The Lewmar V1-6 & Sport Windlass is a marine anchoring system designed for the deployment and recovery of anchors on vessels. This manual covers the V1, V2, V3, V4, V5, and V6 models, including Sport versions, and provides comprehensive information on installation, operation, and basic servicing.
Function Description:
The windlass is primarily used for anchor control in marine applications, facilitating the raising and lowering of anchors. It is available in both electric and hydraulic power options. The V1-5 range is designed to handle rope/chain combination rodes, while the V6 range is chain-only. Some models feature a gypsy for rope/chain handling and/or a drum for independent warping. Manual recovery options are available for certain models, allowing for anchor retrieval in case of power failure.
Important Technical Specifications:
The windlass models vary in their dimensions, power options, and rope/chain handling capabilities.
- Deck Thickness:
- V1-3 models: Minimum 25 mm (1"), suitable for deck and packing thickness of 25-60 mm (1"-2¼"). Optional extended versions can accommodate decks up to 140 mm thick.
- V4-5 models: Minimum 40 mm (1½"), suitable for deck and packing thickness of 40-66 mm (1½"-2½").
- V6 models: Minimum 40 mm (1½"), suitable for deck and packing thickness of 40-56 mm (1½"-2¼").
- Rope/Chain Suitability:
- V1-3 models:
- Gypsy No. 006: 6 mm ISO 4565 (D 6mm, P 18mm, W 21.6mm), ¼" ACCO G43 (D 7.3mm, P 21.1mm, W 24mm), ¼" BBB (D 7.1mm, P 22.5mm, W 25.2mm). Suitable for 12-14 mm (½") 3 Strand and 8 Plait rope.
- Gypsy No. 000: 7 mm DIN 766 (D 7mm, P 22mm, W 23.3mm), ¼" ACCO G43 (D 7.3mm, P 21.1mm, W 24mm), ¼" BBB (D 7.1mm, P 22.5mm, W 25.2mm). Suitable for 12-14 mm (½") 3 Strand and 8 Plait rope.
- Gypsy No. 001: 8 mm DIN 766 (D 8mm, P 24mm, W 27.2mm), 8 mm ISO 4565 (D 8mm, P 24mm, W 28.8mm). Suitable for 12-16 mm (½"-⅝") 3 Strand and 8 Plait rope (⅝" only).
- Gypsy No. 002: 10 mm DIN 766 (D 10mm, P 28mm, W 36mm), ⅜" Cambell S4 (D 10mm, P 29mm, W 35mm). Suitable for 12-16 mm (½"-⅝") 3 Strand and 8 Plait rope (⅝" only).
- Gypsy No. 003: 10 mm ISO 4565 (D 10mm, P 30mm, W 36mm), ⅜" Campbell S3 (D 10mm, P 34.5mm, W 34.5mm), Lewmar 9.5mm G30/G40 (D 9.5mm, P 28mm, W 32mm). Suitable for 16 mm (⅝") 3 Strand and 8 Plait rope.
- V4-5 models:
- Gypsy No. 201: 8 mm ISO 4565 (D 8mm, P 24mm, W 28.8mm), 5/16" Campbell S4 (D 9mm, P 32mm, W 30mm), 5/16" G40 (D 8mm, P 24mm, W 28.8mm), 8 mm DIN 766 (D 8mm, P 24mm, W 27.2mm), Lewmar 9.5mm G30/G40 (D 9.5mm, P 28mm, W 32mm). Suitable for 12-14 mm (½") 3 Strand and 8 Plait rope.
- Gypsy No. 202: 5/16" Campbell S3 (D 8mm, P 32mm, W 28mm), ⅜" Campbell S4 (D 10mm, P 29mm, W 35mm), 10 mm DIN 766 (D 10mm, P 28mm, W 36mm), 10 mm ISO 4565 (D 10mm, P 30mm, W 36mm). Suitable for 16 mm (⅝") 3 Strand and 8 Plait rope.
- Gypsy No. 203: Lewmar 9.5mm G30/G40 (D 9.5mm, P 28mm, W 32mm), ⅜" Campbell S3 (D 10mm, P 34.5mm, W 34.5mm). Suitable for 16 mm (⅝") 3 Strand and 8 Plait rope.
- Gypsy No. 204: 12 mm ISO 4565 (D 12mm, P 36mm, W 43.2mm), 13 mm DIN 766 (D 13mm, P 36mm, W 47mm). Suitable for 18-20 mm (¾") 3 Strand and 8 Plait rope.
