Lewmar V1/Sport User manual

Lewmar V1-6 & Sport Windlass
65001201 Issue 2
Owner’s Installation,
Operation & Basic
Servicing Manual

Lewmar V1, V2, V3 & SPORT Windlass | 2
Contents
1. Introduction 4
1.1 Product support 4
1.2 CE Approvals 4
1.3 Important information about this
manual 4
2. Safety Notices 5
2.1 Windlass general 5
2.2 Fitting 6
2.3 Electrical 6
3. Installation 7
3.1 Basic requirements 7
3.2 Accessories 7
3.3 Gypsy Suitability 7
3.4 V1-6 Above deck preparation 8
3.5 V1-6 Deck thickness 9
3.6 V1-6 bellow deck preparation 10
3.7 V1-6 above deck fitting 11
3.8 V1-3 under deck fitting 12
3.9 V4-5 under deck fitting 13
3.10 V6 under deck fitting 14
3.11 V1-6 loading rope/chain 15
4. Electrical Wiring 16
4.1 Electric cable selection 16
4.2 Wiring 16
4.3 Control switch installation 17
4.4 V1-6 wiring diagram 18
5. Hydraulic System 19
5.1 Installation 19
5.2 Hydraulic motor/gearbox 19
5.3 Hose types 20
5.4 Motor ports - standard motor/gearbox 20
6. Operation 21
6.1 V1-6 braked anchor free-fall 21
6.2 Power up/down 22
6.3 V1-3 manual recovery 23
6.4 V2-6 Independent warping 24
6.5 Operating tips 25
7. Servicing 26
7.1 Servicing schedule 26
7.2 V1-6 gypsy replacement/service 27
7.3 Manual recovery gypsy replacement 27
7.4 Gypsy/drum replacement 27
7.5 V1-5 control arm replacement/service 28
7.6 V1-3 fall-safe pawl and lever
replacement/service 28
7.7 V1 Parts list 29
7.8 V2 & V3 Parts list 30
7.9 V4 & V5 Parts list 31
7.10 V6 Parts list 32
Contents
8. Specifications 33
33
34
35
36
37
8.1 V1-3 dimensions
8.2 V4-5 dimensions
8.3 V6 dimensions
8.4 V1-6 deck template guide
8.5 Electric specifications
9. Trouble shooting 38
38
38
38
9.1 Electric windlass
9.2 Hydraulic windlass
9.3 Hydraulic question & answer
10. Warranty 40
10.1 Limited Warranty and Key Terms of
Supply by Lewmar 40
DearCustomer,
Thank you for choosing Lewmar.
Lewmar products are world renowned
for their quality, technical innovation
and proven performance. With a
Lewmar product you will be provided
with many years of outstanding
service.
1.1 Product support
Lewmar products are supported by a
worldwide network of distributors and
Authorised Service Representatives. If
you encounter any difficulties with this
product, please contact your national
distributor, oryour local Lewmar
dealer.
1.2 CE Approvals
For CE approval certificates contact
Lewmar.
1.3 Important information
about this manual
Throughout this manual, you will see
safety and product damage warnings.
You must follow these warnings
carefully to avoid possible injury or
damage.
The type of warnings, what they look
like, and how they are used in this
manual are explained as follows:
1. Introduction
WARNING!
This is a warning against
anything which may cause
injury to people if the warning is
ignored. You are informed about
what you must or must not do
in order to reduce the risk of
injury to yourself and others.
SAFETY SYMBOL
When you see the safety
symbol it means: “Do not...”;
“Do not do this”; or “Do
not let this happen”.
WARNING!
IMPORTANT: Read these notes
before continuing.
2.1 Windlass general
Classification Societies and Lewmar
require that a vessel at anchor must
have its chain/rode held by a chain
stopper or equivalent strong point at
all times!
At all times it is the responsibility
of the boat user to ensure that the
anchor and rode are properly stowed
for the prevailing sea conditions.
This is particularly important with
high-speed powerboats, because an
anchor accidentallydeployingwhile
under way can cause considerable
damage. An anchor windlass is
mounted in the most exposed position
on a vessel and is thus subject to
severe atmospheric attack resulting in
a possibility of corrosion in excess of
that experienced with most other items
of deck equipment. As the windlass
may only be used infrequently, the risk
of corrosion is further increased. It is
essential that the windlass is regularly
examined, operated and given any
necessary maintenance.
Please ensure that you thoroughly
understand the operation and safety
requirements of the windlass before
commencing the installation. Only
persons who are completely familiar
with the controls and those who have
been fully made aware of the correct
use of the windlass should be allowed
to use it. If there is any doubt of how
to install or operate this unit please
seek advice from a suitably qualified
engineer.
• Windlasses used incorrectly could
cause harm to equipment or crew.
• Windlasses should be used with care
and treated with respect.
• Boating, like many other activities
can be hazardous. Even the correct
selection, maintenance and use of
proper equipment cannot eliminate
the potential for danger, serious
injury or death.
• Lewmar windlasses are designed
and supplied for anchor control in
marine applications and are not
to be used in conjunction with any
other use.
2. Safety Notices
• Keep limbs, fingers, clothing and hair
clearofwindlassandanchor rope/chain
and anchor duringoperation. Severe
bodily harm would result.
• Ensure thereare no swimmers or divers
nearbywhendroppinganchor.
• When theWindlass isnot in use the
anchor must betied off onto acleat
or equivalentstrong point to prevent
damage tothe boat.
• Windlass must not be used asthe sole
means of securing theanchor tothe bow
fittingespeciallyunder storm conditions.
Anchors should beindependently
secured toprevent accidentalrelease.
• Classification Societies require that a
vessel lying atanchor musthave its
anchor rope/chain secured to a suitable
independentstrong point.
• Donot use windlass for ANY purpose
other thandeployment and recoveryof
anchor.
• Donot wrap chain around a capstan
barrel or drum wherefitted.
• Acircuit breaker/isolator should always
be used with thiswindlassto protect the
motor and cables from overheatingand
damage.
• Always switch off thiswindlassat the
circuit breaker/isolator when notin use.
• It isthe unavoidable responsibility of
theowner or master or other responsible
party to assess therisk of any operation
onthe vessel.
• Windlass must not be operated whilst
underthe influence of alcoholor drugs.
2.2 Fitting
• This equipment must be installed
and operated in accordance with
the instructions contained in this
manual. Failure to do so could
result in poor product performance,
personal injury and/or damage to
yourboat.
• Consult the boat manufacturer if you
have any doubt about the strength
or suitability of the mounting
location.
2.3 Electrical
• Make sure you have switched off the
power before you start installing this
product.
• This product requires installation
by a suitably qualified electrical
engineer.
WARNING!

