Lewmar REVO Winch (PDF)

SERVICE MANUAL

Rope specification, deck and motor installation, fastenings, wiring and cable sizes, operation, servicing, dimensions, specifications and the full spares list for Lewmar REVO electric self-tailing winches, sizes 40 to 65.

DocumentLewmar REVO Winch Installation, Operation & Servicing Manual

FormatPDF · 20 pages · 3.2 MB

LanguageEnglish

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Specifications Rope & Use Notes Installation Electrical Operation Servicing Spares Products

Lewmar REVO Winch — Installation, Operation & Servicing Manual

REVO Winch Specifications

REVO	Alloy black	Alloy grey	Chrome	WLL	Weight (alloy)	Weight (chrome)	Motor/gearbox	Motor
40	48340210	48340200	48340201	795 kg 1749 lb	18.8 kg 41.4 lb	20.5 kg 45.1 lb	48300014	700 W
45	48345210	48345200	48345201	1200 kg 2640 lb	23.1 kg 50.8 lb	25.6 kg 56.3 lb	48300014	700 W
50	48350210	48350200	48350201	1250 kg 2750 lb	25.7 kg 56.5 lb	29.1 kg 64.0 lb	48300014	700 W
55	48355210	48355200	48355201	1480 kg 3256 lb	30 kg 66.0 lb	35.8 kg 78.8 lb	48300016	1600 W
65	48365210	48365200	48365201	1700 kg 3740 lb	34.6 kg 76.1 lb	41.8 kg 92.0 lb	48300016	1600 W

REVO	B base Ø	H height	L line entry	M	P	T	U	V	W
40	154	176	98	306	50	35	127	73	111
45	174	193	103	306	50	65	127	73	115
50	186	215	109	306	50	65	127	73	117
55	209	253	140	325	63	61	139	84	133
65	234	268	144	325	63	61	139	84	137

Dimensions in mm; the manual also gives inches. WLL = working load limit; keep loads at or below it for a margin against dynamic surges.

Rope Specification

Correct sheet rope is critical: the wrong line can fall out of the self-tailer and need a very high load to back-wind.
Ropes specified: Gottifredi Maffioli Globaltech 75 / Silvertech; Corderie Henri Lancelin Minos / Helios; Liros Dynamic Plus / Regatta 2000; Marlow D2 / Marlowbraid; New England Ropes T-900 / Endura; Samson MLX / XLS Extra.
10mm diameter for every size, REVO 40 to REVO 65; a 10mm line breaks at approximately 4500kg against the REVO 65 WLL of 1700kg.
Otherwise pick a firm, rigid rope with a tightly plaited cover; Dyneema™-cored ropes perform better.

How REVO Behaves

It powers backwards (back-winds) only with load on the sheet, to prevent over-runs and riding turns; with little or no load it just ratchets.
Use the fewest turns that hold; add a wrap only when the line slips while winding in – back-wind works much better. Never wrap above the bottom of the suppressor plate on the feeder arm.
Align the feeder arm so the rope enters the self-tailer at a tangent when back-winding: unscrew the top cap, lift off the arm, rotate the stripper ring, refit.
Not for man hoisting under power: hoist manually, power isolated, hand-tailed. Always keep at least 2 turns on the drum.

Positioning & Fitting

Allow 360° for the handle; the rope should enter the drum at –5° to –10° to the base (use a base wedge if needed). Fix on an even surface.
Check below-deck clearance for the motor/gearbox before cutting; it can be rotated in 45 degree steps. Fitted the opposite way round it reverses the buttons – swap D1 and D2 at the motor gearbox.
Drill a Ø64mm hole for the drive shaft; strip the winch, mark the base bolt holes and drill.
Strip: top cap off anti-clockwise, feeder arm off, (size 40) turn the drum till the upper crown cut-out faces the collets, lift the drum, remove the centre stem screws and lever the stem off its two dowels, holding the gear stack.
Bed the base on a light coat of sealant – never a permanent adhesive such as 5200 – bolt down with countersunk heads, refit the base cover, centre stem, drum, collets, feeder arm and top cap.

Fastenings & Motor Coupling

REVO	(x) min.	Fasteners	Torque
40	30 mm (1 1/4")	5 × M6 (1/4")	9 Nm
45 / 50	33 mm (1 5/16")	5 × M8 (5/16")	21 Nm
55	33 mm (1 5/16")	6 × M8 (5/16")	21 Nm
65	38 mm (1 1/2")	5 × M10 (3/8")	43 Nm

Deck fastenings are not supplied: countersunk heads, stainless washers and locknuts; use the table with your deck thickness for bolt length.
Fit the base motor coupling and isolation shim: Loctite® on coupling bolts #15 (B0678 × 5), 21 Nm.
Grease the drive shaft, check the key, slide the motor/gearbox on and bolt it with Loctite® to 43Nm.

