Lewmar CRW 400 Product Manual - User Manual

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CRW 400 - Product Manual

1- Introduction

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.

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, or your local Lewmar

dealer.

CE Approvals

For CE approval certificates contact Lewmar.

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.

2- Specifications

35m (115ft) of 6mm (1/4”) rope

365 14 3/8 303 11 15/16 188

7 2/5

MODEL

MOTOR

SUPPLY

MOTOR

POWER

MAXIMUM LINE

SPEED

MAX ANCHOR

WEIGHT

NORMAL

CURRENT

DRAW

WEIGHT

Voltage

Watt

m/min. ft/min.

Amp

CRW400

400

8.5

WARNING!

Only genuine Lewmar-supplied replacement rope kit should be used. This is

critical to the correct function of the unit. The auto-stop and level-wind features

will not work if you do not use the genuine Lewmar rode kit and serious damage to

the unit could result.

Lewmar CRW400 Windlass Manual Ref B10416 iss.2

WARNING!

3- Safety Notice

IMPORTANT: Read these notes before continuing.

3.1 Windlass general

At all times it is the responsibility of the boat operator 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 accidentally deploying while 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.

• Keep limbs, fingers, clothing and hair clear of windlass, rode and anchor during operation. Severe bodily

harm could result.

• Ensure there are no swimmers or divers nearby when dropping anchor.
• Windlasses must not be used as the sole means of securing the anchor to the bow fitting especially under

storm conditions. Anchors should be independently secured to prevent accidental release.

• Classification Societies require that a vessel lying at anchor must have its anchor rope/chain secured to a

chain stopper or other suitable independent strong point.

• A windlass should never be used as a mooring bollard, the anchor rode MUST be secured to a mooring

cleat, chain stopper or other designated strong point. Using the windlass to secure the rode will damage

the windlass.

• Do not use windlass for ANY purpose other than deployment and recovery of anchor.
• The circuit breaker in this product must never be deactivated or otherwise bypassed, it is intended to

protect the motor and cables from overheating and damage.

• Always switch off this windlass at the circuit breaker/isolator when not in use.
• It is the unavoidable responsibility of the owner, master or other responsible party to assess the risk of any

operation on the vessel.

• Windlass must not be operated whilst under the influence of alcohol or drugs.

3.2 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 your

boat.

• Consult the boat manufacturer if you have any doubt about the strength or suitability of the mounting

location.

3.3 Electrical

• Make sure that the boat’s battery power supply has been switched off before starting the installation.
• This product requires installation by a suitably qualified electrical engineer.

4- Installation

4.2 Accessories

Use only genuine Lewmar parts and accessories to ensure top performance and eliminate the risk of voiding

your warranty.

4.3 Above deck preparation

IMPORTANT - Plan location carefully and allow for the following:

25mm (1”)minimum

deck thickness

1. 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. 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. Decks

that are thin, or of foam or balsa laminate construction, will require

reinforcement in order to spread the loads that will be applied to the

deck while the windlass is in use.

2. Lewmar recommends a minimum deck thickness of 25mm (1”)

3. The windlass should be placed such that the centre-line of the anchor

shank or bow-roller is coincidental to the centre-line of the windlass

housing.

WINDLASS INSTALLATION
• Electric drill
• 8.5mm (21/64”) drill bit
• 12mm (1/2”) drill bit
• Sealant
• 4 M8 (5/16”) bolts of suitable length, washers, nuts

WIRING INSTALLATION
• Crimping Pliers / Wire Stripper
• Suitable electrical cable and crimp terminals

4.1 Basic requirements

Each installation requires the following tools:

4.4 Below deck preparation

IMPORTANT

: The positioning of the windlass must be checked prior to cutting for deck/hull and bulkhead

clearance for the mounting bolts and wiring (if led below deck).
Lead from the roller should be fed horizontally back to the CRW rope feeder.

Lewmar CRW400 Windlass Manual Ref B10416 iss.2

4.5 Above deck fitting

Remove the lid from the unit by removing the 4 screws (2 on each side of the unit) and lifting up and out of
the locating tabs.

CAUTION - Be aware of wires connected to the controls on the lid. There is enough slack to tilt back

the lid and rotate it around so that it is out of the way during installation.

