Lewmar Wavegrip Winches How to Service Your Winch (PDF)

SERVICE MANUAL

The classic Lewmar "How to Service Your Lewmar Winch" booklet: service intervals, tools, mounting, Wavegrip self-tailer set-up and step-by-step strip-downs for the older single-, two- and three-speed, self-tailing, halyard and electric winches.

DocumentLewmar Wavegrip Winches How to Service Your Winch

FormatPDF · 28 pages · 1.4 MB

LanguageEnglish

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When to Service Tools & Kits Fitting Wavegrip Servicing Notes Electric Winches Products

Lewmar Wavegrip Winches — How to Service Your Winch

Service Intervals

Monthly: lightly oil and grease all sheet winches.
Two or three times during the season: strip, clean and re-lubricate.
End of season / before the new season: strip completely, clean, check for damage and lubricate, using the full service manual.
The booklet's example: the genoa sheet on a 40 ft cruising yacht can easily reach 1000 lbs.

Cleaning the Drum

Chrome: wash with fresh water, dry with chamois; occasionally a non-abrasive liquid chrome cleaner.
Anodised aluminium: wash with fresh water, dry with chamois. No polishes or abrasives.
Stainless steel: wash with fresh water, dry with chamois; occasionally a non-abrasive liquid cleaner.

Tools & Spares Kits

Model	Tools for routine servicing
All models – basic	Small screwdriver or knife blade, clean non-fluffy cloth, cleaning fluid, lubricants
6, 7, 8, 10, 16, 24, 30, 40, 42, 1H	Basic requirement only
16ST, 30ST, 34ST	Plus soft mallet
40ST, 42ST	Plus 3/16" A/F Allen key
44, 48, 44ST, 48ST	Plus 7/32" or 5/16" A/F Allen key
55, 65, 55ST, 65ST	Plus 3/8" A/F Allen key
From Dec. 1983 – 16, 24, 30, 40, 43, 46, 52, 16ST, 30ST, 40ST, 43ST, 46ST, 52ST	Basic, plus cross-head screwdriver

Kit ref.	For
7001	Single-speed winches
7002	Two-speed and small self-tailing winches up to and including 43ST
7003	Three-speed push-button winches
7004	Self-tailing winches 46ST and above
7008	Various circlips (owners are strongly recommended to carry spares for all winches)
7009	Allen key set
7010	Grease, 100 g tube
7011	Grease, 300 g tub

Kits contain the parts owners tend to damage or lose (pawls, springs, circlips, washers, locking caps). Each kit is complete and the parts are not sold separately. These old kit numbers are no longer current; we list Lewmar winch grease below.

Fitting Your Winch

Remove the drum.
Locate the base for the best possible bolt and output gear support.
Mark the bolt holes, remove the winch and drill.
Bed the underside with compound so every bolt is bedded, keeping the gear spindles clean.
Bolt down, tightening the bolts progressively in a clockwise direction.
Clean off surplus compound, refit the drum and check the winch turns correctly.

Three-speed winches are self-draining: keep the drain holes in the underside of the base clear.

Wavegrip Self-Tailers

Place the rope in the jaws so the turn leading off the drum crosses the stripper and drops into the jaws.
Mount the winch so the tail falls into a safe stowage position; the stripper arm can be turned to feed the sheet off correctly.
Always keep at least 3 turns on the barrel.
Use only ropes in the recommended diameter range for the jaws.
16, 30, 40, 43, 46: remove the 4 top-cap screws and rotate the stripper arm in 8 × 45° increments with the winch bolted down.
48, 52, 55, 65: remove the 4 socket-head top-cap screws, lift both collets, and reposition the arm over the stripper ring in the jaw assembly.

Winch	Rope circumference (mm)	Rope circumference (in)	Rope diameter (mm)
16ST	26/45	1/1¾	8/14
30ST	26/45	1/1¾	8/14
40ST	32/45	1¼/1¾	10/14
43ST	32/51	1¼/2	10/16
46ST	32/51	1¼/2	10/16
52ST	38/57	1½/2¼	12/18
55ST	38/57	1½/2¼	12/18
65ST	45/64	1¾/2½	14/20

Servicing Notes

Every Winch

Remove the circlip with a small screwdriver or knife blade.
Wash centre stem, bearings and drum bore with kerosene (paraffin); dry with a non-fluffy cloth.
Oil the pawls; grease spindles, gears, bearings and other moving parts lightly.
Reassemble in reverse sequence and check for correct operation.

Watch Points

Pawls must seat in the matching ratchet faces when reassembling pawl/ratchet gears.
Two-speed self-tailers: the stripper arm must sit over the stripper ring in the jaw assembly.
43/46 crowns: use anti-seize on the crown screws.
52 and 52ST: put the washers back on the bottom of both gear sets.
Three-speed winches: gear order is mid-large-small; never drop the drum onto the centre stem.

No. 1 halyard winch: tighten the brake firmly before hoisting. Never leave the handle in the winch when the brake is released, and never oil or grease the brake mechanism.

Electric Winch Fault Finding

Symptom	Probable cause	Remedy
Works in one speed only	Motor polarity	Check wiring polarity to the motor; reverse if necessary
Does not work at all	Bad connection	Check all wiring connections, especially to the battery
	Blown fuse or circuit breaker	Check the breaker and the fuse on the encapsulated PC board. Do not alter the sealed trimmer. If the fuse blows again immediately, contact Lewmar
	Micro-switch in control unit not operating	Check the air switch bellow operates the micro-switch; adjust for sensitivity if necessary
	Insufficient power	Check battery charge
	Worn brushes or brush hung up	Check brushes and commutator; release or replace