Electrical Wiring

Fully insulated system, type III stranded tinned copper, copper crimp terminals; check polarity.
A circuit breaker/fuse (not supplied) close to the battery, dry and accessible; reset manually after a trip.
Cable sizes keep total voltage drop to 10% at max load (ISO10133). Low current wiring 18awg minimum.
Controller within ± 1 metre of the winch in a dry spot; deck switches in view of the winch. The interlock module stops the winch if both switches are pressed together.

Winch size	Circuit breaker	35 mm²	50 mm²	70 mm²	95 mm²	120 mm²
40	90 A	8 m	12 m	17 m	23 m	29 m
45	110 A	7 m	10 m	15 m	20 m	25 m
50	120 A	6 m	9 m	13 m	18 m	23 m
55	200 A	6 m	8 m	12 m	16 m	20 m
65	200 A	5 m	7 m	10 m	15 m	19 m

Maximum distance for each cable size, (A)+(B)+(C) or (A)+(B)+(D) on the wiring diagram. Consult Lewmar if not using a Lewmar circuit breaker.

Operating the REVO Winch

Wind the rope clockwise round the drum, up over the feeder arm, into the self-tailing jaws and through the hook so it sits in the keeper ring.
Electric hauling: one-speed system; hold the button until the line is at tension.
Manual hauling: a locking winch handle is required. Anti-clockwise = 1st gear (fastest), clockwise = 2nd gear (slowest). There is no manual back-wind.
Electric back-wind: handle out and the plunger up (a short press on "in" releases it); rope tail free to run; hold "out" until the load drops and it ratchets.
Never hold the incoming rope while the winch runs; release the rope from the jaws with care, it is under load. Always remove the handle; isolate the winch when not in use.

Service Schedule

Monthly: hose down with fresh water; remove the drum, lightly oil the pawls and grease the gears and bearings, keeping grease off the pawls.
Two or three times a season: strip, clean, check and lubricate.
End or start of season: full strip and check (see the B2304 manual); clean and repaint a corroded motor with marine oil-based enamel.

Troubleshooting

Will not operate manually: assembly; pawls stuck by over-greasing – strip and clean.
Will not haul electrically: handle still in; plunger not popped up (press "in" briefly); battery and connections; isolator/breaker on; control box fuse (3 Amp); power at winch; switch connections in the control box.
Will not back-wind: clicking = tail not free or load too low (reduce line diameter or wraps); otherwise the same electrical checks.

Spares

Lewmar REVO 40, 45 and 50 winch exploded view

Lewmar REVO 55 and 65 winch exploded view

REVO 40 / 45 / 50

Part no.	Description	Item	Size
48300080	Top cap & O-ring kit	1	40 / 45 / 50	Ask us to source it →
45300100	Feeder arm	2	40	Ask us to source it →
45300101	Feeder arm	2	45	View part →
45300102	Feeder arm	2	50	View part →
48000446	Collet kit	3	40 / 45 / 50	Ask us to source it →
48300081	Jaw kit	4	40	Ask us to source it →
48300082	Jaw kit	4	45	Ask us to source it →
48300083	Jaw kit	4	50	Ask us to source it →
45300032	Drum – black alloy	5	40	Ask us to source it →
45300033	Drum – grey alloy	5	40	Ask us to source it →
45300034	Drum – chrome	5	40	Ask us to source it →
45300035	Drum – black alloy	5	45	Ask us to source it →
45300036	Drum – grey alloy	5	45	Ask us to source it →
45300037	Drum – chrome	5	45	Ask us to source it →
45300009	Drum – black alloy	5	50	Ask us to source it →
45300018	Drum – grey alloy	5	50	Ask us to source it →
45300019	Drum – chrome	5	50	Ask us to source it →
48000456	Drum bearing kit	6	40	Ask us to source it →
48000457	Drum bearing kit	6	45	Ask us to source it →
48000458	Drum bearing kit	6	50	Ask us to source it →
48300027	Gear spindle kit	7, 11	40	Ask us to source it →
45000323	Gear spindle kit	7	45	Ask us to source it →
45000423	Gear spindle kit	7	50	Ask us to source it →
48300028	Pawl gear 1 kit 11T	8	40	Ask us to source it →
48300035	Pawl gear 1 kit 11T	8	45	Ask us to source it →
48300042	Pawl gear 1 kit 11T	8	50	Ask us to source it →
48300029	Ratchet gear kit	9	40	Ask us to source it →
48300036	Ratchet gear kit	9	45	Ask us to source it →
48300043	Ratchet gear kit	9	50	Ask us to source it →
19700200	Spares kit (16-66ST)		40 / 45 / 50	Ask us to source it →
19700501	Std small pawls & springs		40 / 45 / 50	View part →
48300005	Main spindle	10	40	Ask us to source it →
48300006	Main spindle	10	45	Ask us to source it →
48300004	Main spindle	10	50	Ask us to source it →
45000344	Gear spindle kit	11	45	Ask us to source it →
45000444	Gear spindle kit	11	50	View part →
45000222	Ratchet gear	12	40	Ask us to source it →
45000333	Ratchet gear	12	45	Ask us to source it →
45000422	Ratchet gear	12	50	View part →
48300030	Pawl gear 2 kit 17T	13	40	Ask us to source it →
48300037	Pawl gear 2 kit 17T	13	45	View part →
48300044	Pawl gear 2 kit 17T	13	50	Ask us to source it →
48300031	Centre stem kit	14	40	Ask us to source it →
48300038	Centre stem kit	14	45	Ask us to source it →
48300045	Centre stem kit	14	50	Ask us to source it →
48300032	Base kit	15	40	Ask us to source it →
48300039	Base kit	15	45	Ask us to source it →
48300046	Base kit	15	50	Ask us to source it →
48300033	Drive shaft kit	16	40	Ask us to source it →
48300040	Drive shaft kit	16	45	Ask us to source it →
48300047	Drive shaft kit	16	50	Ask us to source it →
45500212	Base plate cover	17	40	Ask us to source it →
45500312	Base plate cover	17	45	Ask us to source it →
45500412	Base plate cover	17	50	Ask us to source it →
B6234	Seal	18	40 / 45 / 50	Ask us to source it →

