Lewmar H3 Windlass Disassembly help needed

[LadyStardust]

I'm trying to dismantle my windlass, I want to replace the solenoid, and also give the motor a service. It must be quite old now and there's lots of corrosion between the stainless and the aluminium parts, I have had to drill out a couple of screws so far.
I'm stuck now trying to remove the motor/gearbox assembly from the alloy casing. Should the gearbox support, item 16 on the gypsy side come out?
I'm wondering if the corrosion that seems to be keeping it all locked together means its days are numbered. It actually works well, but only going up, due to the faulty solenoid, which isn't the end of the world as the clutch works well.

Thanks,
Paul C, SV Sister Midnight
KK, Sabah, N Borneo.

[Paul L]

Isn't the solenoid mounted remote from the motor and gearbox?

[double u]

http://www.comstedt.se/wp-content/up...horizontal.pdf

[LadyStardust]

Originally Posted by Paul L

Isn't the solenoid mounted remote from the motor and gearbox?

Sadly not, it's mounted on top of the motor inside the casing and cannot be removed without pulling the motor/gearbox out. However you have got me thinking that there is no need for the solenoid to remain there, I just need to run an extra big cable out from the motor and I can mount the new solenoid remotely, preferable in case it should fail again! Thanks for the comment.

[LadyStardust]

Originally Posted by double u

http://www.comstedt.se/wp-content/up...horizontal.pdf

Thanks, I have the manual and it's useful to a point, but an actual step by step breakdown would be more useful.

[double u]

my guess is that srews no 35 hold the motorgearbox in place.
if bad comes to worst: disconnetc/bypass integrated solenoid & mount new one externally (which is by far the better position for it anyway)

[ZULU40]

https://www.youtube.com/watch?v=W_MjOJYYZ4A

[ErikFinn]

Hi Paul,

I agree with double u and I believe at the minimum the four M8x20 bolts (items 35) on the starboard side must come off, as the diagram shows bolt holes on the casing for these four bolts and there appears to also be corresponding bolt holes on the gasket and the gearbox. Interestingly, on the port side the casing does not appear to have holes for the port side M8x20 bolts, but the gasket does show bolt holes, so therefore the diagram may just be missing the bolt holes from the casing. It is difficult to estimate from the diagram not seeing the actual parts in situ weather the port side "Gearbox Support" (16) can clear the casing when trying to pull out the Motor/Gearbox assembly, or not. You can probably judge that by looking and analyzing in situ.
After removing the 4 (or 8) M8x20 bolts you should have access to the key (31) and you can pry it off, after which you can slide off the main shaft (some gentle tapping with a mallet may be required) after which you should be able to pull out the motor/gearbox assembly.



For servicing the solenoid, please read this, should not be a biggie (after you have access):

https://www.sailfeed.com/2014/01/how...t-of-10-times/

If you are feeling rich you could get a new Lofrans Tigres 1500W (my personal favorite) from UK for less than £800 plus shipping and taxes. that is about half price compared to defender price in the USA.

Best regards,
Erik

[Boston Blackie]

I am relocating a replacement Lewmar windlass relay behind the now waterproof anchor locker bulkhead in a dedicated box. The old relay in the anchor locker was prone to flooding due to inadequate scuppers. I sealed the bulkhead cutouts with epoxy sploge and a layer of 10oz cloth over the entire bulkhead and tabbing. All wire and hoses now have proper waterproof bulkhead fittings.

[LadyStardust]

Thanks Erik,
Which company did you get that price from, I'm very tempted.

Originally Posted by ErikFinn

Hi Paul,

If you are feeling rich you could get a new Lofrans Tigres 1500W (my personal favorite) from UK for less than £800 plus shipping and taxes. that is about half price compared to defender price in the USA.

Best regards,
Erik

[LadyStardust]

It looks like the four screws on each side hold the motor/gearbox in place. However the motor/gearbox is a sealed non serviceable part, so removing it wont allow my to do anything, other than access the solenoid. Also removing it from the casing will break the gasket seals on each side. The corrosion around the join between the case and the gearbox looks bad, and I expect I might do irreversible damage removing it.
Instead I checked the brushes and armature, which were in good condition and I have run an extra cable from the motor, out of the unit, and bypassed the solenoid. I now have the new solenoid mounted in the chain locker, along with a cheap ebay remote winch control and I'm able to go up and down at last.
I might get another year or two out of the Windlass, in the meantime I will try to get a replacement ready on board, probably the tigres 1500 which seems to be a higher spec anyway.

[double u]

if at all possible change over to a vertical-axis windlass!

[LadyStardust]

Yes, I can see the advantages, especially the extra grip on the chain, however I have a massive wooden bowsprit the windlass sits on top of, and to fit a vertical job will require a fair bit of carpentry or glasswork.

[double u]

...& to move it back a lot?

[ErikFinn]

Originally Posted by LadyStardust

Thanks Erik,
Which company did you get that price from, I'm very tempted.

I just googled something like "Lofrans Tigres windlass price UK"; most prices were including VAT (I believe 20% in England now?), so tax free price at lowest was about GBP 790 or a tad under USD1100.
You should not be liable to pay UK VAT now, right? Of course shipping is not cheap to the other side of the planet.. And how about taxes at your current location?
I believe Lofrans is an Italian company and that might explain the double price in USA, due to distribution costs. I didn't check italian prices or if the factory sells direct though, in theory should be cheaper but on the other hand Italy is known for high prices.