Lewmar Pro Series Owners Installation, Operation & Basic Servicing Manual

11
P
ro-Series & Pro-Fish Windlass
GB
4. Maintenanc
e
4
.1
G
enera
l
recommen
d
at
i
on
s
• After the fi rst two or three anchor recoveries
,
check the
m
ountin
g
nuts to ensure that the windlass is still fastened
t
ightl
y
to
y
our deck, as it should now be bedded-in.
• Regu
l
ar
l
y was
h
d
own t
h
e exterior of your win
dl
ass wit
h
fres
h
w
a
t
er.
• Examine a
ll
e
l
ectrica
l
connections for possi
bl
e corrosion, c
l
ean
and lightl
y
grease as necessar
y.
• Anchor rode splice should be checked regularl
y
and remade
if there is an
y
evidence of wear
.
• The G
y
ps
y
should be examined on a regular basis, because i
t
is a high wear item. The G
y
ps
y
is designed for short scopes
of c
h
ain an
d
wi
ll
l
ast
l
onger if proper
l
y use
d
.
5. Dismantling procedures
5
.1 Gypsy replacement (Pro-Series
)
Remove t
h
e C
l
utc
h
Nut
(
1
)
, anti-c
l
oc
k
wise using t
h
e c
l
utc
h
operating
l
ever. Wit
hd
raw t
h
e Gypsy Cone
(
2
)
, carefu
ll
y set asi
d
e
t
h
e two Stain
l
ess Stee
l
Drive Pins
(
28
)
. Pu
ll
t
h
e Contro
l
Arm
(
8
)
into t
h
e uprig
h
t position. Remove t
h
e Screws
(
31
)
t
h
at retain
the Stri
pp
er (4) usin
g
a 4 mm (
5
/
32
”
)
Allen Wrench. Remove the
G
y
ps
y
assembl
y
. Remove the stripper from the G
y
ps
y
. To replace
the G
y
ps
y
, reverse the above procedure.
5
.2
G
ypsy rep
l
acement
(
Pro-F
i
s
h)
Remove t
h
e S
h
ou
ld
er Screw
(
45
)
antic
l
oc
k
wise using a 8 mm
(
5
/
1
6
”)
A
ll
en wrenc
h
. Remove t
h
e Was
h
er
(
46
)
from t
h
e centre
of t
h
e Pro-Fis
h
Drive Cap
(
36
)
. Loc
k
t
h
e Pro-Fis
h
P
l
unger
(
38
)
in, using t
h
e Stopper
(
41
)
. Remove t
h
e Pro-Fis
h
Drive
Ca
p
(36) anticlockwise. Remove Socket Head Ca
p
Screws (10)
anticlockwise, usin
g
a 4 mm (
5
/
32
”)
Allen wrench. Remove the
Pro-Fish Stopper Cam (37). Remove the G
y
ps
y
assembl
y
(3)
and Stri
pp
er (4) from the unit. Remove the Stri
pp
er (4) from
the G
y
ps
y
(3).
To replace the G
y
ps
y
, reverse the above procedure. Clean
t
h
rea
d
of S
h
ou
ld
er Screw
(
45
)
an
d
use Loctite® 638
(
66200160
)
(
Loctite® 2701 or 262 may a
l
so
b
e use
d)
on t
h
rea
d
d
uring re-
assem
bl
y. T i g
h
ten
b
o
l
t to 21 Nm
(
15.4
lb/
ft
)
an
d
a
ll
ow at
l
east
15 minutes for t
h
e Loctite® to cure
b
efore use.
5
.3
C
ontro
l
arm rep
l
acemen
t
To remove the Control Arm (8) rotate it to the vertical
p
osition.
Unscrew the Grub Screw (33) usin
g
a 2 mm (
5
/
64
”
)
Allen Wrench
b
y
3 mm (
1
/
8
”
)
. Allow the Control Arm to return to its normal
position. Wit
hd
raw t
h
e Contro
l
Arm Pivot
(
6
)
using a 4 mm
(
5
/
32
”)
A
ll
en wrenc
h
. T
h
e A
ll
en wrenc
h
s
h
ou
ld
b
e use
d
initia
ll
y
to pus
h
t
h
e Contro
l
Arm Pivot in towar
d
s t
h
e center
l
ine of t
h
e
win
dl
ass. On
d
oing t
h
is t
h
e Torsion Spring
(
7
)
wi
ll
ten
d
to turn
t
h
e Contro
l
Arm Pivot an
d
A
ll
en wrenc
h
c
l
oc
k
wise. A
ll
ow it
to travel clockwise as far as it can and, usin
g
some side force
on the wrench
,
withdraw the Pivot. Remove the Control Arm
,
Pivot Pin Washer (34) and Torsion S
p
rin
g
from the maincase.
Reverse this
p
rocedure to re
p
lace the Control Arm. Place the
Torsion Spring in t
h
e
h
o
l
e, ensuring t
h
at t