REVO 55 / 65

Part no.	Description	Item	Size
48300080	Top cap & O-ring kit	1	55 / 65	Ask us to source it →
45300103	Feeder arm	2	55	View part →
45300104	Feeder arm	2	65	View part →
48000446	Collet kit	3	55 / 65	Ask us to source it →
48300084	Jaw kit	4	55	Ask us to source it →
48300085	Jaw kit	4	65	Ask us to source it →
45300038	Drum – black alloy	5	55	Ask us to source it →
45300039	Drum – grey alloy	5	55	Ask us to source it →
45300040	Drum – chrome	5	55	Ask us to source it →
45300041	Drum – black alloy	5	65	Ask us to source it →
45300042	Drum – grey alloy	5	65	Ask us to source it →
45300043	Drum – chrome	5	65	Ask us to source it →
48000460	Drum bearing kit	6	55	Ask us to source it →
48000462	Drum bearing kit	6	65	Ask us to source it →
45000523	Gear spindle kit	7	55	Ask us to source it →
45000624	Gear spindle kit	7	65	Ask us to source it →
48300049	Pawl gear 1 kit	8	55	View part →
48300055	Pawl gear 1 kit	8	65	Ask us to source it →
1300/SA2	Roller bearing kit (3)	9	55	View part →
15000017	Roller bearing kit (3)	9 (65), 15	55 / 65	View part →
45000520	Ratchet gear kit	10	55	Ask us to source it →
45000851	Ratchet gear kit	10	65	Ask us to source it →
15000981	Washer	11	55	View part →
15000646	Washer	11	65	View part →
19700200	Spares kit (16-66ST)		55 / 65	Ask us to source it →
19700401	Std large pawls & springs		55 / 65	View part →
48300007	Main spindle	12	55	View part →
48300008	Main spindle	12	65	Ask us to source it →
45000744	Gear spindle kit	13	55 / 65	Ask us to source it →
45000522	Ratchet gear	14	55	Ask us to source it →
45005183	Ratchet gear	14	65	Ask us to source it →
48300050	Pawl gear 2 kit	16	55	View part →
48300056	Pawl gear 2 kit	16	65	Ask us to source it →
48300051	Centre stem kit	17	55	Ask us to source it →
48300057	Centre stem kit	17	65	Ask us to source it →
48300052	Base kit	18	55	Ask us to source it →
48300058	Base kit	18	65	Ask us to source it →
48300053	Drive shaft kit	19	55	Ask us to source it →
48300059	Drive shaft kit	19	65	Ask us to source it →
45500412	Base plate cover	20	55	Ask us to source it →
45500612	Base plate cover	20	65	View part →
B6234	Seal	21	55	Ask us to source it →
B6235	Seal	21	65	View part →
15000019	Roller bearing kit	22	55 / 65	View part →
B2092	Circlip	23	55 / 65	View part →
45000533	Washer	24	65	View part →

Some of these numbers are used by Lewmar for different parts on other winches; where our store item does not match the description it is marked "Ask us".

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