Lewmar V1-V6 Vertical Windlass Owner's Manual (PDF)

OWNER'S MANUAL

Performance, gypsy selection, deck and below-deck preparation, cable and breaker sizing, wiring, operation, servicing and the full kit lists for the Lewmar V1, V2, V3, V4, V5 and V6 vertical windlasses.

DocumentLewmar V1-V6 Vertical Windlass Owner's Manual

FormatPDF · 40 pages · 7.3 MB

LanguageEnglish

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Specifications Gypsy Sizing Installation Dimensions Electrical Hydraulic Operation Maintenance Parts Products

Lewmar V1-V6 Vertical Windlass — Owner's Manual

Electric Specifications

Model	V	Motor W	Typical max. pull	Max. line speed	Typical working load	Normal current draw (A)	Weight gypsy only	Weight gypsy/drum	Breaker
V1	12	700	750 kg 1653 lb	28 m/min 92 ft/min	188 kg 414 lb	112	19 kg / 42 lb	–	90 A
V1 MO	12	700	750 kg 1653 lb	28 m/min 92 ft/min	188 kg 414 lb	112	19 kg / 42 lb	–	90 A
V2	12	700	850 kg 1874 lb	29 m/min 95 ft/min	213 kg 470 lb	121	19 kg / 42 lb	22 kg / 48.5 lb	90 A
V2	24	900	850 kg 1874 lb	29 m/min 95 ft/min	213 kg 470 lb	60	19 kg / 42 lb	24.5 kg / 54 lb	50 A
V3	12	1000	1025 kg 2260 lb	39 m/min 128 ft/min	257 kg 567 lb	131	21.5 kg / 47 lb	24.5 kg / 54 lb	110 A
V3	24	1000	1025 kg 2260 lb	39 m/min 128 ft/min	257 kg 567 lb	74	21.5 kg / 47 lb	36 kg / 79 lb	90 A
V4	12	1600	1250 kg 2750 lb	25 m/min 82 ft/min	313 kg 688 lb	125	29 kg / 64 lb	36 kg / 79 lb	150 A
V4	24	2000	1500 kg 3306 lb	27 m/min 90 ft/min	375 kg 825 lb	70	29 kg / 64 lb	38 kg / 84 lb	110 A
V5	12	2000	1450 kg 3190 lb	27 m/min 90 ft/min	363 kg 798 lb	120	31 kg / 68 lb	38 kg / 84 lb	150 A
V5	24	2000	1600 kg 3520 lb	29 m/min 97 ft/min	400 kg 880 lb	60	31 kg / 68 lb	63 kg / 139 lb	110 A
V6	24	2000	1800 kg 3960 lb	16 m/min 52 ft/min	450 kg 990 lb	60	60 kg / 132 lb	–	150 A

The V1–5 gypsies are designed for Lewmar rope/chain rodes (rope spliced to a chain tail); the V6 is chain only. Rope must be windlass-grade, medium-lay nylon.

