Lewmar Winch Service Manual Volume II (PDF)

SERVICE MANUAL

Strip, service and re-assemble the 1970s Lewmar winches: single, two and three speed, self-tailing 16ST to 65ST, the No. 80 grinder and the halliard reels. Service intervals, tools, lubricants, exploded views, full parts lists and spare parts kit numbers.

DocumentLewmar Winch Service Manual Volume II

FormatPDF · 62 pages · 7.8 MB

LanguageEnglish

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Models Service Notes Maintenance Spare Kits Products

This manual is split into 7 pages: Part 1 · Part 2 → · Part 3 → · Part 4 → · Part 5 → · Part 6 → · Part 7 →

Winches Covered

Type	Winch	Introduced	Discontinued
Single speed	6 & 7	Late 1975
Single speed	8 & 10	Late 1975
Two speed	16	Spring 1978
Two speed	30	Spring 1978
Two speed	40	Early 1976
Two speed	43	Early 1976
Three speed	44	Late 1974
Three speed	48	Late 1974
Three speed	55	Late 1974
Three speed	65 Mark II	Early 1976
Self-tailing	16	Early 1978
Self-tailing	30	Early 1978
Self-tailing	34 Mark I	Early 1977	Spring 1978
Self-tailing	34 Mark II	Spring 1978
Self-tailing	42	Summer 1978
Self-tailing	44	Spring 1976
Self-tailing	48	Spring 1976
Self-tailing	55	Spring 1976
Self-tailing	65	Spring 1976
Grinder	80	Early 1976
Halliard reel	1 Mark I	Summer 1975	Spring 1978
Halliard reel	1 Mark II	Spring 1978
Halliard reel	2	Early 1976
Halliard reel	2 × 2	Early 1976
Halliard reel	3	Early 1976

Dates as printed in the Volume II contents. The manual covers both 34ST versions (Spring Loaded Jaw and Fixed Top) without saying which is Mark I or Mark II.

Service Intervals and Mounting

Monthly: lightly oil and grease every winch.
Two or three times during the active season: strip, clean and re-lubricate.
End of each season or before the new one: strip completely (remove from the mounting where necessary), clean, check for damage, lubricate and reassemble.
Dismantle and assemble only in the sequence given for each winch.
Mount on a flat, clean surface with the correct size and type of bolts. Take the drum off to mark and drill the bolt holes separately.
Bed the winch on a LIGHT coat of sealing compound: too much gets into the gears and pawls. Tighten the fastenings securely but do not overtighten.
The winch is self draining: keep the drain holes clear.
Handles: current winches take any standard International handle (Lewmar red grip). Winches made before the conversion to International size need a 5/8" square drive handle with a black grip.

Lubricants, Circlips and Tools

Grease: Lewmar Grease (7385) (Lubriplate Marine Lube 'A' etc.). Oil: light machine oil (3 in 1 or equivalent).
Circlip kits (12 circlips): 7060 for current winch Nos. 6, 7, 8, 10, 16, 25, 30, 40, 43, 44, 48, 55, 65, 1H; 7160 for No. 2H. Old style: 1328 (5/8" handle socket) for Nos. 8, 16, 1H, 2H; 7160 (11/16" handle socket) for Nos. 8, 16, 1H. Carry spare circlips for all winches.
Routine servicing: small screwdriver or knife blade, clean non-fluffy cloth, cleaning fluid, lubricants; 3/16" AF Allen key for 42ST, 44ST, 48ST, 55ST and 65ST only.
Full service, extra: nothing for Nos. 6, 7, 8, 10, 16 (new) and 30. Nos. 16 (old), 25, 40, 43, 44, 48: medium screwdriver, flat nosed drift and hammer. Model 55: screwdriver, drift and hammer, 3/8" AF Allen key. Model 65: medium screwdriver, drift and hammer, 3/8" and 7/32" AF Allen keys, 1/2" BSF spanner. Model 1H: 1/8" and 3/16" AF Allen keys. Models 2, 2×2, 3: 1/8" and 5/32" AF Allen keys.