3.4-2
3.4 V1-6 Above deck
preparation
IMPORTANT: Plan location carefully
and allow for the following:
1. Make an accurate drilling template
using the product dimensions from
the dimension template and decide
upon a position for it with reference
to the vessel’s bow roller and the
chain locker below and the rotation
of manual operating handle.
• If possible, select a flat area of
deck.
2. Models V1-3
If the deck is not flat, a suitable
mounting pad may be required to
take up camber or sheer.
3. Models V4-5
If a pad is required for these models,
care must be taken to ensure
that the windlass base is parallel
to the motor/gearbox mounting
flange. Shims may be used, before
the motor/gearbox is installed, to
correct minor misalignment.
4. Model V6
If the deck is not flat, a suitable
mounting pad may be required to
take up camber or sheer.
• NOTE: If in doubt about the suitable
construction of the pad consult a
qualified marine engineer.
• NOTE:Decksthat are thin,or of foam
or balsalaminate construction, will
require reinforcement in order to
spread the loadsthatwillbe appliedto
thedeckwhilethe windlassis inuse.
3.4-1 3.4-3 3.4-4
3. Installation
3.1 Basic requirements
Each installation requires:
WINDLASSINSTALLATION
The following tools:
• An appropriate marine sealant
V1-3
• 10 mm (3/8”) Drill
• 14 mm (9/16”) Drill
• 75 mm (3”) Hole Saw
V4-5
• 12 mm (7/16”) Drill
• 77 & 90 mm (3” & 41/2”) Hole Saw
V6
• 5 mm (3/16”) Drill
• 12 mm (7/16”) Drill
• 115 mm (41/2”) Hole Saw
WIRINGINSTALLATION
• Crimping Pliers/Wire Stripper
• Suitable electrical cable and crimp
terminals
3.2 Accessories
Use only genuine Lewmar parts and
accessories to ensure top performance
and eliminate the risk of voiding your
warranty. For replacement parts,
please visit your dealer or the Lewmar
web site.
3.3 Gypsy Suitability
Gypsies fitted to the V1-5 range
of windlasses are ideally suited to
handling our factory made Rope/Chain
combination rodes, which consist of
rope spliced to a chain tail. The V6
range is chain only. See Specifications
section for details.
Ropes used must be windlass grade,
medium lay nylon. Ropes from different
manufacturers have wide variations in
stretch and consistency in diameter.
Therefore, rope and chain from other
manufacturers may require some
experimentation to determine the
optimum size.
Should you have difficulty in matching
a gypsy to your chain please consult
your local agent or our international
network of distributors.

