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OWNER'S MANUAL

Installation, cable and breaker sizes, hydraulic data, operation, maintenance, gypsy selection, troubleshooting and the full parts lists for the Lewmar Concept, Ocean and Capstan 1, 2 and 3 vertical windlasses and capstans.

DocumentLewmar Concept / Ocean / Capstan 1, 2 & 3 Windlass Owner's Manual
FormatPDF · 26 pages · 1.1 MB
LanguageEnglish
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InstallationHydraulicsOperationGypsyMaintenancePartsProducts
Lewmar Concept / Ocean / Capstan 1, 2 & 3 Windlass — Owner's Manual

Deck Unit

  • Electric: five items to position (deck unit, motor/gearbox, control box/contactor, switches, breaker). Hydraulic: three (deck unit, motor/gearbox, switches).
  • Chain centre line on the gypsy aligned with the bow roller horizontally, and within 10 degrees of the gypsy vertically; get maximum chain contact round the gypsy.
  • Maximise the vertical drop below the chain pipe; with a full locker the rode must sit level with or below the bottom of the shaft or motor/gearbox.
  • Uneven decks need pads above and below; faces parallel, shims for minor misalignment.
  • Cut to the template; angle and smooth the chain pipe hole so rope runs freely; seal sandwich decks.
  • Bolts: 4 × 5/16" UNC or M8 (size 1), 4 × 7/16" UNC or M10 (size 2 & 3), stainless hex head.
  • Seal under the bolt heads, fit the ring gasket in the recess, bed the base in sealant (or the PVC foam gasket).
  • Grease the shaft, slide on the motor/gearbox in the most suitable of the 5 positions, check the drive key.
  • Ocean 2 & 3 with deck spacer: bolt the gearbox adaptor to the spacer tube; if the spacer is removed, shim carefully and use drive key 65000443.

Electric

  • Control box (contactors) near the windlass, dry. Rubber boots on terminals, greased inside. Check up/down rotation; make sure a thermal cutout is connected.
  • Terminals for 5/16" (8mm) studs. Voltage drop over the whole run must not exceed 2 volts. Breaker close to the battery, Lewmar slow blow or equivalent.
Model Breaker Cable 0-7m (0-23') Cable 7-15m (23-50') Switch wire
Concept/Ocean/Capstan 1, 12V 90 Amp 25mm2 (3AWG) 35mm2 (2AWG) 5 Amp
Concept/Ocean/Capstan 1, 24V 50 Amp 25mm2 (3AWG) 25mm2 (3AWG) 0.75mm2
Concept/Ocean/Capstan 2 & 3, 12V 150 Amp 50mm2 (0 AWG) 70mm2 (00 AWG) 5 Amp
Concept/Ocean/Capstan 2 & 3, 24V 110 Amp 35mm2 (2AWG) 50mm2 (0 AWG) 0.75mm2

Cable length = distance from windlass motor to battery.

Hydraulic Version (Size 2 & 3)

Model Hydraulic motor Max pressure Flow rate Connections Main ports
Concept/Ocean/Capstan 2 & 3 50cc per revolution 140 bar
2030 psi 		10-40L/min
2.6-10.6 gal/min 		1/2" B.S.P.F. 2
  • Designed for Lewmar "Commander" powerpacks or any unit with the right flow and pressure; a drain line is required.
  • Concept/Ocean/Capstan 2: restrict and set the maximum pressure to 100 bar (1450 psi); more can damage the windlass.
  • Standard adaptors: 2 × 1/2" BSP male – 1/2" BSP male (US: 1/2" BSP male – 3/4" Jic male).
  • The motor can be rotated round the gearbox flange. Fit a pilot operated check valve to stop the motor slipping.
  • Maximum pressure and flow should not occur together. Switches need at least 3 amps on 12v or 24v DC.

Operation

  • Power up/down: press UP or DOWN.
  • Manual chain release: power off at the breaker, handle in the bi-square, undo the top nut about half a turn; tighten it again with the winch handle to control or stop the chain.
  • Capstan (gypsy/capstan models): tie off or remove the rode from the gypsy (engage the gypsy pawl on Ocean), loosen the top nut and power the capstan alone.
  • Emergency manual override (Ocean only): power off, winch handle in the bi-square, rotate clockwise; remove the handle after.
  • Capstan only units: power up switch; no manual release or override.
  • Keep the top nut clamped when powering: clockwise until resistance, plus a further half turn. Remove the handle before powering.

