Lewmar HX1 Horizontal Windlass

1. Introduction

Dear Customer,

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. Details are available at: www.lewmar.com.

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. The types of warnings, what they look like, and how they are used in this manual are explained as follows:

⚠️ WARNING! This is a warning against anything which may cause injury to people if the warning is ignored. You are informed about what you must or must not do in order to reduce the risk of injury to yourself and others.

[SAFETY SYMBOL] When you see the safety symbol, it means: "Do not..."; "Do not do this"; or "Do not let this happen".

2. Safety Notice

IMPORTANT: Read these notes before continuing.

⚠️ WARNING!

2.1 Windlass General

Classification Societies and Lewmar require that a vessel at anchor must have its chain/rode held by a chain stopper or equivalent strong point 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. An anchor windlass is mounted in an exposed position and is subject to severe atmospheric attack, leading to corrosion. 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 maintained.

Ensure you thoroughly understand the operation and safety requirements before commencing installation. Only persons familiar with the controls and correct use should operate it. Seek advice from a qualified engineer if in doubt.

• Windlasses used incorrectly could cause harm to equipment or crew.
• Windlasses should be used with care and treated with respect.
• Boating is hazardous; proper equipment use cannot eliminate all danger.
• Lewmar windlasses are designed for marine anchor control only.
• Keep limbs, fingers, clothing, and hair clear of the 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, especially under storm conditions. Anchors should be independently secured.
• Classification Societies require anchor rope/chain to be secured to a chain stopper or other suitable independent strong point.
• Never use the windlass as a mooring bollard; secure the anchor rode to a mooring cleat or strong point. Using the windlass for mooring will damage it.
• Do not use the windlass for any purpose other than anchor deployment and recovery.
• The circuit breaker must never be deactivated or bypassed; it protects the motor and cables.
• Always switch off the windlass at the circuit breaker/isolator when not in use.
• The owner/master is responsible for assessing the risk of any operation.
• Windlass must not be operated under the influence of alcohol or drugs.

2.2 Fitting

• Install and operate this equipment according to the manual. Failure to do so could result in poor performance, injury, or damage.
• Consult the boat manufacturer regarding the strength or suitability of the mounting location if in doubt.

2.3 Electrical

• Ensure the boat's battery power supply is switched off before starting installation.
• This product requires installation by a suitably qualified electrical engineer.

3. Installation

3.1 Basic Requirements

Tools required:

• Windlass Installation: Appropriate marine sealant, Jigsaw, Electric drill with 10mm (3/8"), 12mm (1/2"), and 14mm (9/16") drill bits.
• Wiring Installation: Crimping Pliers / Wire Stripper, Suitable electrical cable and crimp terminals.

3.2 Accessories

Use only genuine Lewmar parts and accessories for top performance and to avoid voiding your warranty. For replacement parts, visit your dealer or www.lewmar.com.

3.3 Gypsy Suitability

The HX1 windlasses are suited for Lewmar's factory-made Rope/Chain combination rodes. Ropes used must be windlass grade, medium lay nylon. Variations in ropes from different manufacturers may require experimentation to determine the optimum size. Consult your local agent or Lewmar distributors if you have difficulty matching your chain to the gypsy.

3.4 Above Deck Preparation

IMPORTANT: Plan location carefully, considering the vessel's bow roller and chain locker. Allow for the rotation of the manual operating wrench handle.

If the deck is not flat, a suitable mounting pad may be required. Consult a qualified marine engineer if unsure about the pad's construction. The deck is integral to securing the windlass and must withstand high torque stresses. Thin decks or those with foam/balsa laminate construction will require reinforcement.

Lewmar recommends a minimum deck thickness of 25mm (1"). M8 Studs suit deck and packing thickness of 25-60mm (1" - 21/4").

Diagram Description: Shows drilling template and placement for windlass installation, including measurements for deck thickness.

3.5 Below Deck Preparation

IMPORTANT: Check positioning for deck/hull and bulkhead clearance before cutting.

The lead from the roller should be horizontal to the gypsy's centre line (within ±6°). There must be sufficient vertical fall (minimum 300mm / 12") for the chain or rope when hauling in.

⚠️ WARNING! Failure to provide minimum vertical fall will cause jamming.

