Lewmar EVO Winches Sizes 6–90 Service Manual (PDF)

SERVICE MANUAL

How often to strip your EVO winches, which service kit fits which size, the self-tailer rope range, and the strip-down sequence for every EVO size from the one-speed 6 to the two-speed 90ST.

DocumentLewmar EVO Winches Sizes 6–90 Service Manual

FormatPDF · 38 pages · 9.5 MB

LanguageEnglish

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When to Service Service Kits Know Your Winch Wavespring Servicing Strip-Down Exploded Views Products

Lewmar EVO Winches Sizes 6–90 — Service Manual

Service Intervals

Two or three times during the active season: strip, clean and re-lubricate.
End of each season, or before the new one: strip completely, clean, check thoroughly for damage and lubricate.
Winches carry deceptively high loads: the genoa sheet on a 40' (12 m) cruiser can easily reach 1000 lbs (453 kg).
Every winch strips from the top, on deck, without removing it from its fittings.

Drum Cleaning & Tools

Chrome: fresh water, dry with a cloth; occasionally a non-abrasive liquid chrome cleaner.
Alloy: fresh water, dry with a cloth. No polishes or abrasives.
Stainless steel: fresh water, dry with a cloth; occasionally a non-abrasive liquid cleaner.
Tools: small flat-bladed screwdriver, Allen keys, clean soft cotton, white spirit or paraffin (not petrol), light machine oil, Lewmar winch grease.

Service Kits & Lubricants

Lewmar makes a maintenance kit for every winch in the range. Each kit is complete; the parts are not sold separately.

Part no.	Description
48000014	Service kit: Ocean Standard sizes 6–40, Ocean ST 14–16, EVO ST 15	View part →
48000019	Service kit: Ocean ST 30–48, EVO ST 30–50	View part →
48000017	Service kit: Ocean ST 50–65, EVO ST 50–65	View part →
48000018	Service kit: Ocean ST 68, EVO ST 70	View part →
15000094	Small Super pawl (electric winch drives and racing winches)	Ask us to source it →
15000301	Large Super pawl (electric winch drives and racing winches)	Ask us to source it →
19700900	Allen key set	Ask us to source it →
19701000	GearGrease™, 100 g tube	View part →
19701100	GearGrease™, 300 g tub (waterproof, with solid activation for load carrying)	View part →
19701600	RaceLube™, 55 ml bottle, for pawls, springs and wherever grease is not advised	View part →
19701500	Winch maintenance pack: 100 g GearGrease™, 55 ml RaceLube™, brush, booklet, pawl springs × 10	View part →

Know Your Winch

1 Top cap & O ring · 2 Feeder arm · 3 Collet · 4 Upper crown · 5 Stripper ring
6 Lower crown · 7 Spring · 8 Spring cup · 9 Main spindle · 10 Drum
11 Roller bearing · 12 Drum washer · 13 Gear spindle sleeve · 14 Pawl gear
15 Gear spindle · 16 Centre stem · 17 Pawl spring · 18 Pawl · 19 Ratchet gear

Self-tailer	Rope range	Imperial
15 / 30 / 40ST	8–12 mm	5/16"–1/2"
45 / 50ST	8–14 mm	5/16"–9/16"
55ST	8–16 mm	5/16"–5/8"
65ST	8–18 mm	5/16"–11/16"

Exploded View

Wavespring Self-Tailer

Using It

Mount the winch so the loose tail falls into a secure stowage position.
Always at least three turns on the drum, then lead the tail over the stripper and into the spring jaws.
Release the rope from the jaws with care: it is under LOAD. Ease the line, then take the turns off the drum.
Use only rope within the jaw range in the table above.