Lewmar V1-6 & SPORT Windlass | 9
3.5 V1-6 Deck thickness
• The deck is an integral component
of the windlass it has to secure the
windlass and be strong enough to
cope with the high torque stresses
involved in recovering the anchor.
1. Models V1-3
• Lewmar recommends a minimum
deck thickness of 25 mm (1”),
M8 Studs suit deck and packing
thickness of 25-60 mm (1” - 21/4”).
• NOTE: An optional extended version
can be used on decks up to 140 mm
thick.
2. ModelsV4-5
• Lewmar recommends a minimum
deck thickness of 40 mm(11/2”).
M10 studs suit deck and packing
thickness of 40-66 mm (11/2”-
21/2”).
3. Model V6
• Lewmar recommends a minimum
deck thickness of 40 mm (11/2”).
M10 studs suit deck and packing
thickness of 40-56 mm (11/2”-
21/4”).
3.5-1 3.5-2 3.5-3
25 - 60 mm
1” - 21/4”40 - 66 mm
11/2” - 21/2”40 - 56 mm
11/2” - 21/4”
3. Installation

Lewmar V1-6 & SPORT Windlass | 10
3.6 V1-6 bellow deck
preparation
IMPORTANT: The positioning of the
motor/gearbox must be checked prior
to cutting for deck/hull and bulkhead
clearance.
1. Models V1-3
The motor/gearbox is connected by
a fast fit clamp enabling it to be
rotated and fixed in any position 360
degrees.
Models V4-5
The motor/gearbox is bolted via the
through deck mounting bolts.
Models V6
The motor/gearbox is bolted directly
to the base via a down tube.
• NOTE: In either case do not position
motor/gearbox below rode/chain
pipe fall area.
2. Models V1-5
Lead from the roller should be fed
horizontally back to the top of the
gypsy and along its centre line
within ±5˚. There must be sufficient
vertical fall for the chain or rope
when hauling in.
3. Model V6 (Chain Only)
Chain from the roller should be
fed horizontally back to the top of
the gypsy and along its centre line
within ±5˚. There must be sufficient
vertical fall for the chain when
hauling in.
3.6-1 3.6-2
WARNING! Failure to
provide minimum vertical
fall can cause jamming.
3.6-3
3. Installation

Lewmar V1-6 & SPORT Windlass | 11
3.7 V1-6 above deck fitting
1. Using your template and after you
have checked all the above and
below deck requirements cut the
following holes.
• Model V1-3
Using a 10 mm (3/8”) diameter drill,
make the five holes for the mounting
studs and sensor. With a 75 mm (3”)
diameter hole saw, make two holes
for the rode and down tube to pass
through.
• Models V4-6
Using a 12 mm (7/16”) diameter drill,
make the five holes for the mounting
studs and sensor. With a 115 mm
(41/2”) diameter hole saw, make two
holes for the rode and down tube to
pass through.
2. When all the holes have been made,
remove the template. To help avoid
water absorption by the deck, apply
an appropriate marine sealant to the
freshly cut hole edges.
3. Assemble and tighten studs into
base until they bottom out in their
holes. Some studs have a flat.
Position the flats of the studs
nearest the base of the windlass.
3.7-23.7-1 3.7-3
3. Installation