Lay the chassis in place and mark the location of the 4 mounting holes onto the deck.
If you wish to lead the motor wires below deck, mark a further 12mm (1/2” ) hole in the location shown below.
Alternatively, for above deck installations, lead the wires through the existing chassis hole and secure with a
cable tie as shown below.

1. When all the holes have been made, apply an appropriate marine sealant to the freshly cut hole edges to

help avoid water absorption by the deck.

2. When you are ready to finally install the windlass, apply sealant around all the deck holes. Position the

windlass appropriately.

3. Apply some extra sealant into the deck holes and then push four M8 (5/16”) mounting bolts, with washers,

through the holes. Likewise, if the power wires are being fed under-deck, push the wires through the 12mm
(1/2”) hole and seal to avoid water ingress using extra sealant.

Take extreme care not to pinch the wires

between deck and chassis.

4.6 Under deck fastening

1. With a helper on deck holding the bolt heads static, tighten

up the nuts below-deck until tight. Nylock nuts or Loctite is

recommended. Use washers.

• 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.

6mm - 1/4”

DO NOT use a permanent

adhesive/sealant eg.5200

Place the unit to one side and using an 8.5mm (11/32”) diameter drill bit, make four holes for the mounting
bolts and, if required, use a 12mm (1/2”) drill bit to make the hole for the power wires (optional).

Location of 12mm

hole for power wires

Cable tie

5- Electrical wiring

CABLE SIZING FOR LENGTH OF CABLE RUN

Up to 14 m Up to 40 ft

15 - 24 m

41 - 66 ft

10 mm²

8 AWG

16 mm²

6 AWG

5.2 Electric cable selection

If the distance to the power source is greater, the wires must be extended appropriately and increased in size

dependant on length. The table below gives a recommended cable specification based on total wiring length

(total wiring length = A+B from wiring diagram below).

5.3 Wiring

The wiring system should be fully insulated, 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.

Lewmar recommends that the installation complies with USCG, ABYC, NMMA or other

local regulations. If you are not sure you understand these guidelines, seek professional

help.

Windlass performance is directly related to cable size and length. Voltage drop over the complete wiring run

must not exceed 10%.

DO NOT confuse cable length

with the length of the vessel

WARNING!

5.1 Power source

The windlass must be connected to a suitable 12V DC supply.

The power source must be suitably sized for the expected duration of windlass use. If using a battery, the

cold-cranking ampere rating must be 300CCA or higher.

The windlass is fitted with an integrated 30A circuit breaker for overload protection. The button will pop out
when overload occurs. Push in to reset. Do not hold button in to attempt to over-ride. DO NOT remove circuit
breaker from unit or otherwise bypass.

The windlass is supplied with a 1m cable to allow through-deck connection to a 12V power source.

Installations must use circuit protection to protect the wiring between the power source and the windlass.
This protection should be rated higher than 30A. Refer to ABYC or equivalent standards for exceptions and
restrictions.

Battery

12V DC

Cable Colours

A = Red
B = Black

Power

Disconnect

Circuit

Protection

Lewmar CRW400 Windlass Manual Ref B10416 iss.2

6- Operation

To drop anchor:

1. Release any anchor locks
2. Hold down on the integrated rocker switch
3. Release button when the desired length of rode

has been deployed.

When anchoring, power rode out allowing the vessel to take up stern away, thus preventing the rode tangling
with anchor and providing enough load to activate the “Load Sense” feature. Use this method also for mooring
stern first to a jetty.

6.1 Standard windlass operating procedures

This is an anchor recovery device. DO NOT use the windlass to pull the boat to the anchor as it will damage
the mechanism. DO NOT use the windlass to free a fauled anchor, use a secure fixed point on the deck to
break the anchor free.

To aid recovery, slowly and safely power the vessel at idle speed towards the anchor but not over and beyond,
as this can cause damage to topsides.

As anchor approaches the bow roller, use careful adjustments of controls to avoid damaging vessel. Start and
stop the windlass to bring the anchor slowly into the bow roller.

Pulling the last bit of rode and anchor into the bow roller at full speed can damage the boat, bow roller and
windlass.

When retrieving anchor do not

overload or stall the windlass.

First check that power is turned on to the windlass and that the circuit breaker is not tripped (push the

button in to reset).