Feeder Arm & Jaws

Re-positioning the feeder arm (all ST up to size 65): unscrew the top cap, lift off the feeder arm, rotate the stripper ring to the required position, refit the arm to suit the tail stowage.
Make sure the stripper ring sits in the groove on the back of the feeder arm.
Check the top-cap O ring, replace if needed, smear with winch grease and refit the cap.
Servicing the jaws (EVO 15ST–65ST, lower sprung jaws): remove the 3 Allen screws holding the crown assembly to the drum, lift the crown clear without losing the springs stuck to the lower crown, separate and wash in fresh water.
Check crowns and stripper ring for wear, replace as needed, reassemble in reverse order.

Servicing Rules

Cleaning: strip all components and clean them in a paraffin bath, or a plastic container and an old toothbrush, or a cloth soaked in paraffin or white spirit.
Caution: the winches contain plastic components that some cleaning agents damage. Check the cleaner maker's directions first.
Pawls: never grease them; grease makes pawls stick in their pockets and disables the winch. Lubricate with light machine oil.
Grease: only a light smear on ratchet tracks, gear teeth and bearings. Excess grease gets forced into the pawl pockets.
Pawls and springs are among the most important internal parts and the cheapest to replace: change them before they break. Replace any damaged or worn part immediately with genuine Lewmar parts.
Ratchet gears: check pawl engagement on reassembly. Wrong assembly lets the winch back-wind, which is very dangerous.
Reassemble in reverse order and check the winch works correctly straight away.

Strip-Down by Size

One-Speed EVO Sport 6, 7 & 8

Carefully prise off the circlip; remove the top plate and lift off the drum.
Remove and clean the drum bearings.
Remove the spindle by easing out the retaining key; clean, regrease and refit.
Remove, clean and inspect the four pawls in the drum; replace as needed and lubricate with light oil.
Lightly grease the two ratchet tracks and the bearing surfaces; reassemble in reverse sequence.

One-Speed 15ST

Unscrew the top cap, lift off the feeder arm, lift the main spindle and remove the 2 retaining collets; lift off the drum.
Remove and clean the drum bearings and washer, the gear spindle and gear.
Rotate the main spindle clockwise as you lift it out; remove the ratchet gear.
Clean and inspect pawls and springs, replace if worn, oil the pawls.
Lightly grease the ratchet gear and refit it ratchet face up; reassemble, lightly greasing gears, ratchet tracks, spindles and bearings.
Crown: remove the three fixing screws, lift off the crowns, lift out the springs; service the crown pawls and springs the same way.

Two-Speed EVO 30ST–65ST

Unscrew the top cap, lift off the feeder arm and remove the drum (sizes 30 and 40: align the crown to pass the collets).
Remove the two retaining collets and lift out the main spindle; clean the drum bearings and washer.
Lift out the gear spindles and gear assemblies; inspect pawls and springs, replace if needed, oil the pawls and check they don't stick.
Lightly grease ratchets and bearing surfaces; refit gears, gear spindles and main spindle.
Strip and clean the crown assembly (see Wavespring above).
Refit drum, collets and feeder arm; lightly grease the O ring and top-cap thread first.
EVO Sport 15, 30 & 40 two-speed: unscrew the top cap and follow the same sequence.

Two-Speed EVO 70–90ST

Unscrew the top cap, remove the feeder arm and retaining collets, lift off the drum.
Remove the 6 × 10 mm fixing screws holding the centre stem to the base; lift the centre stem off while supporting the main spindle.
Lift both gear assemblies out together, separate them, clean and check for wear.
With a cross-head screwdriver remove the three screws of the pawl retaining plate; clean and inspect all pawls and springs.
Lightly grease ratchet gears and bearing surfaces; refit the plastic washer before reassembling these gears.
Remove the circlip; clean and inspect the remaining pawls and springs.
Fit the drum washer with the chamfer facing down.

EVO 15 Exploded View

Lewmar EVO size 15 winch exploded view

EVO 30 / 40 / 45 / 50 Exploded View

Lewmar EVO size 30, 40, 45 and 50 winch exploded view

The exploded views carry callout numbers only, no part numbers. The older B2304 edition (standard and self-tailing models 6 to 66) is in the downloads for earlier winches; Lewmar notes the same servicing principles apply to Ocean and older winches, although the construction differs.

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