Lewmar V1-6 & SPORT Windlass | 12
3.7-5
4. Models V1-5
Place the base mat in position on
the deck. Optionally, apply a suitable
sealant to the base of the windlass,
any mounting pad or around the
studs.
Model V6
This model is not supplied with a
base mat. Use sealant
• NOTE: If using silicone or other
rubbery type sealant, it is advisable
to allow curing of the sealant before
final tightening of the mounting
nuts.
5. Lightly coat the shaft with grease
and ensure the drive key is in place
before assembly to motor/gearbox.
3.8 V1-3 under deck fitting
• Lightly grease all moving parts.
1. Remove the Nyloc nut from the end
of the Fast Fit clamp bolt and screw
the bronze nut up to the end of the
thread.
2. Open up the Fast Fit clamp and
offer the gearbox up to the above
deck unit, sliding the shaft into the
gearbox. Ensure the drive key is in
place.
DO NOT use a permanent
adhesive/sealant, eg. 5200.
3.7-4 3.8-1 3.8-2
3. Installation

Lewmar V1-6 & SPORT Windlass | 13
3.8-3
3. Slide the gearbox up the shaft and
rotate it into a suitable position
before finally pushing home onto the
location dowels.
Swing the Fast Fit clamp shut and
tighten up the bronze nut by hand. If
required you can remove the plastic
location plug holding the Fast Fit
clamp in place and rotate the clamp
around the gearbox flange to give a
better location for tightening up the
nut.
• Tighten up the bronze nut to 15 Nm
(11 lb/ft) before adding the Nyloc
nut. Tighten the Nyloc nut up behind
the bronze nut.
3.9 V4-5 under deck fitting
• Lightly grease all moving parts.
1. Ensure drive key is in place then
gently slide the motor/gearbox up
the drive shaft until it contacts the
deck.
• NOTE: Position the motor/gearbox
away from the rope/chain pipe fall.
2. Check the motor/gearbox and
windlass mounting surfaces are
parallel. Assemble the M8 nut first,
secure with Loctite®threadlock to
43 Nm torque. Lock tightened nut
with spanner and then secure with
the M8 Nyloc nut.
• NOTE: If using silicone or other
rubbery type sealant, it is advisable
to allow curing of the sealant before
final tightening of the mounting
nuts.
3.9-1 3.9-2
43 Nm
3. Installation

Lewmar V1-6 & SPORT Windlass | 14
3.10-1
3.10 V6 under deck fitting
• Lightly grease all moving parts.
1. Slide the deck backing plate onto
the windlass studs. Assemble the
M10 nut first, secure with Loctite®
threadlock to 43 Nm torque. Lock
tightened nut with spanner and then
secure with the M10 Nyloc nut.
• NOTE: If using silicone or other
rubbery type sealant, it is advisable
to allow curing of the sealant before
final tightening of the mounting
nuts.
2. Ensure drive key is in place then
gently slide the motor/gearbox up
the drive shaft until motor/gearbox
mounting plate meets the windlass
downtube. Assemble the M10 bolts
secure with Loctite®threadlock to
43 Nm torque.
• NOTE: Position the motor/gearbox
away from the rope/chain pipe fall.
3.10-2
43 Nm
3. Installation

Lewmar V1-6 & SPORT Windlass | 15
3.11 V1-6 loading rope/chain
• For safety and performance Lewmar
recommends the use of matched
Lewmaranchorrodes.
1. Remove cover.
2. Pull out control arm.
3. Feed anchor rope/chain into entry
hole. Tie off to suitable strong point.
4. Replace cover. Release control arm
and wrap rope/chain around gypsy.
5. Power load rest of anchor rope/
chain.
•Model V6 chain only
These models have the same loading
procedure as above but do not have
a control arm.
3.11-1 3.11-5
3.11-2 3.11-3 3.11-4
WARNING! Isolate the windlass
using circuit breaker/isolator.
3. Installation

