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OWNER'S MANUAL

Specifications, installation, hydraulic and electrical hook-up, line fitting, joystick operation, High Load Release and service intervals for the Lewmar Line Management System (LMS) hydraulic captive winches: LMS77, LMS111, LMS125 and LMS150.

DocumentLewmar LMS Captive Winches (LMS77, LMS111, LMS125, LMS150) Owner's Manual
FormatPDF · 28 pages · 1.5 MB
LanguageEnglish
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Owner's ManualPDF · 28 p.LMS111 manualPDF · 26 p.LMS125 manualPDF · 26 p.LMS150 manualPDF · 25 p.
SpecificationsInstallationFitting the LineOperationMaintenanceProducts
Lewmar LMS Captive Winches (LMS77, LMS111, LMS125, LMS150) — Owner's Manual

Specifications

LMS77 LMS111 LMS125 LMS150
Line diameter (specified at order) 12, 14, 16 mm 14, 16, 18, 20, 22 mm 22, 24, 26 mm 28 mm
Stowing capacity Standard: 12 mm – 38 m; 14 mm – 29 m; 16 mm – 22 m
Extended: 12 mm – 55 m; 14 mm – 50 m; 16 mm – 45 m		 14 mm – 95 m; 16 mm – 72 m; 18 mm – 65 m; 20 mm – 50 m; 22 mm – 45 m 22 mm – 81 m; 24 mm – 79 m; 26 mm – 75 m 28 mm – 20 m
Electrical 24 V DC +/- 15%, 5.0 A max 24 V DC +/- 15%, 5.0 A max 24 V DC +/- 15%, 5.0 A max 24 V DC +/- 15%, 5.0 A max
Maximum flow 55 L/min 45 L/min 55 L/min 60 L/min
Max pressure A & B 140 bar 140 bar 210 bar 210 bar
Max pressure, drain 4 bar 4 bar 4 bar 4 bar
Line speed, 1st gear (high speed) 31 m/min @ 45 L/min 38 m/min @ 45 L/min 35 m/min @ 55 L/min 28 m/min @ 60 L/min
Line speed, 2nd gear (low speed) 16 m/min @ 45 L/min 6 m/min @ 45 L/min 7 m/min @ 55 L/min 7 m/min @ 60 L/min
Max line pull, 1st gear 1400 kg @ 100 bar 800 kg @ 100 bar 1500 kg @ 180 bar 2000 kg @ 180 bar
Max line pull, 2nd gear 3300 kg @ 140 bar 4545 kg @ 140 bar 9000 kg @ 210 bar 12000 kg @ 210 bar
Auto change to 2nd gear above 100 bar 100 bar 180 bar 180 bar
Overall dimensions Standard 600 × 550 × 280 mm
Extended 740 × 550 × 280 mm		 750 mm (29.53") × 725 mm (28.54") × 405 mm (15.95") 1070 × 985 × 475 mm 1060 × 1035 × 575 mm
Weight Standard 145 kg 195 kg (430 lb) 387 kg 530 kg
Base bolts 12 × 10 mm 10 × 12 mm 14 × 12 mm 14 × 12 mm
Installation drawing 59600213_2 (standard), 59600223_2 (extended) 59600235_2 59600251_2 59500019_2

Hydraulic fluid (all sizes): mineral oil to ISO 3448 (BS 4231), viscosity grade 32, type HM, filtered to ISO 4406 (BS 5540) class 18/13 or better; optimum fluid temperature 20 °C to 50 °C. The data box printed on the LMS77 drawing does not agree with the specification page in every value; the table above follows the specification page.

Each LMS is a self-contained hydraulic winch with a hauling section and a stowing section on one base plate. The highly loaded line runs round a separate idler drum and the multi-groove main drum, then is stored at low tension on the stowing drum, so riding turns are eliminated and the unit can be close-coupled to the sheet entry point. The hauling section has a two-speed automatic gearbox; fixed-speed or fully proportional control is available.

Mounting

  • Unpacking: lift only with a soft strop round the base plate or the main winch drums. Keep the strop off everything else, especially the ball reverser. Never lift with wire rope.
  • Provide a flat pad to suit the base plate, ideally flat to within 1 mm.
  • Torque the base bolts to 40–45 lbf/ft (54–61 Nm).
  • Leave a working area round the winch for installation, hydraulic connections and future service (see the maintenance-clearance drawing for your size).