Routine and Annual Service (Single Speed Example)

Remove the circlip with a small screwdriver or knife blade, using a spiral motion to lift it from the groove. Lift off the drum and cover plate.
Clean excess grease and salt from the drum bearing surface and centre stem; check the pawls move freely and the spindle turns freely. If not, go to the full service.
Lightly grease the drum bore and centre stem bearing surface; lightly oil the pawls and centre spindle.
Refit the drum by turning it clockwise to engage the lower pawls, holding the upper pawls out with your fingers; turn the drum and spindle to check engagement.
Refit the top cap and wind the circlip back into its groove; check operation with the handle.
Full annual service: also remove pawls and springs, the spindle retaining key, spindle and washer; wash everything, lightly grease and reassemble.

Model Notes

Two and three speed: the insets show the location of the annular groove on the ratchet gear assembly for correct assembly. For a full service remove the mounting bolts, support the centre stem on a firm bench and tap the bearing spindle DOWNWARDS with a flat-ended drift.
No. 48: the winch comes off the deck by removing the 6 × 5/16" UNC c'sk screws. Drive the spindles out about 1mm and check the knurled end is projecting first: the knurled end MUST NOT pass through the gears.
Three speed top cap: with the top cap inverted and the push button depressed the pawls are normally open; rotating the closing ring closes them and locks the button up. If rotation is sluggish or the pawls do not open fully, strip and clean the top cap.
16ST, 30ST, 34ST Fixed Top: loosen the top cap anti-clockwise with a firm tap from a soft mallet or wooden block, and tighten it the same way. Note the colour and position of the washers when stripping.
42ST: release the four Allen screws and remove the top cap, then the split collets and flanged bush.
Halliard reels: release the grub screws to remove the halliard wire. Clean the ratchet ring outer surface and brake strap inner surface with a light abrasive and keep them free of grease; the inset shows the correct ratchet ring orientation. On 2×2 and 3, mark each idler gear and the drum teeth before removing the planet wheel assembly so they re-mesh the same way.