Lewmar V1-6 & SPORT Windlass | 17
• NOTE: Wireless remotealso
available.
• NOTE: Wireless remote can only be
used if a contactor is fitted. See
wireless remote instructions for
wiring details.
Wireless remote 3 button windlass only Wireless remote 5 button windlass and thruster
68000967 68000968
Model Voltage Cable sizing for length of cable run Circuit breaker Contactor Control Box
Modell
V 0 - 7 m 0 - 23 ft 7 - 15 m 23 - 50 ft 15 - 22 m 50 - 73 ft A
V1/Sport 12 10 mm26 AWG 25 mm24 AWG 35 mm20 AWG 90 A (68000349) 68000318 68000129
V2/Sport 12 10 mm26 AWG 25 mm24 AWG 35 mm20 AWG 90 A (68000349) 68000318 68000129
V2/Sport 24 6 mm210 AWG 6 mm28 AWG 10 mm28 AWG 50 A (68000348) 68000319 68000130
V3/Sport 12 16 mm26 AWG 25 mm22 AWG 35 mm20 AWG 110 A (68000350) 68000318 68000129
V3/Sport 24 10 mm28 AWG 16 mm26 AWG 25 mm24 AWG 90 A (68000349) 68000319 68000130
V4 12 25 mm23 AWG 35 mm20 AWG 50 mm20 AWG 150 A (68000351) 68000320 18000200
V4 24 10 mm28 AWG 16 mm24 AWG 25 mm22 AWG 110 A (68000350) 68000321 18000237
V5 12 25 mm23 AWG 35 mm20 AWG 50 mm20 AWG 150 A (68000359) 68000318 68000128
V5 24 10 mm28 AWG 16 mm24 AWG 25 mm22 AWG 110 A (68000350) 68000318 68000130
V6 24 25 mm22 AWG 35 mm20 AWG 50 mm20 AWG 150 A (68000351) 68000321 18000237
4.3 Control switch installation
Follow the mounting instructions
supplied with the switch.
• NOTE: In a multi station installation
all switches must be wired in a
parallel circuit.
4. Electrical Wiring
4.1 Electric cable selection
Lewmar recommends the installer
source and install cable that meets
the requirements of the standards and
regulations relevant to the installation
and codes of practice.
The cable table gives recommended
cable sizes based on total length
of cable required, from the battery,
following the route of the cables.
DO NOT confuse cable Length
with the length of the vessel!
• Windlass performance is directly
related to cable size and length.
Voltage drop over the complete
wiring run must not exceed 10%.
4.2 Wiring
Plan the installation to suit the
controls and give the operator a full
view of the windlass. The wiring
system should be of the fully insulated
type, which avoids possible electrolytic
corrosion problems. We recommend the
use of type III stranded, tinned copper
wire with copper crimp terminals. Most
modern installations are negative
return (negative ground) but polarity
should be checked.
Overload protection, in the form of the
circuit breaker/fuse supplied, must be
built into the windlass wiring circuit.
•NOTE: The circuit breaker should be
positioned close to the battery in a
dry, readily accessible place.
• The breaker must be manually
reset should an overload occur that
causes it to trip to the off position.
• If you are not sure you understand
these guidelines, seekprofessional
help. Ensure that the installation
complies with USCG, ABYC, NMMA
or other local regulations.
WARNING!

Lewmar V1-6 & SPORT Windlass | 18
4.4 V1-6 wiring diagram
• Installation instructions are supplied
separately with any accessories.
Thermal
Switch
(IF fitted)
Reed Switch Sensor
for Chain Counter
(If fitted)
Circuit Breaker
Battery
Isolator
Battery
12/24 VDC
Contactor
Electric Deck Switches
Rocker
Switches
Electric Remote
Control
Thermal
Switch
Fuse
3 A
V1-3 & 5
4
5
4
5
4
5
4
5
4
5
1
2
3
1
2
3
1
2
3
1
2
3
UP DOWN
UP
DOWN
1
2
3
1
2
3
4
5
Control Box
Control BoxControl Box
Contactor Contactor
1
2
3
V4 V6
2
1
−V
BATT +VE
MOTOR D2
MOTOR D1
D1
D2
A2
2
1
−V
BATT +VE
MOTOR
F2
MOTOR
F1
F2
A1
A2
A
F1
2
1
−V
BATT +VE
MOTOR
D2
MOTOR
D1
D1
D2
A1
A
A2
BATT
+VE
MOTOR
F2
MOTOR
F1 A
D1
D2
A1
A2
BATT +VE
MOTOR
F2
MOTOR
F1 A
F2
A1
A2
F1
BATT
+VE
MOTOR
F1
MOTOR
F2
D1
D2
A2
Reed Switch Sensor
for Chain Counter
(If fitted)
Thermal
Switch
(IF fitted)
Reed Switch Sensor
for Chain Counter
(If fitted)
Thermal
Switch
(IF fitted)
4
5
• NOTE: Motor connections
D1 = F1
D2 = F2
• Switch wire thickness:
1.5 mm2(16 AWG)
4. Electrical Wiring

