are completely familiar with the controls and those who have been fully made aware of the correct use of the winch should be allowed to use it If there is any doubt of how to install or operate this unit please seek advice from a suitably qualified engineer e Winches used incorrectly could cause harm to equipment or crew e Winches should be used with care and treated with respect e Sailing like many other sports can be hazardous Even the correct selection maintenance and use of proper equipment cannot eliminate the potential for danger serious injury or death e Lewmar winches are designed and supplied for line control i
18. n marine applications and are to be used in conjunction with appropriate clutches cleats and other manual controls and stoppers e Itis the unavoidable responsibility of the owner or master or other responsible party to assess the risk of any operation on the vessel e Under no circumstances should any self tailing winch be used in self tailing mode for any lifting operation rather suitable and adequate manual tailing should be arranged with proper means of manually cleating or stopping the hoist e Every winch should be installed with adequate means of manually cleating or stopping the loaded ropes e Lewmar recommends the use of appropriate Personal Protective Equipment and hands free communication equipment by any person going aloft and only then where the person going aloft is properly trained in the use of that equipment and where there remain sufficient trained and experienced personnel on deck to ensure constant obser vation and the continued safe conduct both of the vessel and the hoisting operation Haben Sie Fragen zum Thema Finfach ein Email an service sailtec de oder 040 8229940 anrufen A riti ng e This equipment must be installed and operated in accordance with the instructions contained in this manual Failureto do so could result in poor product performance personal injury and or damage to your boat e Consult the boat manufacturer if you have any doubt about the strength or suitability of the mo
19. nly then dill the holes in the deck Once you have selected the position for the Haben Sie Fragen zum Thema Einfach ein Email an 1 6 Fitt nga convertible e Lift drum off Fig 1 64 Take care in refitting the drum washer with bevel on underside electric winch 40 64 NOTE Illustrations are based on a model 50 winch Place the winch in position to ensure correct fit once the holes have been drilled cut Fig 1 61 uopejjesul T Unscrew the top cap Fig 1 62 e Remove all screws holding centre stem to base Fig 1 65 Using aflat bladed screwdriver in the drainage slots lever off centre stem assembly clear of the two dowel pins Fig 1 65 Remove feeder arm and collets Fig 1 63 Ocean Electric Winches Modas 4C 77 service sailtec de oder 040 8229940 anrufen c O D S B T c 1C Take care to hold the gear stack in position as shown Fig 1 66 If pawl gear falls away note shoulder face is down Take care that pawls and pawl springs are kept in place while rebuilding placing the centre stem onto the base Remove the base plate cover Lift the base and bed down with a light coating of sealing compound to prevent leaks Fig 1 67 NOTE Do not use excessive sealant Ocean Electric Winches Models 4C 77 Consult the fastening guide in section 1 8 for bolt type and length Bolt the base plate to the deck ensuring that all fastening he
