Lewmar 8000 User manual

8000 Gypsy/Drum Windlass
Installation Manual
Issue B

PART 1 - HYDRAULIC ANCHOR WINDLASS
INSTALLATION
VERTICAL HYDRAULIC MODELS
Windlass 1 Remove the anchor windlass from the packing case.
Installation Ensure that you have the necessary parts required to
complete your system.
There are three items to position, the windlass, chain
pipe (optional) and controls. Remember to allow space
below deck for the motor - gearbox and for the
connection of the hydraulic lines from the windlass to the
power unit.
2 Position the windlass deck unit on the deck or in the
anchor well (see drawings for cut out dimensions)
such that the centre - line of the chain on the gypsy
aligns with the bow roller in a horizontal plane, and that
the vertical line is within 10 degrees of the chain gypsy.
Ensure that the chain achieves maximum contact around
the chain gypsy (i.e. at least 120 and preferably 180
degrees contact).
3 Cut and drill clearance holes in the deck for the windlass
and chain pipe, to the size detailed on the installation
template.
4 Apply bedding compound onto the joint faces and mount
the windlass and chain pipe with the gypsy facing pawl
facing aft and the chain stripper facing forward.

Hydraulic 5 The Lewmar 8000 hydraulic windlass is designed
Installation to be used with Lewmar Commander power packs or
similar power packs that give the required flow and
pressure. Plan the routing of the hydraulic lines
(including case drain lines) and run them from the
hydraulic supply to the windlass motor (see hose type
recommendations).
6 Connect the hydraulic feed and return lines to the
hydraulic windlass motor, ensuring that the connections
are secure (see motor specifications).
7 Connect the case drain line (see case drain line
specifications).
8 Find a suitable position for electric safety deck
switch(es), remote control and / or toggle switch in view
of the windlass, anchor line and bow roller. Connect up
the switch wiring to the Commander system (see
Commander manual) or a suitable proprietary system
ensuring that the minimum supply is 3 amps. The
switches require a 12V or 24V DC system depending on
available supply.
9 Check correct operation of the windlass (eg up / down).
If the rotation is incorrect swap the A + B hoses at the
motor, or swap the switch wiring, or swap the Directional
Control Valve (DCV) caps.

ANCHOR WINDLASS HYDRAULIC
SPECIFICATIONS
CUSTOM 8000
VERTICAL HYDRAULIC MODELS
Hydraulic The hydraulic motor is a fully reversible, high efficiency
Motors motor gearbox.
Model Motor Flow Min / Max Pressure
(Ltr / min) Max (Bar)
8000 500 cc/Rev 30 - 70 115
(1667 psi)
Note: (a) 3.78 litres
≈ 1 US Gallon
4.54 litres ≈ 1 Imperial Gallon
(b) 14.5 psi = 1 Bar
Anchor Model Max Pull Max Line Working
Windlass Speed Load
Specifications
8000 3750 kg 6-15 m 726 kg
8267 lb (20-49 ft) / min 1600 lb
Model Line Speed @ Weight
Working load
8000 Dependant on 260 kg / 572 lb
Power Pack

Hose For reliable operation and safety reasons, it is essential
Types to use the correct bore size of hose. To reduce pressure
drops in hose runs greater than 5 - 7 m it is
recommended a larger hose size is used.
The recommended hose bore sizes with their flow
requirements are given below.
Model Motor Flow Min
(Ltr / min) Bore Size
8000 500 cc/Rev Up to 40 3/4"
Up to 70 1”
Note: (a) 3.78 litres
≈ 1 US Gallon
4.54 litres ≈ 1 Imperial Gallon
(b) It is important that the correct hose
specification is used as this affects the
efficiency of the hydraulic motor and the
performance of the windlass.

IMPORTANT
Drain To obtain optimum shaft life a case drain line must be
Line fitted.
Min drain line bore diameter: 6mm (1/4")
Safe working pressure: 18 Bar (250 psi)
All drain lines should if possible be connected to the
reservoir separately.
Hydraulic The Lewmar Anchor Windlass hydraulic motors accept
Fittings the following fittings:
Motor ports - 3/4" BSP Female
Case Drain - 1/4" BSP Female
Hydraulic The connection of the service lines should be plumbed in
Connections as follows: -
A Case Drain Line Must Be Fitted.