Lewmar V1-6 & SPORT Windlass | 20
5.3 Hose types
For reliable operation and safety it is
essential to use reinforced braid hose
for connecting to the motor A and B
ports which conforms to SAE100R2A or
DIN 20 021 Part 2.
The recommended hose sizes are:
• Up to 30 l/min + 1/2” (13 mm) bore
diameter.
• Up to 40 l/min + 5/8” (16 mm) bore
diameter.
• Up to 57 l/min + 3/4” (19 mm) bore
diameter.
• Ref: 3.78 litres = 1 US gallon
4.54 litres = 1 Imperial gallon
5.4 Motor ports - standard
motor/gearbox
The location of the ports for the
standard motor/gearbox is shown in
Fig 5.4-1 (no drain connection).
• The Lewmar hydraulic motor ports
are: A & B ports ½” BSP.
• NOTE: Refer to your installed
hydraulic system manual for
hydraulic drives.
5. Hydraulic System
Fig 5.1-1 Standard Motor/gearbox Fig 5.4-1
5.1 Installation
• NOTE: Hydraulic system installation
is NOT covered in this publication.
Lewmar hydraulic windlasses have
been designed for ease of installation
and follow a straightforward hydraulic
and mechanical installation procedure.
Windlass unit should be connected to
a hydraulic powerpack with directional
control valve installed to control the
windlass movement.
Fig 5.1-1 shows a typical hydraulic
circuit for a V6 windlass.
The purpose of this manual is to
provide the reader with sufficient
information to install and operate
a hydraulic windlass. It assumes
the reader will be familiar with
sailing craft, marine hydraulics and
mechanical installation and safety
requirements. If in any doubt consult a
qualified marine engineer.
• The installation of hydraulic systems
requires a high level of cleanliness.
The ingress of dirt will dangerously
impair the safe operation of the
system and cause premature wear of
hydraulic components.
5.2 Hydraulic motor/gearbox
The hydraulic motor/gearbox consists
of a high torque hydraulic motor fitted
to a 7:1 90 degree gearbox.
The hydraulic motors have amaximum
pressure rating of180 bar andcan be
used with anoil supplyofup to57 l/min.
The motor gearboxes are not self
sustaining. A dual Pilot Operated
Check Valve (POCV) must be installed
in the system to temporarily sustain
any load. The POCV can be line
mounted (as shown in Fig 5.1-1) or
modular type if for example a CETOP 3
directional valve is being used.
•NOTE:To permanently sustain a load
a Chain Stopper must be used.
WARNING!

Lewmar V1-6 & SPORT Windlass | 21
6.1-3
6.1 V1-6 braked
anchor free-fall
Use this method for quicker anchor
deployment and to save battery
power.
1. Models V1-3
Check fall-safe pawl is in vertical
disengaged position and held clear
by fall safe lever.
2. Models V4-5
Check pawl is in disengaged
position.
Models V6 & V-Sport
This model has no fall-safe pawl.
Gypsy only
3. Release any anchor locks and when
safe rotate handle anti-clockwise
until anchor pays out.
4. Adjust rate of fall with handle. Once
paid out fully tighten gypsy drive
cap.
Gypsy/drum
5. Place a Lewmar handle into the
drum top nut and operate as gypsy
version above.
6.1-4 6.1-5
WARNING! Always remove
winch handle after use.
WARNING! Isolate the windlass
using circuit breaker/isolator.
6.1-1 6.1-2
6. Operation