Hold the rode on a chain stopper, bollard or cleat at anchor; do not pull more than the rated load; use the engine to help recovery; switch off at the breaker when not in use.

Rope/Chain Combinations

Built for 3 strand nylon rope spliced to calibrated chain; many other makes fit one of the Lewmar universal gypsies.

Size 1 gypsy Rope (size 1) Chain Size 2 & 3 gypsy Rope (size 2 & 3)
000 1/2" (12-14mm) 1/4" ACCO G40, 1/4" ACCO BBB, 7mm ISO N/A N/A
001 1/2"-5/8" (12-16mm) 8mm DIN 766, 8mm ISO 201 1/2"-5/8" (12-16mm)
002 1/2"-5/8" (12-16mm) 5/16" ACCO G40, 9.5mm ISO, 10mm DIN 766 202 5/8" (16mm)
003 5/8" (16mm) 10mm ISO, 3/8" ACCO G40 203 5/8" (16mm)
N/A N/A 12mm ISO, 13mm DIN 766, 7/16" Acco G40 204 3/4" (18/20mm)

Rope to Chain Splice

  • Seize about 12" (300mm) from the rope end and unlay the strands.
  • Two strands through the end link from one side, one from the other; pull tight to the seizing.
  • Back splice 3 or 4 tucks per strand; taper after the first 3 to 4 tucks; hot-knife the strands 1/2" from the standing part.
  • Check the splice regularly and remake it at any sign of wear.

Maintenance & Troubleshooting

  • At least every 6 months: strip the above deck parts, wash with fresh water and lightly oil (SAE10) seal, shaft, cone clutch and spline. Clean the base under the gypsy, check the sealing ring, grease the chain pipe cover and stripper screw threads. The bearing is self lubricating.
  • Below deck: check motor/gearbox and terminals, re-grease as needed; if corroded, clean and repaint with marine grade oil based enamel.
Question If not
Does the windlass motor run but the gypsy not rotate? Check the drive key and circlip are on the shaft and the top nut is tight.
Safety switch on (if fitted)? Switch on.
Correct rotation for up and down? Check switch wiring against the manual and motor connections F1 & F2.
Circuit breaker reset? Reset.
Does it pull sufficient load? Check battery, gypsy size against chain and rope, cable sizes, voltage drop no more than 2V, and that base and motor/gearbox are parallel to the deck.
3 Amp switch protection fuse OK (if fitted)? Change.
Switch connections correct? Check against the wiring diagram.
Battery power OK? Charge the battery.
Power at the windlass motor? Clean and tighten connections, check the wiring diagram.
Voltage drop more than 2V across the installation? Check cable sizes as recommended.