Hydraulic Connections

  • Reference drawings: 51000325 (hydraulic circuit), 58300829 (manifold block). The manifold has male JIC connections; port numbers are stamped on its top face and every hose fitting is stamped to match drawing 51000325.
  • Use straight or 90° swept (bent-tube) hose ends; avoid 90° elbows and sharp bends. Minimum bend radius 150 mm (6").
  • Hose runs longer than approximately 7 m (20 ft): go up a hose bore to limit pressure drop. All hoses rated 140 bar safe working pressure minimum; crimped or swaged ends preferred to reusable ends.
  • Connect ports A and B to the system directional valve (or the Lewmar Commander valve A and B ports). Route the Drain directly to the Commander tank drain fitting.
  • Keep the protective caps on until the last moment and flush every hose before connecting; over 80% of hydraulic component failures are attributed to contamination.
  • Danfoss PVG proportional valve: with the PVEH/PVEM actuator on the valve B end, connect valve B to winch A; with the actuator on the A end, connect valve A to winch A.
  • Electrical wiring: drawing 58400667.

Fitting the Line

Each winch is built for the rope diameter agreed at order: check the rope before fitting. Before the rope goes on, the stowing-drum ball reverser nut and sheave assembly must be aligned.

  • Method 1: turn the stowing drum under hydraulic power until the ball reverser reaches the end of its travel at the end of the drum with the rope stay or rope hole. Stop as soon as it starts to move back away from the end.
  • Method 2 (LMS77): remove the ball reverser drive cover plate and the middle idler gear, turn the ball reverser shaft by hand until the nut and sheave assembly just starts to move away from the flange with the rope stay or rope hole, then refit the idler gear and cover.
  • Method 2 (LMS111, 125, 150): remove the belt drive cover plate and slide the toothed belt off the ball reverser shaft pulley, turn the shaft by hand as above, then refit the belt and cover.
  • Pass the rope through the entry tube to the drive roller assembly, between the small drive roller and the large roller, turning the large drum by hand. The rope must pass above the small drive roller spindle (between spindle and drum).
  • Lead it round the idler drum, the multi-groove main drum and the sheaves, and secure it to the stowing drum with the rope stay and nut or by pushing it into the rope hole (rope path: drawing 55600173).
  • Automatic pay-out is standard: it drives the line off the winch in reel-out mode regardless of load. If not wanted, back off the drive roller tension screw (drawing 58600077). High Load Release works with or without the drive belt.

Operation

Fixed-Speed Control (4-position joystick)

  • Reel in: first position engages low gear (2nd) until maximum load or neutral. Fully over gives high gear (1st), changing automatically to low gear when pressure rises above the change-over pressure.
  • High gear only re-engages once the load falls below the change-over pressure, the joystick has returned to neutral and reel-in is selected again.
  • Reel out: first position low gear; fully over high gear.
  • Neutral: all solenoid coils off, power draw virtually zero.

Proportional Control (single-axis joystick + high-speed button)

  • Reel in: joystick with the high-speed button pressed starts in high gear and changes to low gear automatically above the change-over pressure. Without the button the winch stays in low gear. Speed is proportional to joystick travel.
  • Reel out: low gear unless the high-speed button is held; releasing it returns to low gear.
  • The button means heavily loaded trimming is always done at low speed unless you choose otherwise.

High Load Release

  • Press the lever valve on the winch manifold block (drawing 58300829): the brakes release and the line pays out until the load falls to the region of 15% of maximum pull.
  • A residual tension of between 6% and 17% stays on the line, depending on rope condition.
  • The system is manual and self-contained: it needs no external hydraulic or electrical supply.

Servicing and Maintenance

Regularly

  • Clean dust and fluff from the drive roller assembly.
  • Clean and re-grease the stowing-drum ball reverser screw and nut, sparingly, with Lewmar Multi Purpose Winch Grease.
  • Check the winch and pipework for hydraulic leaks; inspect hoses for damage or chafe.

Every 12 Months

  • Remove the ball reverser drive cover; inspect the toothed belt and replace if needed.
  • Check the belt pulley central retaining screws for tightness.
  • Inspect the drive roller assembly toothed belt and replace if needed.
  • Check the four sheave guard central retaining screws.
  • Check the electrical connections on the manifold, solenoid valves and pressure switch.

Service intervals depend on duty cycle; the list above is Lewmar's recommended minimum.

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

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