Gypsy Sizing

Part no.	Gypsy, chain and rope
68000840	V1/2/3 gypsy & stripper kit 006: 6mm ISO 4565, 1/4" G40*, 1/4" BBB; rope 12–14 mm (1/2") 3-strand and 8-plait	View part →
68000360	V1/2/3 gypsy & stripper kit 000: 7mm ISO 4565, 1/4" G40*, 1/4" BBB; rope 12–14 mm (1/2") 3-strand and 8-plait	View part →
68000361	V1/2/3 gypsy & stripper kit 001: 8mm DIN 766, 8mm ISO 4565; rope 12–16 mm (1/2–5/8") 3-strand, 8-plait 5/8 only	View part →
68000362	V1/2/3 gypsy & stripper kit 002: 10mm DIN 766, Campbell 3/8" S4, 5/16" G40; rope 12–16 mm (1/2–5/8") 3-strand, 8-plait 5/8 only	View part →
68000363	V1/2/3 gypsy & stripper kit 003: 10mm ISO, Campbell 3/8" S3, Lewmar 9.5mm G40; rope 16 mm (5/8") 3-strand and 8-plait	View part →
68000356	V4/5 gypsy 201: 8mm DIN 766, 8mm ISO 4565, 5/16" G40, 5/16" Campbell S4; rope 12–14 mm (1/2") 3-strand medium lay	View part →
68000357	V4/5 gypsy 202: 10mm DIN 766, 5/16" Campbell S3, 3/8" Campbell S4, 9.5mm G30; rope 16 mm (5/8") 3-strand medium lay	View part →
68000358	V4/5 gypsy 203: 10mm ISO 4565, 3/8" Campbell S3, Lewmar 9.5mm G40; rope 16 mm (5/8") 3-strand medium lay	View part →
68000359	V4/5 gypsy 204: 12mm ISO 4565, 13mm DIN 766; rope 18–20 mm (3/4") 3-strand medium lay	View part →
68000903	V6 gypsy (chain only): 10mm DIN 766, 3/8" ISO G4, Lewmar 9.5mm G40	View part →
68000904	V6 gypsy (chain only): 11mm Short Link, Lewmar 12mm G30/G40, 13mm DIN 766, 7/16" G40; remote chain pipe version recommended	View part →
68000905	V6 gypsy (chain only): Lewmar 14mm G30/G40, 14mm DIN 766	View part →
68000906	V6 gypsy (chain only): 1/2" ISO G4, Lewmar 12mm G30/G40, Lewmar 1/2" G30/G40	View part →

* as printed in the gypsy table. Chain from other makers can vary: check pitch (P), wire diameter (D) and width (W) against the chart below.

Deck & Tools

V1–3: 10 mm (3/8") and 14 mm (9/16") drills, 75 mm (3") hole saw. Minimum deck 25 mm (1"); M8 studs suit deck plus packing of 25–50 mm (1"–1 31/32"); optional extended version for decks up to 127 mm.
V4–5: 12 mm (7/16") drill, 77 & 90 mm (3" & 4 1/2") hole saw. Minimum deck 40 mm (1 1/2"); M10 studs suit 40–66 mm (1 1/2"–2 1/2").
V6: 5 mm (3/16") and 12 mm (7/16") drills, 115 mm (4 1/2") hole saw. Minimum deck 40 mm (1 1/2"); M10 studs suit 40–56 mm (1 1/2"–2 1/4").
Thin, foam or balsa-cored decks need reinforcement. V1–3 and V6 may need a pad for camber or sheer; on V4–5 a pad must keep the base parallel to the motor/gearbox flange (shim before fitting the motor).
Lead from the bow roller must arrive horizontally at the top of the gypsy, on its centre line within ±5°, with enough vertical fall below (300 mm / 12" shown). Too little fall causes jamming.
V1–3 motor/gearbox rotates 360 degrees on the Fast Fit clamp; V4–5 bolts via the through-deck bolts; V6 bolts to the base via a down tube. Keep it out of the chain fall.

Fitting Sequence

Holes: V1–3 five 10 mm (3/8") holes for studs and sensor and two 75 mm (3") holes; V4–6 five 12 mm (7/16") holes and two 115 mm (4 1/2") holes (as printed). Seal the cut edges.
Screw the studs into the base until they bottom out, flats nearest the windlass base.
V1–5: lay the base mat; V6 has no base mat, use sealant. No permanent adhesive such as 5200. Let rubbery sealants cure before final tightening.
Grease the shaft lightly and check the drive key before offering up the gearbox.
V1–3 Fast Fit: bronze nut to 15 Nm (11 lb/ft), then the Nyloc nut behind it.
V4–5: check surfaces are parallel; M8 nut with Loctite® threadlock to 43 Nm, then the M8 Nyloc.
V6: deck backing plate, M10 nut with threadlock to 43 Nm, M10 Nyloc; motor/gearbox M10 bolts with threadlock to 43 Nm.
Loading the rode: remove cover, pull out control arm, feed rope/chain into the entry hole and tie off, refit cover, release arm, wrap the gypsy and power-load the rest. V6 has no control arm.