Parts Lists

Concept, Ocean and Capstan 1 exploded view

Concept / Ocean / Capstan 1

Part No. Description Fits
68000120 Motor/Gearbox 12v Concept 1 G/C, Concept 1 G, Capstan 1 Ask us to source it →
68000233 Motor/Gearbox 12v Ocean 1 G/C, Ocean 1 G Ask us to source it →
68000121 Motor/Gearbox 24v Concept 1 G/C, Concept 1 G, Capstan 1 Ask us to source it →
68000234 Motor/Gearbox 24v Ocean 1 G/C, Ocean 1 G Ask us to source it →
68000527 Motor/Gearbox 12V (from Feb '99) Concept 1 G/C, Concept 1 G, Capstan 1 View part →
68000528 Motor/Gearbox 12V (from Feb '99) Ocean 1 G/C, Ocean 1 G Ask us to source it →
68000538 Motor/Gearbox 24V (from Feb '99) Concept 1 G/C, Concept 1 G, Capstan 1 View part →
68000529 Motor/Gearbox 24V (from Feb '99) Ocean 1 G/C, Ocean 1 G Ask us to source it →
B7782 Spirol clip All View part →
B6126 Circlip All Ask us to source it →
65000259 Delrin Washer All Ask us to source it →
65000177 Drive Key All View part →
65000168 Shaft Concept 1 G/C, Ocean 1 G/C Ask us to source it →
65000167 Shaft Concept 1 G, Ocean 1 G Ask us to source it →
65000522 Shaft Capstan 1 Ask us to source it →
68000172 Shaft 6" Extention Kit Concept 1 G/C, Ocean 1 G/C Ask us to source it →
68000171 Shaft 6" Extention Kit Concept 1 G, Ocean 1 G Ask us to source it →
65000246 Bearing All Ask us to source it →
65000171 Upper Cone Concept 1 G, Ocean 1 G View part →
65000262 Top Nut Washer Concept 1 G, Ocean 1 G View part →
65000173 Top nut Concept 1 G, Ocean 1 G Ask us to source it →
65000276 Seal Washer All View part →
65000169 Rubbing Washer All View part →
B2580 Seal All View part →
65000170 Lower Cone All View part →
68000360 Gypsy & Stripper Assy 000 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
68000361 Gypsy & Stripper Assy 001 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
68000362 Gypsy & Stripper Assy 002 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
68000363 Gypsy & Stripper Assy 003 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
B0561 CSK HD Screw M4x20 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
65000582 Stripper Only 000, 001 & 002 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000583 Stripper Only 003 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
65000530 Base (Grey) Concept 1 G/C, Concept 1 G Ask us to source it →
65000566 Base (White) Concept 1 G/C, Concept 1 G Ask us to source it →
65000532 Base (Chrome) Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000521 Base (Chrome) Capstan 1 Ask us to source it →
65000531 Chain pipe cover (Grey) Concept 1 G/C, Concept 1 G Ask us to source it →
65000567 Chain pipe cover (White) Concept 1 G/C, Concept 1 G Ask us to source it →
65000533 Chain pipe cover (Chrome) Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000286 Skt Hd Cap Screw M5x25 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000287 Skt Hd Cap Screw M5x40 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
65000174 Drum Concept 1 G/C, Ocean 1 G/C Ask us to source it →
65000520 Drum Capstan 1 Ask us to source it →
65000263 Drum Washer Concept 1 G/C, Ocean 1 G/C, Capstan 1 View part →
65000176 Drum Top Nut Concept 1 G/C, Ocean 1 G/C, Capstan 1 Ask us to source it →
65000543 In fill Piece Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000565 Skt Hd Cap Screw M6x35 Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
65000306 Sealing Gasket (Grey) Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000518 Sealing Gasket (White) Concept 1 G/C, Concept 1 G Ask us to source it →
65000551 Pawl Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000552 Pawl Pillar Ocean 1 G/C, Ocean 1 G Ask us to source it →
B1554 Ball Spring Delrin Ocean 1 G/C, Ocean 1 G View part →
B0310 Pan Hd Screw M5x16 Ocean 1 G/C, Ocean 1 G Ask us to source it →
68000346 Arm kit Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →
65000540 Arm Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000542 Spring Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G Ask us to source it →
65000544 Shoulder Screw Concept 1 G/C, Concept 1 G, Ocean 1 G/C, Ocean 1 G View part →

