Lewmar Hatch Spares Book Volumes 1 & 2 (PDF)

PARTS LIST

Lewmar's 2000 hatch spares books for every range from Superhatch and Rollstop to Ocean, Concept and the Low and Medium Profile Mk.1 / Mk.2: how to read the acrylic marking and colour-coded kit numbers, fitting and adjustment data, and the seal, hinge, handle, lever, frame and lid kit numbers by size.

DocumentLewmar Hatch Spares Book Volumes 1 & 2

FormatPDF · 80 pages · 2.3 MB

LanguageEnglish

Download PDF ▾

View Collection

Contents Marking & Codes Fitting Seal Kits Products

Lewmar Hatch Spares Book — Volumes 1 & 2

This manual is split into 3 pages: Part 1 · Part 2 → · Part 3 →

What Is in These Books

Lewmar's dealer hatch spares books of 20 December 2000. Volume 1 covers the older ranges (Superhatch, Size 6, Rollstop, Trimline, Coastline, Trimport, Ocean, Concept); Volume 2 covers the Low and Medium Profile Mk.1 and Mk.2 hatches. Each range has an index page with build dates, how to identify it, and the drawing numbers of its fitting instructions and spares kits; the kit drawings follow. Two single sheets are added as extra downloads: the Trimline & Coastline seal kit sheet (B5539-2) and the instructions for fitting outside handles to hatches with glued-on handles.

Range	Build dates	Instructions	Spares drawings
Superhatch	1980 to 1987	B2045 Mk.V	B5525-2 handle, B5526-2 catch block, B5527-1 hinge pins, B5528-1 seals & acrylic/hinge fastening
Size 6 (Superhatch, 882 × 882)	From 1980, remains in build	B2045 Mk.V	B5661-1 alloy outside handles, B5529-1 hinge, B5528-1 seal
Rollstop	1986 to 1992	B2193 (Sz 10 & 20), B2202 (Sz 30 & 40), B2194 (Sz 50, 60, 65 & 70) hinge replacement	B5520-2 catch blocks, B5521-3 hinge kits, B5528-1 seals, B5662-3 / B5664-2 handles
Trimline	1988 to 2000	B2179 Iss B	B5520-2, B5530-2 stays, B5539-2 seals, B5541-1 hinge pins, B5542-2 lower frames, B5550-2 lids, B5666-2 handles
Coastline	1991 to 2000	B4050	B5520-2, B5539-2 seals, B5600-3 lower frames, B5611-4 lids, B5622-2 hinge pins, B5662-3 / B5666-2 handles, B5676-2 friction levers
Trimport (Coastline sizes 00 to 24, 33, 41 and 61)	1991 to 2000	B4050 Iss B	B5520-2, B5540-1 seals, B5541-1 hinge pins, B5668-3 handles; Mk.1 (stay): B5543-3, B5560-1, B5563-2, B5565-2; Mk.2 (friction lever): B5575-3, B5675-2, B5585-2
Ocean	From 1991	B4056 Iss B	B5520-2, B5625-3 flat / B5626-3 flanged lower frames, B5642-3 lids, B5659-2 hinge pins, B5660-3 seals, B5662-3 / B5668-3 handles, B5675-2 / B5676-2 friction levers
Concept	From 1994	B4070-1 (rectangular), B4072-B (round)	B5757-3 main frames, B5758-3 acrylics, B5759-3 trim frames, B5760-4 flyscreens, B5767-2 seals, B5668-3 handles, B5779-2 friction levers, B5761-1 hinges
Low Profile Mk.1 & Mk.2	Mk.1 1998 to 2000; Mk.2 from 2000	B5968, B5970 (disassembly)	B5800-3 to B5810-2, B5825-2 to B5828-1
Medium Profile Mk.1 & Mk.2	Mk.1 1998 to 2000; Mk.2 from 2000	B5968, B5970	B5800-3, B5802-2, B5804-2 to B5806-3, B5814-2 to B5817-2, B5829-1 to B5832-2

Accessories for all ranges: retro-fit lock & key kit (B5677-3, instructions B5677-B & C), inside handle both sides kit (B5966-B), retro-fit stay (B5971, Low/Medium Profile) and trims & flyscreens.

