Lewmar Comprehensive Guide to Windlass Maintenance and Troubleshooting

4. Maintenance

6. Troubleshooting GB

4.1 General recommendations	• Examine all electrical connections for possible corrosion,
	clean and lightly grease as necessary.

6.1 Anchor rode pays out independently

while windlass is not in use

6.2 Electrical troubleshooting

As with most electrical marine equipment the majority of problems

Isolate the windlass electrically, before carrying out any maintenance work.

•After the first two or three anchor recoveries, check the mounting nuts to ensure that the windlass is still fastened tightly to your deck, as it should now be bedded-in.

•Regularly wash down the exterior of your windlass with fresh water.

•Anchor rode splice should be checked regularly and remade if there is any evidence of wear.

•The Gypsy should be examined on a regular basis, because it is a high wear item. The Gypsy is designed for short scopes of chain and will last longer if properly used.

This problem is a result of not securing the anchor rode combined with the Gypsy Drive Cap (31) being slack. Tighten the Gypsy Drive Cap using the tool provided and always secure the anchor rode independently of the windlass whenever it is not being deployed or recovered.

that arise are electrical in nature. Therefore it is essential that the proper voltage be maintained. The proper voltage on a 12 Volt system is 13.5 Volts. (Constant low voltage will destroy the motor). Ensure that electrical cable size is large enough to handle the current draw imposed upon it and to keep the voltage drop within acceptable limits. In any circumstance voltage drop due entirely to cable resistance should not exceed 10%.

Follow the charts to troubleshoot the problem.

5. Dismantling procedures

Isolate the windlass electrically, before carrying out any maintenance work.

5.1 Gypsy replacement

Remove the Gypsy Drive Cap (31), anti-clockwise using the clutch operating lever. Withdraw the Drive washer (21), Remove the Socket Head Cap Screw (40) that retains the Stripper using a (5mm) Allen Wrench. Pull the Control Arm (30) back to clear the Gypsy. Remove the Gypsy Assembly (37). To replace the Gypsy, reverse the above procedure.

5.2 Control arm replacement

This should be carried out with the Gypsy (37) removed as detailed above. To remove the Control Arm (30). Unscrew the Control Arm Shoulder Screw (24) using a (4 mm) Allen Wrench and remove screw. Remove the Control Arm (30) and Torsion

(12)Spring from the base plate. To replace the Control Arm, reverse the above procedure.

5.3 Main shaft lubrication

Note The geartrain and its bearings have been lubricated for you with SFG 100 grease and should require no regular attention.

SFG is a white synthetic grease containing PTFE. Use grease of a similar specification throughout. It is recommended that the external Drive Shaft components be stripped, cleaned and re-greased at least annually. To do this, the Gypsy Assembly (37) should be removed as detailed above. Inspect the Main Shaft (20) and Gypsy (37) for damage before reassembly.

5.4 Fall safe pawl replacement

This should be carried out with the Gypsy (37) removed as detailed above. Turn the fall safe lever (34) so it is horizontal. Remove fall safe shoulder screw (35) using allen wrench. Lift off fall safe pawl (32). Remove fall safe spring (36). Replace new part by reversing the above procedure.

5.5 Fall safe lever replacement

Turn fall safe lever (34) so it is horizontal. Remove socket screw

(6)using allen wrench. Remove fall safe lever (34). To refit use thread lock on the socket screw (6). Screw down screw (6) finger tight and leave to cure before operating fall safe lever (34).

Failure to Operate Troubleshoot Chart: Reversing Toggle Control Switch (Part No. 0052519)

Is there voltage at the input terminal (positive) to the control			If no voltage is present, the battery isolation switch is OFF, the
switch?
			breaker is tripped or a fuse has blown. The battery may also
	NO		have been dead or disconnected.
YES
Check voltage at the output terminals of the control switch
with the switch on forward then reverse.
Is there voltage at either output terminal for forward then			Control switch is defective.
reverse.?
YES	NO
Replace motor.
		Sluggish Operation Troubleshoot Chart
Is windlass overloaded?			Ease the load and ensure the battery is well charged.
YES	NO
Check the voltage across the motor leads with the windlass			There is a severe voltage drop in the circuit.
on. (Proper voltage is 13.5 V. Constant low voltage will destroy
			Check for undersized cables, poor connections or corroded
the motor).
			connections. Also check for resistance across the battery
Is the voltage low? (Below 11.0 V on a 12 V system).
			isolation switch or solenoid. (Feel them to see if they are
			heating up).
YES	NO
Is the voltage correct? (Above 11.0 V and anchor is not
fouled).			The motor is defective. Replace the motor.
YES

10 V700 Windlass V700 Windlass 11