20. nrufen Descriptior Centre Ster Geer Spindle Rache Paw Geer Sprinc Beering Drive Shaft Plan Begrinc Base Plate Cover Base Plate Dowd Shaft Sed Insulation Shin HEX Bolt M amp x25 V sher ME Plde SKT HD screwM6 x12 CSK HD screw M6 x 1 CSK HD screw M8 x 1 CSK HD screw M8 x 25 CSK HD screw M10 x25 8 2 Parts list 40 64 NJ 45000237 45000244 45000242 15000094 1260 7 1500037 45000357 15003287 45000359 45000229 A500022 45000235 B1207 4500035C BO67 B0524 Bel 45000337 45000344 45000342 1260 7 1500039 45000357 15003287 45000358 45000325 4500032 45000235 45000437 45000444 45000342 1260 7 1500039 45000357 15003287 4500035 amp 45000426 4500042 45000235 B1207 4500035C BO6 BO53 4500056C 45000544 45000542 15000301 1269 7 15000017 4500024 45000529 4500052 45000581 45000257 BO17 B1207 4500035C B06 BOs12 54 4500066C 45000744 45000642 15000301 1260 7 15000017 45000248 45000526 4500052 45000581 45000257 BO17 B1207 45000350 BOG7E BOS812 45000760 45000744 45000742 15000301 1260 7 15000017 4500024 4500075 4500075 45000581 B6235 45000257 BO173 B1207 4500035C BO67 BO567 64 A500086C 45000744 45000842 15000301 1260 7 15000017 4500024 45000759 4500075 45000581 B6235 45000257 BO1 2 B1207 4500035C BO67 BO567
21. of workmanship vii Lewmar s products are intended for use only in the marine environment Buyers intending to use them for any other purpose should seek independent professional advice as to their suitability Lewmar accepts no liability arising from such other use B EXCEPTIONS Cover under this Warranty is limited to a period of one year from the date of purchase by the end user in the case of any of the following products or parts of products e Electric motors and associated electrical equipment e Electronic controls e Hydraulic pumps valves and actuators e Weather seals e Products used in Grand Prix racing applications C LIABILITY i Lewmar s liability under this warranty shall be to the exclusion of all other warranties or liabilities to the extent permitted by law In particular but without limitation 30 Ocean Electric Winches Modes 4C 77 F 13 Lewmar limited warranty a Lewmar shall not be liable for e Any loss of anticipated turnover or profit or indirect consequential or economic loss Damages costs or expenses payable to any third party e Any damage to yachts or equipment e Death or personal Injury unless caused by Lewmar s negligence Some states and countries do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you b Lewmar grants no other warranties regarding the fitness for purpose use nature
22. office Haben Sie Fragen zum Thema Einfach ein Email an service sailtec de oder 040 8229940 anrufen uonejjesu T Fig 1 92 Ocean Electric Winches 11 Models 4C 77 2 Electrical wiring installation Power supply to winck Upto 10 m 33 ft 10to 15 m 33 to 49 ft 15 to 20 m 49 to 66 ft Upto 7 m 23ft 7 to 10 m 23 to 33 ft 10 t 13 m 33 to 43 ft Fig 2 11 Cross sectional ares 50 m 70 m 95 rmr 25 m 35 m 50 mr 2 1 Typical electrical layout 2 2 Main spindle rotation NOTE This is not a wiring diagram e Check corect main spindle rotation when fitted l Position the recommended circuit breaker close and operated to the battery See wiring diagrams Sec 3 Route 2 cables seesizetable above from batter y to the control box 3 Attach motor cables to control box see wiring diagram using recommended cable sizes 4 Position the control box near the winch 1 metre in a dry area for watertight security and accessible for maintenance 5 Position deck switches in view of winch Route wire and attach to control box see wiring Winct diagram 5e 66 77 3 Speec 66 7i 12 Ocean Electric Winches Modes 4C 77 1st Gear 2nd Gear 3rd Gear 3 Electrical connections Fig 3 11 Single direction contactor in box with thermel cutout 12 V 18000301 or 24 V 18000302 This simple installation of a power drive unit motor and switch gear controls the winch