- V6 models (chain only):
- 10 mm Gypsy Kit: 10 mm ISO 4565 (D 10mm, P 30mm, W 36mm), 10 mm DIN 766 (D 10mm, P 28mm, W 36mm), ⅜" ISO G4 (D 10mm, P 31mm, W 35mm), Lewmar 9.5 mm G30/G40 (D 9.5mm, P 28mm, W 32mm).
- 12 mm Gypsy Kit: 11 mm Short Link (D 11mm, P 33mm, W 39mm), Lewmar 12 mm G30/G40 (D 12mm, P 36mm, W 40.5mm), 7/16" ISO G4 (D 11.8mm, P 35.5mm, W 40.1mm), 13 mm DIN 766 (D 13mm, P 36mm, W 47mm).
- ½" Gypsy Kit: ½" ISO ACCO G4 (D 13.2mm, P 40.4mm, W 45.7mm), Lewmar 12 mm G30/G40 (D 12mm, P 36mm, W 40.5mm).
- 14 mm Gypsy Kit: Lewmar 14 mm G30/G40 (D 14mm, P 42mm, W 49mm), 14 mm DIN 766 (D 14mm, P 41mm, W 50mm).
- Electrical Specifications (Typical Max. Pull, Line Speed, Working Load, Current Draw, Weight, Circuit Breaker):
- V1 (12V): 700W motor, 454kg (1000lb) pull, 19m/min (65ft/min) line speed, 113kg (250lb) working load, 80A current draw, 19kg (42lb) gypsy only, 90A circuit breaker.
- V1 MO (12V): 700W motor, 454kg (1000lb) pull, 19m/min (65ft/min) line speed, 113kg (250lb) working load, 80A current draw, 19kg (42lb) gypsy only, 22kg (48.5lb) gypsy/drum, 90A circuit breaker.
- V2 (12V): 700W motor, 650kg (1433lb) pull, 21m/min (69ft/min) line speed, 163kg (358lb) working load, 80A current draw, 19kg (42lb) gypsy only, 22kg (48.5lb) gypsy/drum, 90A circuit breaker.
- V2 (24V): 900W motor, 760kg (1675lb) pull, 24m/min (79ft/min) line speed, 180kg (396lb) working load, 45A current draw, 19kg (42lb) gypsy only, 24.5kg (54lb) gypsy/drum, 50A circuit breaker.
- V3 (12V): 1000W motor, 890kg (1962lb) pull, 28m/min (92ft/min) line speed, 215kg (473lb) working load, 85A current draw, 21.5kg (47lb) gypsy only, 24.5kg (54lb) gypsy/drum, 110A circuit breaker.
- V3 (24V): 1000W motor, 1020kg (2248lb) pull, 30m/min (98ft/min) line speed, 243kg (535lb) working load, 60A current draw, 21.5kg (47lb) gypsy only, 36kg (79lb) gypsy/drum, 90A circuit breaker.
- V4 (12V): 1600W motor, 1360kg (2998lb) pull, 25m/min (82ft/min) line speed, 136kg (300lb) working load, 125A current draw, 29kg (64lb) gypsy only, 36kg (79lb) gypsy/drum, 150A circuit breaker.
- V4 (24V): 2000W motor, 1600kg (3528lb) pull, 27m/min (90ft/min) line speed, 136kg (300lb) working load, 70A current draw, 29kg (64lb) gypsy only, 38kg (84lb) gypsy/drum, 110A circuit breaker.
- V5 (12V): 2000W motor, 1860kg (4100lb) pull, 27m/min (90ft/min) line speed, 136kg (300lb) working load, 120A current draw, 31kg (68lb) gypsy only, 38kg (84lb) gypsy/drum, 150A circuit breaker.
- V5 (24V): 2000W motor, 2000kg (4410lb) pull, 29m/min (97ft/min) line speed, 136kg (300lb) working load, 60A current draw, 31kg (68lb) gypsy only, 63kg (139lb) gypsy/drum, 110A circuit breaker.
- V6 (24V): 2000W motor, 1800kg (3960lb) pull, 16m/min (52ft/min) line speed, 450kg (990lb) working load, 60A current draw, 60kg (132lb) gypsy only, 150A circuit breaker.