Lewmar V1-6 & SPORT Windlass | 22
6.2 Power up/down
To release anchor.
1. Models V1-3
Check fall-safe pawl is in vertical
disengaged position and held clear
by fall safe lever.
2. Models V4-5
Check pawl is in disengaged
position.
V6 & V-Sport versions
Operate as below, this model has no
fall-safe pawl.
3. Release any anchor locks.
4. When safe, operate DOWN control.
To retrieveanchor.
• Retrieving the anchor is the reverse
to the above.
• NOTE: Models V1-3 fall-safe does
not need to be disengaged during
retrieval as it acts as a rachet.
• When safe, operate the UP control.
When anchor has been retrieved and
stowed, the fall-safe pawl should be
left engaged.
• NOTE: Remember, on models
V1-3 the fall-safe does need to be
disengaged before anchor can be let
go again.
• Once anchor is retrieved, ensure
it is adequately secured to an
independentstrongpoint.
WARNING! Check Fall-
Safe pawl is disengaged
and held clear by Fall-Safe
lever - Except Sport & V6.
6.2-4
6.2-3
6.2-1 6.2-2
6. Operation

Lewmar V1-6 & SPORT Windlass | 23
6.3 V1-3 manual recovery
• Gypsy only (optional manual
recovery Kit No.66840054)
• Gypsy/drum (optional manual
recovery Kit No.66840056)
• Sport versions
These units have no manual
recovery.
1. Engage fall safe pawl.
2. Place a Lewmar winch handle into
gypsy drive cap/drum top nut and
rotate anti-clockwise by half a turn.
3. Remove handle and place into the
bi-square in the cap and rotate
clockwise.
4. Once anchor is retrieved, ensure
it is adequately secured to an
independentstrongpoint.
• Gypsy/drum versions
These units use emergency manual
recovery attachment 66840056. See
document66300003RevA forfitting
and operating instructions.
WARNING! Isolate the windlass
using circuit breaker/isolator.
6.3-1 6.3-46.3-3
6.3-2
6. Operation

Lewmar V1-6 & SPORT Windlass | 24
1
DO NOT wrap chain around
the capstan drum.
WARNING! Always remove
winch handle after use.
6.4 V2-6 Independent warping
• NOTE: V6 do not have Fall-Safe.
• Gypsy/drum only
1. Lock anchor chain before warping.
2. Models V2-3
Engage fall safe pawl.
Models V4-5
Check pawl is in disengaged
position.
3. Place a Lewmar winch handle into
top nut. Disengage clutch by turning
anti-clockwise by half a turn.
• Remove handle.
4. When safe, operate the drum.
• If warping speed is too fast, ease
tension in rope.
• When finished re-engage clutch by
tightening the drum top nut.
5.4-1 6.4-4
6.4-3
6.4-1 6.4-2
6.4-2
6. Operation

Lewmar V1-6 & SPORT Windlass | 25
6.5-1
6.5 Operating tips
• Vessels at anchor will snub on the
rode and this can cause slippage
or apply excessive loads to the
windlass.
1. When anchoring, power rode out
allowing the vessel to take up stern
away preventing the rode tangling
with anchor. Use this method for
mooring stern first to a jetty.
2. To aid recovery, under power, move
vessel towards anchor but not over
and beyond, as this can cause
damage to topside.
• As anchor approaches the vessel
use careful adjustments of controls
to avoid damaging vessel.
•Scope: As a guide it is
recommended that the depth of
chain to rope is 7 to 1 at anchor.
When retrieving anchor do not
overload or stall in windlass.
To prevent damage the fall-
safe pawl MUST NOT be left to
take the entire force from the
anchor rode while at anchor.
The rode should be secured
directly to a bollard, sampson
post or cleat and a chain
secured by a chain stopper.
6.5-2
6. Operation
7.1 Servicing schedule
Regularly:
• Wash down the windlass using fresh
water.
• Examine all electrical connections
for corrosion, clean and lightly
grease.
• Check anchor locker drain to avoid
water damage to motor/gearbox.
• If anchor locker fills with water,
check motor is dry and free of rust.
• Check anchor rode splice for wear.
• Check gypsy as it is a high wear
item and will last longer if properly
used. When re-assembling the cone
and gypsy, add a small smear of
grease to the contact surfaces.
• Check mounting studs after first
two or three recoveries and regularly
thereafter.
Annually:
• Check electric cables for damage.
Repair/renew as required.
• Strip the above deck components,
clean and lightly grease.
• Check motor/gearbox for corrosion,
clean and repaint with a suitable
marine grade oil based enamel
paint.
• Remove electric motor cover and
blow dust away from brushes using
foot pump or similar taking care not
to breathe any dust.
WARNING! Isolate the windlass
using circuit breaker/isolator.
WARNING! Ensure rode is
adequately secured to an
independent strong point.
7. Servicing