23. ontroller which can drive the winch in 3 different ways NOTE Standard EVC used on 50 64 24 V High power EVC used on 50 64 12 V SW 1 drives the winch at full speed SW 2 drives the winch at a set speed determined by adjustable dial marked SP on the control box On supply the dial is preset by Lewmar to drive the winch at 60 of full speed If optional Vario Control is fitted then the winch will drive at a soeed determined by adjustment of the Vario Control when deck switch SW 2 is engaged NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS O L Negative earth MUST be used 2 The deck switch wires MUST be fitted as shown on Wiring diagrams 1 Ocean Electric Winches Modes 4C 77 3 6 EVC Electric Variable Control Standard amp high power controller single speed winches 50 64 12 V amp 24V The EVC controller uses current sensing to halt the operation of the winch when the winch has reached its M aximum Safe Working Load TheEVC controller features a Ramp Soft Start to control the winch start up adjustment of dial RA will vary the start period between 0 5 5 seconds The dial is preset by Lewmar for a start period of 1 second In order to adjust the speed SP and Ramp RA dials unscrew the plug screws on top of the controller 4 full turns and retract the plug screw assembly Use an electrical slotted 2 5mm M ax screwdriver to adjust the internal dial to the desired setting 3 Connect all low power wiring d
24. or satisfactory quality of the products ii Where applicable law does not permit a statutory or implied warranty to be excluded then such warranty if permitted by that state or countr y s law shall be limited to a period of one year from the date of purchase by the end user Some states and countries do not allow limitations on how long an implied warranty lasts so this limitation may not apply to you D PROCEDURE Notice of a claim for service under this warranty shall be made promptly and in writing by the end user to the Lewrnar outlet which supplied the product or to Lewmar at Southmoor Lane Havant Hampshire England POO 1JJ E SEVERANCE CLAUSE If any clause of this warranty is held by any court or other competent authority to be invalid or unenforceable in whole or in part the validity of the remaining clauses of this warranty and the remainder of the clause in question shall not be affected F OTHER RIGHTS This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state and country to country In the case of European States a Consumer customer as defined nationally has legal rights under the applicable national law governing the sale of Consumer Goods this Warranty does not affect those rights G LAW This warranty shall be governed by and read in accordance with the laws of England or the state or country in which the first end user is domiciled at the time of
25. oy Deck Unit oe en saat 4E 57 2 66 4 64 5 63 0 66 2 48000075 12 V Motor Geerbox E 4804425 Chon Deck Unit 5C 66 15 78 7 76 7 76 5 78 7 4804425 St Sted Deck Unit OE ZAMMA See A 12 V E Cortactor 2 5A 67 4 82 C 80 2 78 5 82 C 4804425 Al Chrome Deck Unit N Bo eo 4804426C Al Bronze Deck Unit WA ME Sot ee o 5E 73 89 5 80 2 84 C 89 5 ABGOGOGE mu E z 4800011 12 V Motor Gearbox Eorum 64 78 7 96 3 94 88 4 96 3 4800009C epus 48000117 24 V Motor Gearbox ENS EEES 6 92 4 109 2 107 2 101 2 109 2 4A EEES mE 4800014 12 V EVC Contd Box 66 2 105 2 120 1144 122 5 or 0052505 48000147 24 V EVC Control Box Z 48054055 Power Drive Kit 7 1085 121 7 116 137 7 SETTED AVE Corie POR or 005250 48058200 Alloy Deck Unit a Cc E 77 3 1126 126 1 121 C 1415 ABODOCOS yas Es m em 48000084 24 V HS Cortrol Box 48058204 St Sted Deck Unit 4800014C 12 V EVC Control Box 48058202 Al Chrome Deck Unit 48000143 24 V EVC Contol Box 48058202 All Bon Deck Unit 48048255 Alloy Dack Unit 48000075 12 V Motor Geerbox 4804825 Chrorre Deck Unit 4800007 24 V Motor Gearbox 48048258 St Stea Deck Unit NA 12 V E Cortactor Box 4804825 Al Chrome Deck Unit NA 12 V E Cortactor Box 4804826C Al Brorze Deck Unit 48000091 12 V ELS Corto Box 4800011 12 V Motor Gearbox 48000092 24 V ELS Control Box 48000117 24 V Motor Gearbox 48000145 12 V EVC Contro Box 1800030 i AS 12 V E Cortector Bor 4800014 24 V EVC Contol Box or 0052505 48058055 Power D
