Lewmar CRW 400 User manual

CRW 400 - Product Manual

2
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
A
C
B
35m (115) of 6mm (/”) rope
A B C
mm in mm in mm in
365 14 ⁄ 303 11 ⁄ 188 7 /
MODEL MOTOR
SUPPLY
MOTOR
POWER
MAXIMUM LINE
SPEED
MAX ANCHOR
WEIGHT
NORMAL
CURRENT
DRAW
WEIGHT
Voltage Watt m/min. ft/min. kg lb Amp kg lb
CRW400 12 400 25 82 16 40 15 8.5 19
GB
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 | 3
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
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:
1
25mm (1”)minimum
deck thickness
2
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 (/”) drill bit
• 12mm (/”) drill bit
• Sealant
• 4 M8 (/”) 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.
GB
3

Lewmar CRW400 Windlass Manual Ref B10416 iss.2 | 5
4.5 Above deck fitting
Remove the lid from the unit by removing the 4 screws (2 on each side of the unit) and liing 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 (/” ) 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 (/”) mounting bolts, with washers,
through the holes. Likewise, if the power wires are being fed under-deck, push the wires through the 12mm
(/”) hole and seal to avoid water ingress using extra sealant. Take extreme care not to pinch the wires
between deck and chassis.
31 2
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 - /”
DO NOT use a permanent
adhesive/sealant eg.5200
Place the unit to one side and using an 8.5mm (/”) diameter drill bit, make four holes for the mounting
bolts and, if required, use a 12mm (/”) drill bit to make the hole for the power wires (optional).
Location of 12mm
hole for power wires
Cable tie

6
5- Electrical wiring
CABLE SIZING FOR LENGTH OF CABLE RUN
Up to 14 m Up to 40  15 - 24 m 41 - 66 
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%.
GB
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.
A
B
Battery
12V DC
Cable Colours
A = Red
B = Black
Power
Disconnect
Circuit
Protection

Lewmar CRW400 Windlass Manual Ref B10416 iss.2 | 7
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
dris 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 (115) 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!

8
7- Servicing
The service period is determined by the frequency of use. Professional users will need to carry out these
operations more oen 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 oen.
• Check mounting bolts are tight and tighten if required.
Annually or more oen 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
GB

Lewmar CRW400 Windlass Manual Ref B10416 iss.2 | 9
9. Parts list
1
2
3
5
6
7
8
13
14
49
16
17
18
19
26
27
28
29
30
31
32
37
38
40
10
11
12
24
25
33
4
9
23
39
21
20
22
36
41
43
42
46
45
44
47
48

10
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 Sha 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)
GB