Spare Parts Kits

Winch	Kit part no.	Contents
No. 6 (single speed)	19706400	1 × Key 15006005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B2075
No. 7 (single speed)	19707400	1 × Key 15010005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B2075
No. 8 (single speed)	19708400	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B.2075
No. 10 (single speed)	19707400 (as printed, same number as the Model 7 kit)	1 × Key 15010005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B.2075
No. 16 (two speed)	19716100	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip 82075 (as printed), 1 × Washer 15008004
No. 30 (two speed)	19730100	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B2075, 1 × Washer 15030007
No. 40 (two speed)	19740400	1 × Circlip B2075, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Washer 1260/9, 2 × Pawl 15001012, 1 × Tab washer 1260/19
No. 43 (two speed)	19743400	4 × Spring 1260/7, 2 × Pawl 15001012, 2 × Pawl 1264/8, 1 × Tab washer 1260/19, 1 × Circlip B2075, 1 × Washer 1264/7, 2 × Pawl 1260/8
No. 44 (three speed)	19744400	2 × Washer 15025106, 1 × Pin 15044119, 2 × Plunger 1300/24, 2 × Spring 1300/20, 8 × Pawl 1260/8, 8 × Spring 1260/7, 2 × Washer 15025107, 1 × Plunger 15044111, 1 × Spring 15044112, 1 × Circlip B2083, 1 × Circlip B2075, 2 × Spring 15044113
Model 48 (three speed)	19748400	4 × Pawl 1260/8, 8 × Spring 1260/7, 4 × Pawl 1264/8, 2 × Washer 1300/22, 2 × Washer 1264/7, 2 × Plunger 1300/24, 2 × Spring 1300/20, 1 × Plunger 15044111, 1 × Spring 15044112, 1 × Washer 15025107, 1 × Circlip B2083, 1 × Circlip B2075, 1 × Pin 15044119, 2 × Spring 15044113
No. 55 (three speed)	19755400	1 × Pin 15044119, 1 × Washer 1301/19, 1 × Washer 1301/11, 1 × Washer 1300/22, 1 × Washer 15055119, 1 × Washer 15025107, 2 × Plunger 1300/24, 2 × Spring 1300/20, 1 × Plunger 15044111, 1 × Spring 15044112, 4 × Pawl 1264/8, 4 × Pawl 1260/8, 8 × Spring 1260/7, 1 × Circlip B2075, 1 × Circlip B2083, 2 × Spring 15044113
No. 65 Mark II (three speed)	19765400	3 × Washer 1301/19, 1 × Washer 1301/11, 1 × Washer 15025107, 4 × Pawl 1260/8, 4 × Pawl 1264/8, 8 × Spring 1260/7, 2 × Plunger 1300/24, 2 × Spring 1300/20, 1 × Plunger 15044111, 1 × Spring 15044112, 1 × Pin 15044119, 1 × Circlip B2077, 1 × Circlip B2075, 1 × Circlip B2083, 2 × Spring 15044113
No. 16ST (self-tailing)	19716600	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Washer 15008004, 1 × Washer 15016010
No. 30ST (self-tailing)	19730600	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Washer 15030007, 1 × Washer 15030607
No. 34ST (Spring Loaded Jaw)	19740700	2 × Pawl 1260/8, 5 × Pawl Springs 1260/7, 3 × Pawl 1264/8, 1 × Washer 1260/9, 1 × Key 15040605, 1 × Washer B2454
No. 34ST (Fixed Top)	19734600	1 × Key 1501005 (as printed), 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Washer 15034637, 1 × Washer 15034638
No. 42ST (self-tailing)	19742100	1 × Key 15010005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Washer 15042010, 1 × Circlip B2075
No. 44ST (self-tailing)	19744600	1 × Washer 15044116, 2 × Washer 15025106, 1 × Washer 1300/21, 2 × Spacer 15025107, 2 × Key 15040605, 6 × Pawl Spring 1260/7, 6 × Pawl 1260/8
No. 48ST (self-tailing)	19748600	1 × Washer 15044116, 2 × Washer 1264/7, 1 × Washer 1300/21, 2 × Washer 1300/22, 2 × Key 15040605, 6 × Pawl Spring 1260/7, 2 × Pawl 1260/8, 4 × Pawl 1264/8
No. 55ST (self-tailing)	19755600	1 × Washer 15044116, 1 × Washer 15055119, 1 × Washer 1300/21, 1 × Washer 1300/22, 1 × Washer 1301/11, 1 × Washer 1301/19, 1 × Spacer 15025107, 2 × Key 15040605, 1 × Circlip B2077, 1 × Circlip B2079, 6 × Pawl Spring 1260/7, 2 × Pawl 1260/8, 4 × Pawl 1264/8
No. 65ST (self-tailing)	19765600	1 × Washer 15080014, 1 × Washer 1300/21, 2 × Washer 1301/19, 1 × Washer B2451, 1 × Spacer 15025107, 2 × Key 15040605, 6 × Pawl Spring 1260/7, 2 × Pawl 1260/8, 4 × Pawl 1264/8
No. 80 (three speed automatic grinder)	19765400 (as printed, same number as the 65 Mark II kit)	3 × Washer 1301/19, 1 × Washer 1301/11, 1 × Washer 15025107, 4 × Pawl 1260/8, 4 × Pawl 1264/8, 8 × Spring 1260/7, 2 × Plunger 15137203, 2 × Spring 15137204, 1 × Plunger 15044111, 1 × Spring 15044112, 1 × Pin 15044119, 1 × Circlip B2077, 1 × Circlip B2075, 1 × Circlip B2083, 2 × Spring 15044113
Halliard Reel No. 1 Mk I	19701400	2 × Pawl 15001012, 1 × Tab Washer 1266/6, 4 × Spring 1260/7, 4 × Pawl 1260/8, 2 × Grub Screw B0901, 1 × Circlip B2076, 1 × Circlip B2080, 1 × 1/4" 20 UNC Socket Head × 1/2" long B0776
Halliard Reel No. 1 Mk II	no number printed	1 × Key 15008005, 4 × Spring 1260/7, 4 × Pawl 1260/8, 1 × Circlip B2075, 2 × Grub Screw B0901
Halliard Reel No. 2	19702400	1 × Tab Washer 1266/6, 4 × Spring 1260/7, 4 × Pawl 1260/8, 2 × Grub Screw B0901, 1 × Circlip B2076, 1 × Circlip B2080
Halliard Reel No. 2 × 2	19703400	4 × Spring 1260/7, 4 × Pawl 1264/8, 2 × Grub Screw B0904, 2 × Grub Screw B0901
Halliard Reel No. 3	19703400 (as printed, same number as the No. 2 × 2 kit)	4 × Spring 1260/7, 4 × Pawl 1264/8, 2 × Grub Screw B0904, 2 × Grub Screw B0901