Concept and Ocean 2 and 3 exploded view

Concept / Ocean / Capstan 2 & 3

Part No. Description Fits
68000213 Motor/Gearbox 12v Concept 2 G/C, Concept 2 G, Capstan 2 Ask us to source it →
68000215 Motor/Gearbox 12v Concept 3 G/C, Concept 3 G, Capstan 3 Ask us to source it →
68000235 Motor/Gearbox 12v Ocean 2 G/C, Ocean 2 G Ask us to source it →
68000237 Motor/Gearbox 12v Ocean 3 G/C, Ocean 3 G Ask us to source it →
68000214 Motor/Gearbox 24v Concept 2 G/C, Concept 2 G, Capstan 2 Ask us to source it →
68000216 Motor/Gearbox 24v Concept 3 G/C, Concept 3 G, Capstan 3 Ask us to source it →
68000236 Motor/Gearbox 24v Ocean 2 G/C, Ocean 2 G Ask us to source it →
68000238 Motor/Gearbox 24v Ocean 3 G/C, Ocean 3 G Ask us to source it →
68000530 Motor/Gearbox 12v (from Feb '99) Concept 2 G/C, Concept 2 G, Capstan 2 Ask us to source it →
68000534 Motor/Gearbox 12v (from Feb '99) Concept 3 G/C, Concept 3 G, Capstan 3 View part →
68000532 Motor/Gearbox 12v (from Feb '99) Ocean 2 G/C, Ocean 2 G Ask us to source it →
68000536 Motor/Gearbox 12v (from Feb '99) Ocean 3 G/C, Ocean 3 G Ask us to source it →
68000531 Motor/Gearbox 24v (from Feb '99) Concept 2 G/C, Concept 2 G, Capstan 2 Ask us to source it →
68000535 Motor/Gearbox 24v (from Feb '99) Concept 3 G/C, Concept 3 G, Capstan 3 View part →
68000533 Motor/Gearbox 24v (from Feb '99) Ocean 2 G/C, Ocean 2 G Ask us to source it →
68000537 Motor/Gearbox 24v (from Feb '99) Ocean 3 G/C, Ocean 3 G Ask us to source it →
B7782 Spirol clip All View part →
65000443 Drive Key Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Capstan 2, Capstan 3 View part →
65000772 Drive Key Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000445 Shaft Concept 2 G/C, Ocean 2 G/C View part →
65000446 Shaft Concept 3 G/C, Ocean 3 G/C View part →
65000448 Shaft Concept 2 G, Concept 3 G, Ocean 2 G, Ocean 3 G View part →
65000511 Shaft Capstan 2 Ask us to source it →
65000508 Shaft Capstan 3 Ask us to source it →
68000352 Shaft 8" Extention Kit Concept 2 G/C, Ocean 2 G/C Ask us to source it →
68000354 Shaft 8" Extention Kit Concept 3 G/C, Ocean 3 G/C Ask us to source it →
68000355 Shaft 8" Extention Kit Concept 2 G, Concept 3 G, Ocean 2 G, Ocean 3 G Ask us to source it →
65000441 Bearing All Ask us to source it →
B6126 Circlip All Ask us to source it →
65000259 Delrin Washer All Ask us to source it →
65000442 Sealing Gasket (Grey) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000595 Sealing Gasket (White) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G Ask us to source it →
65000764 Base (Grey) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G Ask us to source it →
65000780 Base (White) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G Ask us to source it →
65000771 Base (Chrome) Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000526 Base (Chrome) Capstan 2, Capstan 3 Ask us to source it →
B2580 Seal All View part →
65000437 Seal Washer All Ask us to source it →
65000438 Rubbing Washer All Ask us to source it →
65000436 Lower Cone Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000170 Lower Cone Capstan 2, Capstan 3 View part →
68000356 Gypsy 201 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
68000357 Gypsy 202 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
68000358 Gypsy 203 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
68000359 Gypsy 204 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
B0677 SKT HD CAP Screw M5x20 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
B1525 Spirol Pin Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000775 Chain Stripper Only Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000439 Chain Stripper Screw Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000776 In-fill Piece Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000565 Screw Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000778 Chain pipe cover (Grey) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G Ask us to source it →
65000781 Chain pipe cover (White) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G Ask us to source it →
65000779 Chain pipe cover (Chrome) Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000439 Skt Hd Cap Screw M6x25 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000440 Skt Hd Cap Screw M6x60 Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000435 Upper Cone Concept 2 G, Concept 3 G, Ocean 2 G, Ocean 3 G View part →
65000262 Top Nut Washer Concept 2 G, Concept 3 G, Ocean 2 G, Ocean 3 G View part →
65000434 Top nut Concept 2 G, Concept 3 G, Ocean 2 G, Ocean 3 G Ask us to source it →
68000241 Drum Assembly Concept 2 G/C, Ocean 2 G/C Ask us to source it →
68000242 Drum Assembly Concept 3 G/C, Ocean 3 G/C Ask us to source it →
68000312 Drum Assembly Capstan 2 Ask us to source it →
68000313 Drum Assembly Capstan 3 Ask us to source it →
65000263 Drum Washer Concept 2 G/C, Concept 3 G/C, Ocean 2 G/C, Ocean 3 G/C, Capstan 2, Capstan 3 View part →
65000176 Drum Top Nut Concept 2 G/C, Concept 3 G/C, Ocean 2 G/C, Ocean 3 G/C, Capstan 2, Capstan 3 Ask us to source it →
65000551 Pawl Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000782 Sleeve Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
B1554 Ball Spring Delrin Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
B0679 Skt Hd Screw M6x16 Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G View part →
65000741 Spacer Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000773 Adaptor Plate Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
B0008 Screw Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000773 Screw (as printed) Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
68000499 Arm Kit (Complete) Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000762 Arm Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000542 Spring Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →
65000763 Screw Concept 2 G/C, Concept 3 G/C, Concept 2 G, Concept 3 G, Ocean 2 G/C, Ocean 3 G/C, Ocean 2 G, Ocean 3 G Ask us to source it →

G/C = gypsy/capstan, G = gypsy only. Motor/gearbox numbers marked "from Feb '99" replace the earlier ones.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

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