To raise anchor:

1. Hold up on the integrated rocker switch
2. Release when the anchor is approaching the

bow-roller

3. Use the controls carefully until the anchor is

home.

The CRW400 has 2 electrical control features which may affect the expected functionality of the unit when

dropping anchor.

1. “Load Sense” - when the down button is held, there must be a pull on the anchor rode for the CRW’s

electronics to activate the motor.

If no load is present, the motor will not activate.

For instance, as the

anchor hits the sea-bed, you may find the motor stops automatically. As reverse gear is engaged, or the boat

drifts away from the anchor, load will increase and the motor will re-activate.

2. “Auto-Stop” - a sensor on the slider arm and magnet embedded in the anchor line allows the windlass to

automatically cut power to the motor when the unit is close to paying out the full 35m (115ft) length of line.

This prevents damage to the unit by retaining a safe number of wraps on the drum. The line can be retrieved

as normal.

IMPORTANT!

7- Servicing

The service period is determined by the frequency of use. Professional users will need to carry out these
operations more often than the weekend user. Before commencing any work on this or any other electrical
product, isolate from the power source.

Bedding in period:

When new there are some areas that will need frequent checking. If no movement is found they can be
inspected less often.
• Check mounting bolts are tight and tighten if required.

Annually or more often if frequent user:

• Use light machine oil sparingly to lubricate slider arm rails (item 3)
• Examine all electrical connections, to make sure they are sound and corrosion hasn’t set in. Tighten if

necessary and protect if required.

• Check mounting bolts and tighten if required.
• Check rode for wear.
• Check main case for damage

WARNING! Isolate the windlass

using circuit breaker/isolator

WARNING! Ensure rode is adequately

secured to an independent strong point

1. Failure to power anchor down.
• Check that power to the motor is turned on and that the inbuilt circuit breaker is not tripped (press button

in to reactivate), as well as checking the secondary circuit protection device.

• Ensure that there is sufficient load on the windlass - if the load sense device is not detecting load, then the

motor will not turn when down is pressed.

• Ensure that you are not at maximum extension of rope deployment - in this case the reed sensor will

activate and prevent further pay-out, although hauling should still work.

• Check all wiring connections and that voltage is reaching the motor wires when the down button is

pressed. If so, the motor has become defective and must be changed.

2. Failure to power anchor up.
• Check that power to the motor is turned on and that the inbuilt circuit breaker is not tripped (press button

in to reactivate), as well as checking the secondary circuit protection device.

• Operate the up switch. Check voltage is reaching the motor wires. If so, the motor has become defective

and must be changed. If not, then either the PCB or switch gear has become defective and must be
changed.

3. Rope is not laying properly / becoming tangled
• This indicates that the haul speed and slider arm is not synchronised correctly for the rope.
• Rope specification is crucial to the correct functioning of the unit and therefore only the genuine Lewmar

CRW rope kit.

8- Troubleshooting

Lewmar CRW400 Windlass Manual Ref B10416 iss.2

9. Parts list

KIT NO

DESCRIPTION

ITEMS INCLUDED (QTY)

66000777

Side Gears Kit

11(1), 10(2). 33(2)

66000778

Worm Gear Kit

2(1), 49(1)

66000779

Slider Arm Assembly

16(1)

66000780

Drum/Rope Kit

14(1), 19(1)

66000781

Motor Kit

13(1)

66000782

PCB Kit

9(1), 22(4), 23(4), 36(4)

66000783

Cover Kit

6(2), 7(2),17(1), 28(2), 29(2)

66000784

Gear Housing Kit

8(1), 15(1)

66000785

Worm Drive Shaft Kit

4(1), 32(2), 39(1), 37(1), 10(1), 33(1)

66000786

Electrics Kit

46(1), 44(1), 48(1), Reed Sensor(1), Loom (1)

66000787

Fastenings Kit

20(2), 21(1), 22(4), 24(1), 25(1), 26(11), 27(1), 28(2), 29(2), 31(1), 33(2), 36(4), 37(4), 38(1),

39(2), 40(1), 43(2)