Acrylic Marking, Date Codes and Colour Digits

All Lewmar hatches and portlights (except the old Standard portlight) made since October 1997 are stamped on the acrylic. On hatches the marking is between the right-hand handle and the edge of the acrylic; on Low and Medium Profile hatches it is on the inside near a handle, and you may need to lift the seal away from the acrylic to read it. Quote it when ordering spares.

Range name and size (Ocean, Coastline, Trimport, Trimline or Concept), or
399SSXR: SS = hatch size, X = acrylic colour, R = range (3 = Low Profile, 2 = Medium Profile). Example 3996003 = size 60, grey, Low Profile. Mark 2 Low and Medium Profile hatches add an "A" in front, e.g. A3996002.
300XXX: the first 6 digits of a custom hatch or portlight part number (300380 → 300380000).
Date code DDMY, e.g. 11J7 = 11th day, September, 1997 (2000 is 0). Months A–M: A Jan, B Feb, C Mar, D Apr, E May, F Jun, G Jul, H Aug, J Sep, K Oct, L Nov, M Dec (letter I is not used). The same code is stamped into the alloy frame under the lid extrusion.
Box label: year and week, e.g. 9739 = 1997, week 39.

Many kit numbers in the books contain a letter in place of a colour digit. Replace it with the digit for your colour:

Acrylic (X)

X digit	Acrylic colour
0	Smoke grey
1	Bronze
2	Clear
3	White
4	Green

Frame (Y)

Y digit	Frame colour
0	Silver anodise
1	Black anodise
2	White paint
8	Shiny silver

Some high volume builders use custom paint colours not shown.

Mouldings – handles, levers, catch blocks (Z)

Z digit	Moulding colour
0	Standard grey
1	Beneteau grey

Trims (W)

W digit	Trim colour
2	White
5	Ivory

Fitting and Adjustment Data

Range	Deck / hull thickness	Mark the deck around	Fixings
Trimline (B2179), Trimport / Coastline (B4050)	15-61mm	Outside edge of the lower frame flange	M5, 10UNC, 2BA, 3/16"; wood screws min. length 40mm
Ocean (B4056)	25-70mm (flanged version only)	Inside edge of the lower frame; flanged frames: aperture 3mm larger all round	As above; hinge fixings M6 or 1/4" through bolts only
Concept (B4070, B4072)	20-40mm	Outside edge of the frame flange (snug fit)	M5, 10UNC, 2BA, 3/16"; wood screws min. length 40mm
Low Profile (B5968)	Minimum 15mm (5/8")	Outside edge of the lower frame flange (allow for trims)	M6 in way of the hinge, M5 elsewhere

Flat mounting surface within ±1mm. Bed the lower frame in a marine sealant (e.g. silicone) at least 3mm thick, drill two holes in opposite corners, then fasten from the centre out. Hatches are not stiffening members.
Ocean hinge backing plates: 3669913999 (M6) and 3669914999 (1/4" UNC).
Friction levers (Trimport, Coastline, Ocean, Concept circular): turn the socket-head adjusting screw on each side about 1/8 turn clockwise with a 4mm (5/32") hex key to increase the holding force; adjust all levers on a hatch to a similar load. No lubricant on the levers.
Low/Medium Profile: lever stays adjust with a 3mm hex key, 1/8 turn clockwise. Friction hinges (smaller hatches): remove the plastic hinge cover with the hatch open, hold the jacking nut and turn the bolt anti-clockwise with two small pins to increase friction, 1/4 turn at a time.
Small "vent" hatches open to 90 degrees; larger hatches are not self-supporting past vertical. Concept hatches open to 85 degrees. Trimline: remove the rubber bung stop to lay the lid back to about 145 degrees for maintenance.
Wash with soap and water only; never abrasive or solvent cleaners on the acrylic.

Low & Medium Profile: removing the lid and the acrylic (B5970)

Detach any friction levers from the lid (Philips screwdriver). Open fully and remove the friction hinge caps (they can spring off).
Turn the two jacking screws towards each other with two Allen keys and remove them; pull the black friction tapers into the middle of the lower hinge and lift the lid free.
Remove the screws on one side of each upper-frame join and slide the two frame halves off the acrylic; the seal stays on the acrylic, the joining inserts on one frame half.
Reassemble in reverse, using a strong washing-up liquid solution to slide the frame over the seal, then rinse it off. One friction taper has a recess for the jacking screw, the other has cut-outs that locate in the upper frame – check it is the right way round before refitting the lid.