- Hydraulic System: Hydraulic motors have a maximum pressure rating of 180 bar and can be used with an oil supply of up to 57 l/min. Reinforced braid hose conforming to SAE100R2A or DIN 20 021 Part 2 is recommended. Hose sizes vary based on flow rate: ½" (13 mm) bore for up to 30 l/min, ⅝" (16 mm) bore for up to 40 l/min, and ¾" (19 mm) bore for up to 57 l/min. Lewmar hydraulic motor ports are ½" BSP.
Usage Features:
- Installation: Requires careful planning for deck and hull clearance. Templates are provided for drilling holes. Marine sealant should be applied to cut edges to prevent water absorption. Proper greasing of moving parts and correct tightening of nuts are crucial.
- Electrical Wiring: Cable selection is critical, with voltage drop not exceeding 10%. Wiring should be fully insulated, preferably with type III stranded, tinned copper wire. A circuit breaker/fuse is essential for overload protection and should be positioned close to the battery. Control switches can be installed in multi-station configurations, wired in parallel. Wireless remote controls are also available.
- Hydraulic System: Requires a high level of cleanliness during installation to prevent contamination and premature wear. A dual Pilot Operated Check Valve (POCV) must be installed to temporarily sustain loads. A chain stopper is required for permanent load sustainment.
- Operation:
- Braked Anchor Free-fall (V1-6): Allows for quicker anchor deployment and saves battery power. Involves releasing anchor locks and rotating the handle anti-clockwise to pay out the anchor. The rate of fall can be adjusted with the handle. V1-3 and V4-5 models have a fall-safe pawl that needs to be disengaged. V6 and V-Sport models do not have a fall-safe pawl.
- Power Up/Down: For releasing the anchor, ensure the fall-safe pawl (if present) is disengaged and operate the DOWN control. For retrieving, operate the UP control. The fall-safe pawl acts as a ratchet during retrieval on V1-3 models.
- Manual Recovery (V1-3): For gypsy-only or gypsy/drum versions, engage the fall-safe pawl, place a winch handle into the gypsy drive cap/drum top nut, rotate anti-clockwise by half a turn, then place the handle into the bi-square and rotate clockwise. Sport versions do not have manual recovery.
- Independent Warping (V2-6): For gypsy/drum models, lock the anchor chain, engage the fall-safe pawl (V2-3), or check pawl is disengaged (V4-5). Place a winch handle into the top nut, disengage the clutch by turning anti-clockwise by half a turn, then operate the drum. Re-engage the clutch by tightening the drum top nut. Do not wrap chain around the capstan drum.
- Operating Tips: Avoid overloading or stalling the windlass. Secure the rode to an independent strong point (bollard, sampson post, or cleat) and use a chain stopper to prevent the fall-safe pawl from taking the entire force. Move the vessel towards the anchor under power to aid recovery, avoiding contact with the topside. Maintain a chain-to-rope scope of 7:1 at anchor.
Maintenance Features:
- Regular Servicing:
- Wash down the windlass with fresh water.
- Examine electrical connections for corrosion, clean, and lightly grease.
- Check anchor locker drain to prevent water damage to the motor/gearbox. Ensure the motor is dry and rust-free if the locker fills with water.
- Check anchor rode splice for wear.
- Check the gypsy for wear. Apply a small smear of grease to contact surfaces when re-assembling the cone and gypsy.
- Check mounting studs after initial recoveries and regularly thereafter.
- Annual Servicing:
- Check electric cables for damage and repair/renew as needed.
- Strip above-deck components, clean, and lightly grease.
- Check motor/gearbox for corrosion, clean, and repaint with suitable marine-grade oil-based enamel paint.
- Remove the electric motor cover and blow dust from brushes using a foot pump or similar, taking care not to inhale dust.
- Component Replacement/Service:
- Gypsy Replacement/Service (V1-6): Involves removing the chain pipe cover, gypsy drive cap, washer, top cone, and gypsy assembly. Components should be washed with clean water (no jet wash) and reassembled in reverse order with greasing of threads and contact surfaces.
- Control Arm Replacement/Service (V1-5): Requires removing the gypsy, unscrewing the control arm shoulder screw, and removing the control arm and torsion spring. Components should be washed, replaced if necessary, and reassembled.
- Fall-Safe Pawl and Lever Replacement/Service (V1-3): Involves removing the gypsy, turning the fall-safe lever horizontally to remove its shoulder screw, then lifting the fall-safe pawl, spring, lever, and spacer. Components should be replaced and reassembled. The screw from the inner edge of the fall-safe pawl also needs to be removed to lift off the pawl.
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