Lewmar CRW400 Windlass Manual Ref B10416 iss.2

9- Warranty

Lewmar warrants that in normal private pleasure boat

usage and with proper maintenance its products will

conform with their specification for a period of three years

from the date of purchase by the end user, subject to the

conditions, limitations and exceptions listed below. Any

product which proves to be defective in normal usage during

that three-year period, will be repaired or, at Lewmar’s

option, replaced by Lewmar.
A CONDITIONS AND LIMITATIONS
i Lewmar’s liability shall be limited to the repair or

replacement of any parts of the product which are

defective in materials or workmanship.

ii Responsibility for the selection of products appropriate

for the use intended by the Buyer shall rest solely with

the Buyer and Lewmar accepts no responsibility for any

such selection.

iii Lewmar shall not be liable in any way for Product failure,

or any resulting loss or damage that arises from:

a. use of a product in an application for which it was not

designed or intended;

b. corrosion, ultra violet degradation or wear and tear;
c. a failure to service or maintain the product in

accordance with Lewmar’s recommendations;

d. faulty or deficient installation of the product (unless

conducted by Lewmar);

e. any modification or alteration of the product;
f. conditions that exceed the product’s performance

specifications or safe working loads.

g. Abuse

iv Product subject to a warranty claim must be returned

to the Lewmar outlet that supplied the product for

examination unless otherwise approved by Lewmar in

writing.

v This warranty does not cover any incidental costs

incurred for the investigation, removal, carriage,

transport or installation of product.

vi Service by anyone other than authorized Lewmar

representatives shall void this warranty unless it accords

with Lewmar guidelines and standards of workmanship.

vii Lewmar’s products are intended for use only in the

marine environment. Buyers intending to use them for

any other purpose should seek independent professional

advice as to their suitability. Lewmar accepts no liability

arising from such other use.

B EXCEPTIONS

Cover under this Warranty is limited to a period of one

year from the date of purchase by the end user in the case

of any of the following products or parts of products:

• Electric motors and associated electrical equipment
•  Electronic controls
• Hydraulic pumps, valves and actuators
•  Hatch & Portlight weather seals
• Products used in “Grand Prix” racing applications
• Products used in commercial or charter applications
•  Anchor rodes
C  LIABILITY
i   Lewmar’s liability under this warranty shall be to the

exclusion of all other warranties or liabilities (to the

extent permitted by law). In particular (but without

limitation):

a. Lewmar shall not be liable for:
• Any loss of anticipated turnover or profit or indirect,

consequential or economic loss;

• Damages, costs or expenses payable to any third party;
• Any damage to yachts or equipment;
• Death or personal Injury (unless caused by Lewmar’s

negligence).
Some states and countries do not allow the exclusion or

limitation of incidental or consequential damages, so the

above limitation or exclusion may not apply to you

b. Lewmar grants no other warranties regarding the fitness

for purpose, use, nature or satisfactory quality of the

products.

ii Where applicable law does not permit a statutory or

implied warranty to be excluded, then such warranty, if

permitted by that state or country’s law, shall be limited

to a period of one year from the date of purchase by

the end user. Some states and countries do not allow

limitations on how long an implied warranty lasts, so this

limitation may not apply to you.

D PROCEDURE

Notice of a claim for service under this warranty shall

be made promptly and in writing by the end user to the

Lewmar outlet that supplied the product or to Lewmar

Limited.

E SEVERANCE CLAUSE

If any clause of this warranty is held by any court or other

competent authority to be invalid or unenforceable in

whole or in part, the validity of the remaining clauses of

this warranty and the remainder of the clause in question

shall not be affected.

F OTHER RIGHTS

This warranty gives you specific legal rights, and you may

also have other legal rights, which vary from state to

state and country to country.
In the case of European States a Consumer customer (as

defined nationally) has legal rights under the applicable

national law governing the sale of Consumer Goods; this

Warranty does not affect those rights.

G LAW

This warranty shall be governed by and read in

accordance with the laws of England or the state or

country in which the first end user is domiciled at the time

of purchase of the product.

H DISPUTES

Any dispute arising under this warranty may, at the

option of the end-user, be referred to alternative

dispute resolution under the rules of the British Marine

Federation or to the Courts of the State whose law shall

govern the warranty or to the Courts of England and

Wales.

Limited Warranty and Key Terms of Supply by Lewmar

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