Retro-fit lock & key kit 360259990 (B5677)

Does not fit the Size 6 hatch; square and rectangular hatches only. Fit the lock first, then the catch block.
Drill a 20mm (3/4") hole half way from each side (water as lubricant, controlled speed), and a 5mm (3/16") hole 3.0mm (1/8") deep on the underside for the anti-rotation washer.
Hole position from the drawing: 43mm (1-11/16") on Rollstop and Ocean sizes 00 to 40; 39mm (1-1/2") with spacer on Rollstop and Ocean size 44 and above; 45mm (1-3/4") on Low Profile, Medium Profile and Coastline/Trimport (Trimline uses the same lid and dimension).
Two catch block types are supplied (Ocean/Coastline and Low/Medium Profile): use the same type as the handle catch blocks, the same way up, riveted with a 5mm drill. Tools: 12mm and 24mm spanners, rivet gun.

Retro-fit stay (B5971)

For Low Profile sizes 10, 30, 40, 44, 50, 54 & 60 and Medium Profile size 70 (two stays).
Rivet the stay handle and pivot bush to the lower frame in place of the factory plug. Drill the acrylic for the upper pivot: 5mm (3/16") pilot, then 10mm (3/8") half way from each side.
Tube: short for sizes 10 and 30, medium for 40, 44, 50 and 54, full length for 60 and 70 (2 off). On sizes 10 to 54 cut 2mm (1/16") from the hole; never cut the flared end.

Outside handle on hatches with glued-on handles (extra download)

This invalidates the hatch warranty, and there is no lock on the inside handle.
Remove the handle from the glued moulding. With a pillar drill, drill a 3mm pilot through the moulding and acrylic, then a 15mm hole, drilling the acrylic from both sides.
Fit a standard outside handle or mushroom to the existing inside handle; file a few mm off the spindle if needed so the O-ring pulls down on the acrylic. The retainer turns up to 50 degrees before engaging; dry-assemble, then glue or mechanically lock retainer and inside handle.

Seal Kits

Ocean hatch replacement seals (B5660-3)

Kit No.	Hatch	Hatch overall size
360370999	Size 00	276 x 276	Ask us to source it →
360371999	Size 10	325 x 325	View part →
360372999	Size 20	267 x 412	View part →
360373999	Size 30	392 x 522	View part →
360374999	Size 40	486 x 486	View part →
360381999	Size 44	509 x 509	View part →
360375999	Size 50	445 x 575	View part →
360382999	Size 54	459 x 574	View part →
360376999	Size 60	575 x 575	View part →
360377999	Size 63	624 x 624	Ask us to source it →
360378999	Size 65	Trapezoidal 676x554x557	View part →
360379999	Size 70	695 x 695	View part →
360380999	Size 75	Trapezoidal 807x552x695	Ask us to source it →
360383999	Size 77	767 x 767	View part →

Trimline & Coastline (B5539-2)

Kit No.	Hatch	Hatch overall size ref.
360580999	Size 00	281 x 281	Ask us to source it →
360583999	Size 10	330 x 330	Ask us to source it →
360604999	Size 18	Round dia 490	View part →
360584999	Size 20	417 x 272	View part →
360603999	Size 22	Round dia 588	Ask us to source it →
360595999	Size 30	527 x 397	View part →
360595999	Size 31	397 x 527 (side hinge)	Ask us to source it →
360596999	Size 35	585 x 455	Ask us to source it →
360597999	Size 40	491 x 491	View part →
360593999	Size 44	512 x 512	View part →
360598999	Size 45	577 x 491	Ask us to source it →
360599999	Size 50	577 x 447	Ask us to source it →
360594999	Size 54	577 x 462	View part →
360600999	Size 60	577 x 577	View part →
360601999	Size 65	Trapezoidal 675x559x560	View part →
360602999	Size 70	697 x 697	Ask us to source it →

Trimport (B5540-1)