The deck template guide is a guide only, not a cutting template: check every dimension before drilling. Print the PDF at 100% if you work from it.

Dimensions

Dimension D for V1–3 reads 348 mm in the installation section and 394 mm in the specifications section (as printed).

Electrical

Model	Current at working load (A)	Breaker supplied (A)	CSA mm² (ISO 10133, 20 m)	AWG (ABYC E11, 66 ft)
V1	126	90	25	2
V2 12V	120	90	25	2
V2 24V	60	50	10	8
V3 12V	131	110	25	2
V3 24V	70	90	16	8
V4 12V	125	150	25	2
V4 24V	70	110	10	8
V5 12V	120	150	25	2
V5 24V	60	110	10	8
V6	90	150	16	6

Length is battery + to the windlass and back to battery –, including breaker and switch gear. Do not confuse it with boat length.
Voltage drop over the whole run must not exceed 10%. Use cable insulation rated 90°C or higher; tinned type III stranded copper with crimp terminals.
Breaker close to the battery, dry and accessible. Never bypass it; it must be reset by hand after a trip.
Motor terminals: hold the back nut with a second wrench and tighten the M8 front nut to 15–18 Nm. A turning back nut damages the motor and voids the warranty.
Motor connections D1 = F1, D2 = F2. Switch wire 1.5 mm² (16 AWG); control circuit fuse 3 A.

Part no.	Accessory
68000967	Wireless remote, 3 button, windlass only	View part →
68000968	Wireless remote, 5 button, windlass and thruster	View part →

The wireless remote works only with a contactor fitted.

Model	Circuit breaker	Contactor	Control box
V1/Sport	90 A (68000349)	68000318	68000129
V2/Sport	90 A (68000349)	68000318	68000129
V2/Sport	50 A (68000348)	68000319	68000130
V3/Sport	110 A (68000350)	68000318	68000129
V3/Sport	90 A (68000349)	68000319	68000130
V4	150 A (68000351)	68000320	18000200
V4	110 A (68000350)	68000321	18000237
V5	150 A (68000359) (as printed)	68000318	68000128
V5	110 A (68000350)	68000318	68000130
V6	150 A (68000351)	68000321	18000237

Hydraulic Drive

Hydraulic system installation is not covered by the manual. The windlass connects to a powerpack with a directional control valve.
Motor/gearbox: high-torque hydraulic motor on a 7:1, 90 degree gearbox; maximum 180 bar, oil supply up to 57 l/min. A & B ports ½" BSP, no drain.
The gearbox is not self-sustaining: fit a dual pilot-operated check valve (POCV), line mounted or modular. Hold a load permanently on a chain stopper.
Hose: reinforced braid to SAE100R2A or DIN 20 021 Part 2. Up to 30 l/min 1/2" (13 mm) bore; up to 40 l/min 5/8" (16 mm); up to 57 l/min 3/4" (19 mm).
Minimum hose bend radius 6" (150 mm). Keep the system clean: dirt causes dangerous malfunction and wear.

Operation

Free-Fall & Power

Fall-safe: V1–3 pawl vertical and held clear by its lever; V4–5 pawl disengaged; V6 and V-Sport have no fall-safe.
Braked free-fall: isolate at the breaker, release anchor locks, turn the gypsy cap anticlockwise with a winch handle and control the fall with it; tighten the cap fully afterwards. Gypsy/drum: handle in the drum top nut.
Power down/up: top nut tight for retrieval (V6: 250 Nm for maximum load). On V1–3 the fall-safe acts as a ratchet on the way up and stays engaged once stowed; disengage it before letting go again.
Always remove the winch handle after use.

