Andersen 68ST & 72ST E2 Electric Winch — Product Manual

Product Information (Data Sheets)

Exploded View & Parts List

Optional Accessories

Both optional push buttons are described the same way in the parts list (as printed). Circuit breaker: rating per the Winch Data Sheet.

Installation

• Tools: mounting template and metric hex keys (included), cross head screwdrivers and a small flat screwdriver (circlip), Ø10.5mm drill for M10 bolts (13/32" for 3/8"), Ø3mm (1/8") drill, Ø86mm (3 3/8") and Ø25mm (1") hole saws, 13mm spanner (motor terminals), 17mm spanner for M10 nuts (9/16" for 3/8), Andersen winch grease, sealant, crimping tool.
• Fasteners: 6 x ISO 4762-A4 M10 (or 3/8") bolts (length for deck thickness), 6 x M10 locking nuts and large washers or backing plate.
• Circuit breaker (not included): "slow blow" or "long delay" type, rating per the Winch Data Sheet. Terminals are M8 for the motor and for Andersen circuit breakers.
• Record the winch version (production year-month and version engraved on the base of the centre stem) and the motor serial number (engraved on the drive shaft housing flange).

1. Position. Motor at least 1m from any compass; recalibrate afterwards. Line entry 3-8° from horizontal. Check below-deck clearance in the Winch Data Sheet.
2. Deck plate [1]. The arm can be moved after installation into one of eight positions (on the template). Cut the Ø86mm (3 3/8") hole, drill Ø10.5mm holes for M10 bolts (13/32" for 3/8"), clean, seal (aluminium boats: galvanic isolating ring/gasket) and fit the plate with countersunk bolts, large washers or backing plate and locking nuts.
3. Motor unit (two persons). With circlip [9], gearwheel [15] and screws [8] removed, grease the top of the driveshaft housing [4], the O-ring [18] and the eight countersunk holes in the deck plate. Lift the motor on the M6 eye bolt [A4] so the eight threaded holes align, fit screws [8] – first at 3, 6, 9 and 12 o'clock, then the other four. The O-ring seals; no sealant. Remove the eye bolt, grease the octagonal shaft, fit the gearwheel recess up, secure with the circlip and grease the gear teeth.
4. Push buttons [A7]. 25mm clearance depth below the surface; 500mm leads, motor leads 1400mm. Drill three Ø3mm (1/8") screw holes, fit gasket and button with 3x M4x20mm self-tapping screws [A6] and a little sealant; keep the breather channel clear.
5. Wiring. Shortest cable route; total length battery → motor → back via the breaker; size from the Data Sheet (thicker if in doubt). Breaker accessible and close to the battery. Battery (–) to motor (–); battery (+) to motor (+) via the breaker; push buttons to motor with the cables and connectors provided.
6. Check. Nobody and nothing near the deck plate and gearwheel, push button covers closed, breaker ON: buttons light up; each button runs the motor (in opposite directions); breaker OFF again.
7. Winch. Remove the arm screws and lift off arm and drum, set base cover and centre stem on the deck plate and secure with the M10 countersunk screws [19]; reassemble. Do not overtighten the three self-tailing arm screws – no more than 4Nm.

Mounting template (Compact Motor™ Below Deck and E2, 1:1 on A3): winch base 280mm (11 1/32"), 6 x Ø10.50mm (13/32") holes equally spaced on a 240mm (9 7/16") P.C.D., Ø86mm (3 3/8") cut-out, arm in 45 degree increments. Print at 1:1 and check the printed dimensions before drilling.

Electrical (24V)

Data sheets: 150A slow blow / long delay breaker; start-up current 350A (spike no longer than 0.1 seconds); additional battery capacity 125Ah per winch (one winch 15 minutes a day at 1/2 MWL = 165A, 41Ah, then 3 x total Ah); minimum bank 200Ah to hold 21V at start-up. Supplied with installation manual, 2 x push buttons and cable terminals.

Reversed polarity blows the motor controller's internal fuse.

Operation Checks

• Breaker OFF: turn the drum by hand – clockwise only – then crank with no load: smooth in fast and slow speeds.
• Remove the handle and try each push button: one drives the fast speed, the other the slow speed.
• Changing quickly between gears gives a delay of slightly more than 1 second (factory setting).
• The motor cuts out after 60 seconds at 70% of maximum load and after 30 seconds at 90%; normal operation resumes after 4 seconds.

Flashing Status Codes

Service & Maintenance

• Disconnect power first.
• Every year: lubricate the motor drive shaft lip seal (remove the centre stem from the deck plate) with a high quality bearing grease such as Klüber Isoflex® TOPAS NB52, or Andersen Winch Grease.
• Every 10 years (depending on usage): replace the lip seal; it must have a stainless steel spring – order the correct seal through Ronstan or your Andersen distributor.
• Every two years: inspect and service the winch per its own product manual.

Appendix – Converting a Manual 68ST / 72ST

1. Remove the self-tailer arm and drum to expose the centre stem (steps 7.1–7.3).
2. Remove the six screws holding the top part with the drive shaft; lift off the top part and the main roller bearing.
3. Holding the bronze lower centre stem in its stainless base cover, turn the assembly over to expose the gears.
4. Install the two extra gear sets from the E2 conversion kit so the hexagonal ends of their stainless shafts mate with the hexagonal recesses in the bronze base.
5. Turn it back over and fit the two screws that secure the shafts of the extra gear sets – a drop of thread lock on each.

Safety Notices

• Keep children and anyone not qualified to operate an electric winch clear of the winch and of rigging under load; tie back long hair and loose clothing.
• Rope override or other fault: stop the winch and turn off power before clearing it.
• Turn off power at the circuit breaker and remove winch handles when not in use, and before any maintenance.
• Lifting operations: never with the rope in the self-tailer, two persons with constant visual contact with the load, and never use the self-tailer as a cleat for a lifted or suspended load – tie off or lead the rope to a cleat or bollard.