26. purchase of the product H DISPUTES Any dispute arising under this warranty may at the option of the end user be referred to alternative dispute resolution under the rules of the British Marine Federation or to the Courts of the State whose law shall govern the warranty or to the Courts of England and Wales The British M arine Federation may be contacted at M arine House Thorpe Lea Road Egham England TW20 8BF Haben Sie Fragen zum Thema Finfach ein Email an service sailtec de oder 040 8229940 anrufen
27. rive Kit 18000302 24 V E Cortactor Box or 005250 48000085 12 V ELS Control Box 4800008 24 V ELS Control Box 48000142 12 V EVC Control Box 48000142 24 V EVC Control Box 48048055 Power Drive Kit Ocean Electric Winches 27 Modas 4C 77 2 Ocean Electric Winches Modes 4C 77 Haben Sie Fragen zum Thema Einfach ein Email an E service sailtec de oder 040 8229940 anrufen c bes O el 11 2 Circuit breakers Model PartNo Finist Descriptior 4806420C Alloy Deck Unit 48064201 Chone Dack Unit 48064204 St Sted Deck Unit 48064203 All Chone Dack Unit 48064202 Al Bronze Deck Unit 48000075 12 V Motor Gearbox 4800007 24 V Motor Gearbox vr N A 12 V E Contactor Box N A 12 V E Contactor Box 48000093 12 V H S Control Box 48000094 24 V H S Control Box 4800015C 12 V EVC Control Box 48000151 24 V EVC Control Box 48064055 Power Drive Kit 4806620C Alloy Deck Unit 48066201 Chore Dack Unit 6 48066204 St Sted Deck Unit 48066203 Al Chone Deck Unit 48066202 Al Brorze Dack Unit 12 V Motor Gearbox 24 V Motor Gearbox 12 V E Cortector Box 12 V E Cortector Box 12 V HS Control Box 24 V ELS Control Box 12 V EVC Coriro Box 24 V EVC Conrod Box Deck Unit Deck Unit Deck Unit Deck Unit Deck Unit Deck Unit Deck unit Deck Unit 24 V Motor Gearbox 12 V Motor Gearbox 12 V E Cortector Box 12 V E Cortector Box 12 V HS Control Box 24 V
28. t 11 Model range Model Alloy ka Al Brome Kj Chrome lg St Steel o All Chrome Il 11 1 Model range 40 77 Part No Firist Description 40 19 212 207 20 5 212 ee Alley Docs Unit 25 25 8 25 25 8 x els 44 3 t 5 E en Model Part No Finist Description AS050204 es Deck Unit 4E 2 304 29 4 28 6 30 1 48040255 Alloy Deck Unit 18050203 Ala SERIEN Cc a XL 5C 3C 35 7 34 8 34 7 35 7 4804025 Chone Deck Unit ASS hoes eee e 2 54 30 37 2 36 4 35 37 2 SAS Siete Drnocps 48000075 12 V Moter Geerbor F 2 5E 334 40 30 38 1 40 ODDS DIUSTTORTE Deck Unit 4800007 24 V Motor Geerbox 4804026C AI Bronze Deck Unit ip 6A 35 7 43 7 42 6 40 1 43 7 NA 12 V E Contactor Box 4800011 12 V Motor Gearbox im 6 42 C 49 7 48 46 C 49 7 Dy ME Sorte EON z 48 C 54 8 52 0 55 7 pru 4C 12 V E Contactor Box 4800008 24 V BLS Cord Box 7j 49 3 2 53 0 z or 0052505 48000144 12 V EVC Corto Box 77 2 51 3 57 3 55 C 3 48000302 E 3 GE H 24 V E Cortector Box 48000145 24 V EVC Control Box or 005250 4800008 12 V H S Control Box SS DONS ETE 4805420 Alloy Deck Unit 48000082 24 V ELS Corto Box Model Alloy Ibs Al Bronze Ibs Chrorre Ibs St Stee Ibs All Chrone 48054201 Chone Dak Unit ibs 480001 3 12 V EVC Control Box AC 41 46 7 45 45 2 46 7 Es E m 4804005 Drive Kit 48054202 Al Crrorre Deck Unit 44 51 4 56 8 56 56 2 56 8 48054 Brorze Deck Uri 48044255 All