Kit No.	Hatch	Hatch overall size
360580999	Size 00	281 x 281	Ask us to source it →
360581999	Size 03	301 x 246	View part →
360582999	Size 05	330 x 246	Ask us to source it →
360583999	Size 10	330 x 330	Ask us to source it →
360584999	Size 20	417 x 272	View part →
360585999	Size 21	413 x 330	Ask us to source it →
360586999	Size 23	425 x 201	Ask us to source it →
360587999	Size 24	424 x 209	Ask us to source it →
360588999	Size 33	554 x 259	Ask us to source it →
360589999	Size 41	494 x 246	Ask us to source it →
360590999	Size 52	557 x 301	Ask us to source it →
360591999	Size 61	577 x 330	Ask us to source it →

Low Profile Mk.1 & Mk.2 (B5810-2)

Kit No.	Hatch
360860999	Size 00	View part →
360861999	Size 03	Ask us to source it →
360862999	Size 05	Ask us to source it →
360863999	Size 10	View part →
360864999	Size 20	View part →
360865999	Size 21	View part →
360866999	Size 30	View part →
360867999	Size 40	View part →
360868999	Size 41	View part →
360869999	Size 44	View part →
360870999	Size 50	View part →
360871999	Size 54	View part →
360872999	Size 60	View part →
360873999	Size 61	Ask us to source it →
360874999	Size 65	View part →
360875999	Size 18 (round)	View part →
360876999	Size 22 (round)	View part →

Medium Profile Mk.1 & Mk.2 (B5817-2)

Kit No.	Hatch
360959999	Size 30	View part →
360960999	Size 40	View part →
360961999	Size 44	View part →
360962999	Size 50	View part →
360963999	Size 54	View part →
360964999	Size 60	View part →
360966999	Size 70	View part →
360968999	Size 77	View part →

Concept seal & tape kit (B5767-3)

Kit No.	Hatch	Overall size
360640999	Size 40	476 x 476	Ask us to source it →
360641999	Size 55	529 x 529	Ask us to source it →
360643999	Size 57	540 x 540	Ask us to source it →
360642999	Size 60	577 x 577	Ask us to source it →
360646999	Size 13	364 dia.	Ask us to source it →
360648999	Size 22	577 dia.	Ask us to source it →

Rollstop (B5528-1)

Kit No.	Description
19783100	RS 10 seal kit	Ask us to source it →
19783200	RS 20 seal kit	Ask us to source it →
19783300	RS 30 seal kit	Ask us to source it →
19783400	RS 40 seal kit	View part →
19783500	RS 50 seal kit	Ask us to source it →
19783600	RS 60 seal kit	Ask us to source it →
19783700	RS 70 seal kit	Ask us to source it →

Superhatch (B5528-1)

Kit No.	Description
19781000	SH 0 seal kit (Sz 20)	Ask us to source it →
19781100	SH 1 seal kit (Sz 30)	Ask us to source it →
19781200	SH 2 seal kit (Sz 50)	Ask us to source it →
19781300	SH 3 seal kit (Sz 60)	Ask us to source it →
19781400	SH 4 seal kit (Sz 70)	Ask us to source it →
19781500	SH 5 seal kit (Sz 40)	Ask us to source it →
19781600	SH 6 seal kit (Sz 6)	Ask us to source it →
19781700	SH 7 seal kit (Sz 10)	Ask us to source it →
360265999	Acrylic/upper hinge fastening (3 x Tappex nut insert & M6 x 20 machine screws)	Ask us to source it →

Trimline, Coastline, Trimport: you need solvent-based contact adhesive. Lift the old seal at one point and pull it off all round (a blunt scraper helps), clean excess adhesive from the channel without damaging the frame, apply adhesive sparingly and press the new seal in with the seal vent hole facing the inside of the hatch; check it is fully home all round. Trimlines built before December 1992 had an older seal; the Coastline seal replaces it.
Low/Medium Profile: the seal is stretched over the acrylic; 3M Scotch-Grip 7434 or similar water-based contact adhesive holds it to the acrylic to aid assembly.
Concept: pull the old seal off the adhesive tape, cut the old glue with a sharp knife, clean the alloy frame, stick the new tape on (leave the yellow backing), locate the seal, then peel the backing while pushing the seal onto the tape; finish with a bead of superglue between the lower edge of the seal and the frame.

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