Lewmar V1-6 & SPORT Windlass | 27
7.2 V1-6 gypsy
replacement/service
• Illustrations based on V1-3.
1. Remove chain pipe cover screws
using 5 mm Allen key.
2. Place winch handle into gypsy drive
cap, rotate anti-clockwise and
remove.
3. Remove washer and top cone.
4. Pull control arm back to clear gypsy
and remove gypsy assembly.
• Wash with clean water - DO NOT JET
WASH.
• NOTE: Model V6 does not have a
controlarm.
• Assemble in reverse order greasing
threads of chain pipe and washer
and stripper screw. When re-
assembling the cone and gypsy,
add a small smear of grease to the
contact surfaces.
7.3 Manual recovery
gypsy replacement
• Proceedas7.2.
7.4 Gypsy/drum replacement
• Proceed as 7.2 except place the
winch handle into the drum top nut
and remove drum assembly to get to
gypsy.
WARNING! Isolate the windlass
using circuit breaker/isolator.
1
7.2-1 7.2-2 7.2-3 7.2-4
7. Servicing
7.6-17.5-1
7.5 V1-5 control arm
replacement/service
• Remove gypsy, proceed as sec. 7.2.
1. Unscrew control arm shoulder screw
using a 4 mm Allen key.
• Remove control arm and torsion
spring from the base plate.
• Wash with clean water (Not
Jetwash). Replace components, (if
necessary) and assemble in reverse
order.
7.6 V1-3 fall-safe pawl and
lever replacement/service
• NOTE: V-Sport & V4-6 do not have
fall-safe.
• Remove gypsy, proceed as sec. 7.2.
1. Turn fall-safe lever so it is horizontal
and remove shoulder screw.
• Lift fall-safe pawl and spring, fall
safe lever and spacer.
• Replace components and assemble
in reverse order.
2. Remove screw from inner edge of
fall-safe pawl.
• Lift off pawl and replace
components.
WARNING! Isolate the windlass
using circuit breaker/isolator.
WARNING! Ensure rode is
adequately secured to an
independent strong point.

Lewmar V1-6 & SPORT Windlass | 29
7.7 V1 Parts list
30
22
14
34
6
7
22
27
11
28 31
17
32
18
15
19
26 25 8
20
9
10
33
23
24
12
12
35
36
16
29
Kit No. Kit Description Items Included (Qty.)
66000060 Cap Kit 22(1)
66000624 V1/2/3 Base 3(1), 10(1), 34(1)
66000625 Chain Pipe Cover 11(1), 34(2)
66000626 Fastener Kit 1(1), 2(1), 4(3), 5(1), 8(1), 14(2)
66000627 Drive Kit 1(1), 2(1), 3(1), 4(3), 5(1), 14(1), 15(2),
17(1), 35(1)
66000628 Manual Recovery Pawl Kit (Fall Safe) 12(1), 18(1), 19(1), 28(1),
29(1), 33(1)
66000629 Motor Gearbox 30(1)
66000631 Mounting Kit (Metric) 9(1), 16(1), 20(1),
26(4), 27(4)
66000632 Fast Fit Assembly. 36(1), 37(1)
66000633 Deck Spacer Kit 13(1), 32(4)
66200076 Sensor & Magnet Kit 21(1), Magnet(1)
66810030 Control Arm Kit 7(1), 8(1), 23(1)
66810065 Motor Gearbox Kit 17(1), 30(1), 36(1), 37(1)
66840054 Manual Recovery Kit 4(1), 24(1), 25(1)
68000360 V Range Gypsy & Stripper Kit (000) 31(1), Magnet(1)
68000361 V Range Gypsy & Stripper Kit (001) 31a(1), Magnet(1)
68000362 V Range Gypsy & Stripper Kit (002) 31b(1), Magnet(1)
68000840 V Range Gypsy & Stripper Kit (006) 31c(1), Magnet(1)
7. Servicing