PART 2 - OPERATION, MAINTENANCE.
CUSTOM 8000
OPERATION OF VERTICAL HYDRAULIC MODELS
Operation The main shaft, driven by the motor / gearbox, is splined
Explained directly to the capstan. There is a fail-safe integral
brake fitted to the capstan. The brake is released when
hydraulic power is applied to the capstan. The gypsy can
either be powered by the capstan or free running. The
gypsy is powered by engaging the dog drive teeth of
the capstan to those of the gypsy. Engagement and
disengagement of the dog drive is controlled by turning
the top nut, which lifts and lowers the capstan. Spring
loading between the capstan and gypsy facilitates
engagement / disengagement.
The free running gypsy is controlled by tightening or
loosening the full wrap brake band.
Power Up Press the deck switch, remote control or toggle switch
(Anchor Up).
NOTE: Ensure that the brake band is released and that
the dog drive is fully engaged.
Power Down Press the deck switch, remote control or toggle switch
(Anchor Down).
NOTE: Ensure that the brake band is released and that
the dog drive is fully engaged.
Manual Chain Place a Lewmar winch handle in the brake band bi –
Release square and secure the chain gypsy. Place the Lewmar
winch handle into the top nut and raise the capstan until
the dog drive is fully disengaged.
Replace the handle in the brake band bi - square and
carefully release the brake to allow the gypsy to run free.
The descent of the chain can be controlled and stopped
by tightening the band.

Capstan Gypsy / Capstan model - To use the capstan (with rope
Operation only) lock the gypsy off with the brake band to stop the
chain from free running. Place a Lewmar winch
handle into the top nut and raise the capstan until the
dog drive is fully disengaged.
Press the Up button to power the Capstan.
Dog Drive Place a Lewmar winch handle into the top nut and lower
Engagement the capstan down onto the gypsy until resistance is felt,
then backwind one quarter of a turn.
Press the Up / Down switch and the dog drive will spring
down into positive engagement. Tighten down the top nut
securely if required.
Once the dog drive has been fully engaged, stop power
operation and release the brake band before powered
operation is continued.
Warning !
Ensure that the dog drive is fully engaged
when powering in or out.
Keep hands and feet clear of free running chain.
Do not leave a winch handle in the windlass while
operating.
Classification society rules require that a vessel lying at
anchor should have its chain held by a cable / chain
stopper or equivalent strong point as a windlass should
not be subjected to the loads generated under storm
conditions.
We recommend that the vessels engine should always be
used to aid anchor recovery.
Do not attempt to pull a load greater then the rated load of
the windlass.
When the windlass is not in use the anchor must be tied off
onto a cleat or equivalent strong point to prevent damage to
the vessel.

Maintenance The windlass is housed in the harshest environment on
the vessel. The windlass should be checked and cleaned
every six months. Wash away salt deposits using fresh
water, clean and grease the main shaft, spline and
bearings (using marine grade grease).
Remove the brake band assembly, clean brake band and
gypsy (Do not allow grease onto the brake band
surface). Check for wear and replace if necessary.
Check the motor / gearbox for signs of corrosion. If
corrosion is evident, clean and repaint with a marine
grade oil based enamel paint.

PART 3 - PARTS LIST, TECHNICAL DRAWINGS
SPARE PARTS LIST
8000 Part No Description Qty
Windlass 15001459 Support Pin 3
15001461 Friction Plate 1
15044121 Roller Bearing 6
65000405 Brake Band Cover Mk II 1
65000406 Centre Stem Mk II 1
65000407 Drive Shaft Mk II 1
65000411 Support Plate Mk II 1
65000412 Adjusting screw Mk II 1
65000413 Chain Stripper Mk II 1
65000423 Cleat Nut 8000 1
65000444 Top Bolt Mk II 1
65000449 Spacer Mk II 2
65000466 Pivot C / Bored Mk II 1
65000467 Pivot Threaded Mk II 1
65000480 Collet Ring Mk II 2
65000483 Bearing Retainer Mk II 1
65000545 Pillar Mk II 2
65000594 Washer 2
65000597 Sleeve 4
65000793 Hollow Dowel 4
65000798 Drum AW 1
65000858 Base 1
65000883 Spacer 1
68000243 Brake Band Assembly 1
B1798 Spring 4
B7789 Spiral Ext Clip 1
B8315 O ring 139.5 x 3.0 1
B8983 Rotary Seal 1
B9294 Brake Hose Assembly 1
B9397 Motor GearBox/Brake 1
B9467 Motor Valve Assembly 1
Gypsy Kits 60000004 16mm Shortlink
60000143 19mm Shortlink