h
e outer tang is a
l
igne
d
para
ll
e
l
to t
h
e ri
d
ge on t
h
e maincase an
d
t
h
e
d
og
l
eg is para
ll
e
l
to t
h
e
d
ec
k
. P
l
ace t
h
e Pivot Pin Was
h
er in
b
oar
d
of t
h
e fl ange
an
d
offer up t
h
e Contro
l
Arm suc
h
t
h
at it is pointing at t
h
e two
o’clock position. Pick up the Pivot Pin, align the groove on its
head also to the two o’clock
p
osition. Insert it throu
g
h the hole
on the maincase and en
g
a
g
e the s
p
rin
g
with its slot. Holdin
g
the Control Arm in
p
osition, use the Allen wrench to
p
ush the
Pivot Pin in. Then turn it anti-clockwise as far as it will
g
o. Usin
g
si
d
e force again, pu
ll
t
h
e wrenc
h
out unti
l
t
h
e
h
ea
d
of t
h
e Pivot
Pin sits s
l
ig
h
t
l
y prou
d
of t
h
e case. Rotate t
h
e contro
l
arm to t
h
e
vertica
l
an
d
, app
l
ying a spot of Loctite® 2701 t
h
rea
dl
oc
k
, fu
lly
re ti
g
hten the Grub Screw
.
5.4
Gyp
s
y
d
r
i
ve s
h
a
f
t re
pl
acement
&
l
u
b
r
i
cat
i
on serv
i
ce
• N
O
TE: Lu
b
r
i
cat
i
on an
d
i
nterna
l
parts w
ill
not
f
a
ll
out w
h
en t
h
e w
i
n
dl
ass
i
s
di
sassem
bl
e
d
.
T
h
e gear train an
d
its
b
earings
h
ave
b
een
l
u
b
ricate
d
for you wit
h
SFG 100
g
rease an
d
s
h
ou
ld
not re
q
uire re
g
u
l
ar attention. SFG is
a white s
y
nthetic grease containing PTFE. Use grease of a simila
r
s
p
ecifi cation throu
g
hout. It is recommended that the external
Drive Shaft com
p
onents be stri
pp
ed, cleaned and re-
g
reased a
t
least annuall
y
. To do this, the G
y
ps
y
(3) and Stripper (4) should
b
e remove
d
as
d
etai
l
e
d
a
b
ove. To inspect t
h
e Maincase Wipe
r
Sea
l
(
29
)
for signs of wear t
h
e Mains
h
aft must
b
e remove
d
as
d
etai
l
e
d
b
e
l
ow. If t
h
e sea
l
is foun
d
to
b
e unservicea
bl
e, t
h
e
Gypsy Drive S
h
aft
(
30
)
wi
ll
h
ave to
b
e wit
hd
rawn an
d
t
h
e sea
l
re
p
laced. Remove the Gear train Cover (17) usin
g
a 4 mm (
5
/
32
”)
All
e
n Wr
e
n
c
h
.
If there is sealant
p
resent, use a razor blade to cut throu
g
h it.
Withdraw the 1st Compound Gear Assembl
y
(16), taking care
not to
l
ose t
h
e Tefl on™ F
l
at Was
h
ers
(
14
)
. Remove t
h
e 2n
d
Compoun
d
Gear Assem
bl
y
(
22
)
.
• N
O
TE: Rotate t
hi
s gear assem
bl
y as you pu
ll
on
i
t, eventua
ll
y t
hi
s act
i
on w
ill
or
i
entate a
fl
at on its washer and allow the assembly
to pass the Drive Shaft Gear
(
25
)
.
Remove the External Circli
p
(23) and withdraw the Drive Shaf
t
Gear (25). Gentl
y
tap the Drive Roller (27) through the Drive
S
h
a
f
t.
The Drive Shaft can now be withdrawn with or without the G
y
ps
y
Assem
bl
y attac
h
e
d
, provi
d
e
d
t
h
e Stripper is no
l
onger attac
h
e
d
to t
h
e Case. Remove t
h
e Sea
l
an
d
rep
l
ace it wit
h
a new one.
C
l
ean t
h
e strippe
d
d
own components in
k
erosene,
d
ry t
h
em an
d
inspect t
h
em for wear
.
To reassem
bl
e, reverse t
h
e a
b
ove proce
d
ure. Re
b
ui
ld
t
h
e
windlass applying generous amounts of grease.
Isolate the windlass electrically, before carryin
g
out any
ma
int
e
n
a
n
ce
w
o
rk.
DO NOT use a screwdriver or shar
p
ed
g
ed tool to
p
ry the Gear
t
rain Cover o
p
en
.

Lewmar Pro Series Specifications

General

Series	Pro Series
Gear Type	Spur Gear
Voltage	12V
Type	Electric Windlass
Handle Options	Manual Override (varies by model)
Mounting	Horizontal