29. tput gear is situated in the optimum position in relation to the load Fig 1 42 Fig 1 42 Haben Sie Fragen zum Thema Finfach ein Email an service sailtec de oder 040 8229940 anrufen Ocean Electric Winches 7 Models 4C 77 c O J f vi c 1 5 Positioning winch ancillaries below deck The positioning of the motor gearbox must be Checked prior to cuffing for dedghil and bulkhead Cleararce e The motor gearbox can be rotated in 90 steps Fig 1 51 Fig 1 51 e The motor rotation is factory set for fitting as Fig 1 52 Ocean Electric Winches Modes 4C 77 NOTE The motor can be fitted as Fig 1 53 Contact Lewmar for correct fitting of electrical connections If the motor is unitentionally fitted this way on a single speed winch it will not operate and make a clicking noise on a 2 or 3 speed winch it will dramatically reduce performance A MI 07 Check clearance below deck and accessibility then position the deck switches near and in view of the winch Use the templates provided as a guide to cut drill hole fit switch and seal NOTE Air switch tubing must be twist and chafe free to the switch unit sub box Q DO NOT cover the air bleed hole with sealant as this will stop air escaping and could result in Winches self operating as the air eqancs with rising temperatures in the tube Winch motor gearbox and controls double check everything and o
30. unting location A Electrical e Make sure you have switched off the power before you start installing this product e fin doubt about installing electrical equipment please seek advice from a suitably qualified electrical engineer Ocean Electric Winches 5 Modas 4C 77 Use the template provided as a guide to position the winch on the deck e NOTE Check the scale of the template matches the winch Fig 1 43 1 4 Positioning winch above deck e Lewmar recommend that the rope enters onto the drum at an angle of 5 to 10 to the base axis of the winch To achievethis angleit may be necessar y to use a base wedge when installing the winch Fig 1 41 The winch must be mounted on an even surface 1 Installation Make sure there is room below deck for motor and sub box gt PRE 1992 1992 gt AUG 2000 40 44 48 AUGUST 2000 gt Always keep in mind the space available below the deck for the motor gearbox uopejjesul T Fig 1 41 Convertible Manual vvith Povver Drive Unit Convertible Complete Electric Wavespring Manual Manual Wavegrip Winch Convertible Winch 1 1 Identifying the manual 1 2 Preparing the manual convertible winch winch for conversion to electric e Fig 1 11 Pre Ocean winches i e fixed jaw Wave Remove the winch from the deck if already installed and remove the Centre Plate which e If practical for best performance the winch Ocean Electric Winch
31. ws the winch to be operated up to the Safe Working Load for winch size Other features as Section 3 1 A Total voltage drop MUST NOT exceed 570 Of supply over con pleted cabling installation Check all connections for water tight security Levwurer recommends an isolator to be fithed in the circuit in an accessible position as dose as possible to the supply Connectthe power supply cables to the battery last when the winch installation has been completed and checked for correct installation Incorrect connection of motor cables may damage the unit NUMBER KEY FOR ALL ELECTRICAL DIAGRAMS 3 Gonnect all low power wiring deck switches O 14 L Negative earth MUST be used 2 The deck switch wires MUST be fitted as shown on wiring diagrams Ocean Electric Winches Modds 4C 77 motor cubout etc before fitting high power cables to coniroller 4 Cable boots are supplied for all high power cable connections follow guidelines Fig 2 11 for cable sizing 3 3 ELS Electric Load Sensing 50 64 12 V or 24 V This installation controls the winch by Lewrnar s unique Overload Protection Control Box Fig 3 21 this allows the winch to be operated up to the Safe Working Load for winch size Other features as Section 3 1 Fig 3 31 12 V or 24 V Control box with overload protection A Total voltage drop MUST NOT exceed 570 Of supply over completed cabling installation Check all connections for water tight s
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