Recovery, Warping & Anchoring

V1–3 manual recovery (gypsy only, optional kit 66840054; gypsy/drum kit 66840056): engage the fall-safe, handle in the cap, half a turn anticlockwise, then handle in the bi-square and wind clockwise. Sport versions have no manual recovery.
Independent warping (V2–6 gypsy/drum): lock the chain, half a turn anticlockwise on the top nut to free the clutch, then run the drum. Retighten after. Never wrap chain on the drum.
Lay the rode under power as the boat falls back; motor up toward the anchor when recovering, never over and past it.
Scope guide: 7 to 1 at anchor (as printed). Don't stall or overload the windlass.
At anchor the load goes on a chain stopper or strong point, never on the fall-safe pawl or the windlass.

Servicing Schedule

Regularly: fresh-water wash; clean and lightly grease electrical connections; keep the locker drain clear; check the motor is dry if the locker floods; check the rope splice and the gypsy (high-wear item); check mounting studs after the first two or three recoveries.
Annually: check cables; strip, clean and lightly grease the above-deck parts; clean and repaint the motor/gearbox with marine oil-based enamel; blow dust from the brushes without breathing it.
Gypsy service: chain pipe cover screws out with a 5 mm Allen key, gypsy cap off anticlockwise with a winch handle, washer and top cone off, control arm back, gypsy out. Wash with fresh water, never jet wash; grease the threads and a smear on the cone/gypsy faces on reassembly.
Control arm (V1–5): 4 mm Allen key on the shoulder screw. Fall-safe (V1–3): lever horizontal, remove the shoulder screw, then the pawl screw.

Troubleshooting

Rode pays out by itself: gypsy cap slack and rode not secured. Tighten the cap and always secure the rode independently.
Sluggish or no operation: usually electrical. Keep 13.5 V on 12 V systems (26.5 V on 24 V); constant low voltage damages the motor. Check cable size, switches, connections, battery, isolator, fuse and motor.
Hydraulic leak: excess pressure, dirt on a seal, loose fittings or damaged parts. Never work on the system under pressure.
Hydraulic, slow or weak: check flow, port connections (swap if reversed), switch function, kinked pipes and system pressure against the Commander manual.

Kit Lists

V1

Kit no.	Description	Items
66000060	Cap kit	22	View part →
66000624	V1/2/3 base	3, 10, 34	View part →
66000625	Chain pipe cover	11, 35	View part →
66000626	Fastener kit	1, 2, 4, 5, 8, 17, 28, 33, 34	View part →
66000627	Drive kit	1, 2, 3, 4, 5, 14, 15, 17, 35	View part →
66000628	Manual recovery pawl kit (fall safe)	11, 17, 18, 27, 28, 32	View part →
66000629	Motor gearbox	30	Ask us to source it →
66000631	Mounting kit (metric)	9, 16, 20, 26, 27	View part →
66000632	Fast Fit assembly	36, 37	View part →
66000633	Deck spacer kit	13, 32	View part →
66200076	Sensor & magnet kit	21, magnet	View part →
66810030	Control arm kit	7, 8, 23	View part →
66810065	Motor gearbox kit	17, 30, 36, 37	View part →
66840054	Manual recovery kit	4, 24, 25	Ask us to source it →

