Lewmar 45ST EVO Self-Tailing Alloy Winch Instruction Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Lewmar 45ST EVO Self-Tailing Alloy Winch. Designed for marine applications, this two-speed winch offers superior performance and ease of use for sail trimming and halyard adjustments. Please read these instructions carefully before using the product to ensure safe and efficient operation.

2. Features and Benefits

• Top-Performing Winch: Built on the success and expert design of the Lewmar Ocean Winch, crafted with high-quality alloys and metals for optimal sailing performance.
• Two Speeds: Features two gears; the first gear is for major adjustments to halyards or sail trims, while the second gear allows for precise sail trim and handling of heavier loads with less effort.
• Quality Design: Incorporates a stainless steel top-mounted feeder arm to prevent line trap above the jaws. The wave spring jaws automatically adjust to various line diameters, ensuring taut sails. This model features a durable chrome bronze drum.
• Sized Right: Measures 5-5/8" base diameter and is 7" tall. The gear ratio is 2.4:1 in 1st gear and 7.6:1 in 2nd gear. The power ratio is 13.9:1 in 1st gear and 44.8:1 in 2nd gear, with a total weight of 10.7 lbs.
• No Tools Required for Access: Lewmar has simplified maintenance; simply unscrew the cap and remove the drum to access the gear train. All components are uniquely designed for straightforward re-assembly.

An infographic pointing out the winch's key attributes: ease of use, top choice among boaters, engineering excellence, and highest quality.

3. Specifications

This diagram illustrates the key dimensions of the winch, including its 7.00-inch height and 6.625-inch base diameter, along with its gear ratios (2.4:1 in 1st gear, 7.6:1 in 2nd gear) and power ratios (13.9:1 in 1st gear, 44.8:1 in 2nd gear).

4. Setup and Installation

The Lewmar 45ST EVO winch is designed for straightforward installation on your vessel. While specific mounting instructions may vary based on your boat's deck structure, general principles apply:

• Mounting Location: Choose a strong, flat area on the deck that can support the winch's load and provide clear access for operation and maintenance. Ensure adequate clearance for the winch handle and line.
• Drilling: Carefully mark and drill holes for the mounting bolts according to the winch's base pattern. Use appropriate drill bits for your deck material.
• Securing: Use marine-grade fasteners (bolts, washers, nuts) to secure the winch firmly to the deck. Apply marine sealant around the bolt holes to prevent water ingress.
• Internal Access: A key feature of this winch is its tool-free access to the gear train. Simply unscrew the top cap and remove the drum to access internal components for inspection or maintenance.

A detailed view of the Lewmar 45ST EVO Self-Tailing Alloy Winch, showcasing its chrome finish and compact design.

5. Operating Instructions

The Lewmar 45ST EVO winch features a two-speed mechanism for efficient line handling:

• Line Loading: Ensure the line is properly wrapped around the winch drum, typically 3-4 turns, in a clockwise direction. The self-tailing jaws are designed to grip the line securely.
• First Gear (High Speed, Low Power): For rapid line retrieval or initial tensioning of halyards and sheets, insert the winch handle and turn it clockwise. This gear provides faster line movement with less mechanical advantage.
• Second Gear (Low Speed, High Power): For fine-tuning sail trim or handling heavy loads, reverse the direction of the winch handle. The winch will automatically shift into the second gear, providing significantly more power with slower line movement. This allows for precise adjustments and easier handling of high-tension lines.
• Self-Tailing Function: The integrated self-tailing mechanism, featuring a stainless steel feeder arm and wave spring jaws, automatically holds the line under tension, freeing your hands for other tasks. Ensure the line is properly seated in the jaws.

This image shows a winch with a rope properly wrapped around its drum, highlighting its two-speed functionality for efficient sail trimming and handling of heavy loads.

A close-up image showing a hand operating a winch, emphasizing the stainless steel top-mounted feeder arm and wave spring jaws designed to prevent line trap and adjust to various line diameters.

6. Maintenance

Regular maintenance is crucial for the longevity and optimal performance of your Lewmar winch. The tool-free access feature simplifies this process:

• Annual Inspection: At least once a year, or more frequently with heavy use, remove the drum by unscrewing the top cap. Inspect all internal components, including gears, bearings, and pawls.
• Cleaning: Clean all parts thoroughly using a suitable solvent to remove old grease, salt, and dirt. Ensure no debris is lodged in the gear teeth or pawl mechanisms.
• Lubrication: Apply a thin layer of marine-grade grease to all gear teeth and bearing surfaces. Use a light oil specifically designed for pawls on the pawl pivots to ensure they move freely. Do not over-lubricate pawls, as this can cause them to stick.
• Reassembly: Reassemble the winch, ensuring all components are correctly aligned. The unique design of the parts ensures they can only be re-assembled one way, simplifying the process.
• External Cleaning: Regularly rinse the exterior of the winch with fresh water to remove salt residue and dirt. Avoid using abrasive cleaners that could damage the chrome finish.

7. Troubleshooting

If you encounter issues with your Lewmar winch, consider the following common problems and solutions:

• Winch is Stiff or Hard to Turn:
  • Cause: Lack of lubrication, old hardened grease, or internal corrosion.
  • Solution: Disassemble the winch (tool-free access), clean all internal components thoroughly, and re-lubricate with fresh marine-grade grease and pawl oil.
• Winch Slips or Does Not Hold Line:
  • Cause: Worn or dirty self-tailing jaws, incorrect line size, or insufficient wraps on the drum.
  • Solution: Inspect and clean the self-tailing jaws. Ensure the line diameter is within the recommended range for the winch. Add more wraps (3-4 turns) to the drum.
• Winch Handle Spins Freely (No Engagement):
  • Cause: Stuck or broken pawls, or damaged gears.
  • Solution: Disassemble the winch and inspect the pawls and their springs. Clean and lubricate them. Replace any broken pawls or damaged gears.
• Line Jams in Feeder Arm:
  • Cause: Improper line angle, worn feeder arm, or excessive line tension.
  • Solution: Ensure the line enters the winch at an appropriate angle. Inspect the feeder arm for damage. Reduce excessive tension if possible.

8. Warranty and Support

Lewmar is a globally recognized leader in marine equipment, committed to quality and customer satisfaction. Your Lewmar 45ST EVO Self-Tailing Alloy Winch is manufactured to high standards, reflecting decades of engineering excellence.

For specific warranty details, claims, or technical support, please refer to the official Lewmar website or contact their customer service directly. It is recommended to keep your purchase receipt as proof of ownership.

Lewmar is a proud member of Lippert, a leading global manufacturer and supplier for the marine and other industries, reinforcing their commitment to continuous improvement and customer experience.

A sailboat actively sailing on the water, with the Lewmar winch visible on deck, demonstrating its application in a marine environment.