V1 Exploded View

Lewmar V1 windlass exploded view

V2 & V3

Kit no.	Description	Items
66000060	Cap kit	22, 5	View part →
66000624	V1/V2/V3 base	3, 10, 35	View part →
66000625	Chain pipe cover	11, 34	View part →
66000626	Fastener kit	1, 2, 4, 5, 6, 8, 17, 28, 33, 34	View part →
66000641	Drive kit V2/V3, gypsy only	1, 2, 3, 4, 5, 14, 15, 17, 35	View part →
66000628	Manual recovery pawl kit (fall safe)	12, 18, 19, 28, 29, 33	View part →
66000640	Drum kit V2/V3 Fast Fit	38, 39, 40	View part →
66000065	Drum top nut	39, 40	View part →
66000642	Drive kit V2/V3, gypsy/drum	1, 2, 3, 4, 5, 14, 15, 17, 35	View part →
66000631	Mounting kit (metric)	9, 16, 20, 26, 27	View part →
66000632	Fast Fit assembly	36, 37	View part →
66000633	Deck spacer kit	13, 32	View part →
66200076	Sensor & magnet kit	21, magnet	View part →
66810030	Control arm kit	7, 8, 23	View part →
66840054	Manual recovery kit (gypsy only)	4, 24, 25	Ask us to source it →
68000813	12V V2 Fast-Fit motor gearbox assembly	30, 36, 37	View part →
68000814	24V V2 Fast-Fit motor gearbox assembly	30, 36, 37	View part →
68000815	12V V3 Fast-Fit motor gearbox assembly	30, 36, 37	View part →
68000816	24V V3 Fast-Fit motor gearbox assembly	30, 36, 37	View part →
68000817	12V V2 M/O Ride motor gearbox assembly	30, 36, 37	Ask us to source it →
68000818	24V V2 M/O Ride motor gearbox assembly	30, 36, 37	Ask us to source it →
68000819	12V V3 M/O Ride motor gearbox assembly	30, 36, 37	Ask us to source it →
68000820	24V V3 M/O Ride motor gearbox assembly	30, 36, 37	Ask us to source it →
66840056	V2/V3 gypsy/drum manual recovery kit	not shown	View part →

V2 & V3 Exploded View

Lewmar V2 and V3 windlass exploded view

V4 & V5

Kit no.	Description	Items
66000065	Drum top nut	24, 25	View part →
66000070	Fastener/drive	2, 3A, 3B, 6, 7, 18, 19, 21, 24, 28, 29, 32, 33, 37, 38, 40, 43, 44, 45; hex keys 2, 4, 5 & 6 mm	View part →
66000071	Mainshaft assembly, gypsy/drum	4A, 13	View part →
66000072	Mainshaft assembly, gypsy only	4B, 13	View part →
66000073	Bearing/seal	5, 8, 12, 12A	View part →
66000075	Stripper/pawl	15, 16, 26, 28, 29, 37, 38, 39; hex keys 2, 4, 5 & 6 mm	View part →
66000076	Base	5, 9	View part →
66000077	Chain pipe cover	17, 18, 19; hex key 5 mm	View part →
66000079	Spacer	3B, 30, 31, 32, 33	View part →
66810031	Control arm kit	34, 35, 36; hex keys 4, 5 & 6 mm	View part →
66200076	Optional sensor & magnet	sensor, magnet & housing	View part →

V4 & V5 Exploded View

Lewmar V4 and V5 windlass exploded view

V6

Kit no.	Description	Items
66000692	Blank cover with stripper	31, 12	View part →
66000688	Top cap (gypsy only)	29, 25	View part →
66000687	Top nut (gypsy/drum)	27, 28	Ask us to source it →
66000686	Cone (gypsy only)	24, 25, 26	Ask us to source it →
66000685	Cone (gypsy drum)	24, 25	View part →
66000684	Drum	23	View part →
66000683	14 mm gypsy	22	Ask us to source it →
66000682	1/2" gypsy	21	Ask us to source it →
66000681	12 mm gypsy	20	Ask us to source it →
66000680	10 mm gypsy	19	Ask us to source it →
66000679	Mainshaft (gypsy only)	18, 15, 16, 17	View part →
66000678	Mainshaft (gypsy/drum)	14, 15, 16, 17	View part →
66000677	R/H chain cover	13, 12	View part →
66000676	L/H chain cover	11, 12	Ask us to source it →
66000675	Mounting	7, 8, 9, 10	Ask us to source it →
66000674	Base	1, 2, 3, 4, 5, 6	View part →