Diagram Description: Illustrates the required horizontal lead and minimum vertical fall for the anchor rode below deck.

3.6 Above Deck Fitting

Using the template, cut the necessary holes: 10mm drill for mounting studs and chain hole; 12mm drill for the chain hole; 14mm drill for motor and chain sensor wires.

1. After cutting holes, remove the template. Apply marine sealant to the cut edges to prevent water absorption.
2. Assemble and tighten studs into the base until they bottom out. Position the flats of the studs nearest the base of the windlass.
3. Place the windlass in position. Optionally, apply sealant to the base of the windlass, mounting pad, or around the studs.

Diagram Description: Shows steps for cutting holes, applying sealant, and fitting studs.

3.7 Under Deck Fastening

Fit the windlass to the deck. Trim the studs back to 6mm (1/4") below the fully tightened nuts to prevent snagging the anchor rope/chain.

NOTE: If using silicone or rubbery sealant, allow it to cure before final tightening of mounting nuts. DO NOT use permanent adhesive/sealant (e.g., 5200).

Diagram Description: Shows trimming studs to 6mm (1/4") below the nut.

3.8 Loading Rope/Chain

For safety and performance, Lewmar recommends matched Lewmar anchor rodes.

⚠️ WARNING! Isolate (turn off) the windlass using the circuit breaker/isolator.

1. Pull out the control arm (do not use excessive force).
2. Feed anchor rope/chain into the entry hole. Tie off to a suitable strong point in the anchor locker.
3. Align rope/chain in the gypsy. Release the control arm and wrap rope/chain around the gypsy.
4. Turn on the breaker and power load the rest of the anchor rope/chain.

Diagram Description: Illustrates the steps for loading rope/chain onto the windlass.

4. Electrical Wiring

4.1 Electric Cable Selection

Installation must meet relevant regulations (e.g., ISO 10133). Lewmar recommends cable with insulation rated at 90°C or higher. Cable length calculation includes the return path to the battery, including breaker and switch gear.

Cable size guide is for guidance only. The installer is responsible for confirming capacity and voltage drop. Contact a marine electrician if in doubt.

4.2 Wiring

Plan the installation to suit controls and provide a clear view of the windlass. Use a fully insulated wiring system to avoid electrolytic corrosion. Lewmar recommends type III stranded, tinned copper wire with copper crimp terminals.

• Overload protection via the provided circuit breaker must be integrated into the wiring circuit.
• Circuit breakers supplied: HX1 500 - 50A (Part No 68000348), HX1 800 - 70A (Part No 68000240).
• Position the circuit breaker close to the battery in a readily accessible place, conforming to regulations.
• The breaker must be manually reset after tripping.

Contact your local marine electrician if in doubt.

4.3 Control Switch Installation

The unit is supplied with:

• Guarded rocker switch (product ref 68000593)
• Contactor (product ref 68000939)

Follow the wiring diagram (Section 4.4).

Optional electric foot switches and remote handheld control are available. Visit www.lewmar.com for more information.

Optional wireless remote also available.

Diagram Description: Wiring diagrams are provided for different configurations: 4.4 using a contactor, 4.5 using a contactor box, and 4.6 using a pre-wired control box. These diagrams illustrate connections between the windlass, battery, circuit breaker, switches, and optional controls.

5. Operation

5.1 Manual Controlled Free-Fall Gypsy Only

Use this method for quicker anchor deployment, in emergencies, or to save battery power. Observe maritime anchor deployment safety rules.

1. Engage the circuit breaker/isolator and press the UP button.
2. Release any anchor locks.
3. When safe, insert the Lewmar wrench into the windlass drive cap. Rotate clockwise to grip the gypsy and anticlockwise to free it, controlling the anchor's descent rate. Lock the clutch by turning the drive cap clockwise and engage anchor locks.
4. To return to powered operation, lock the clutch by rotating the drive cap clockwise until tight and remove the wrench handle.
5. Engage the circuit breaker/isolator and press the UP button.
6. NOTE: If the clutch nut is not tight, the internal clutch mechanism will rotate freely and not engage the gypsy.

⚠️ WARNING! Always remove the wrench handle after use.

Diagram Description: Illustrates the steps for manual free-fall operation using the gypsy.

5.2 Manual Controlled Free-Fall Gypsy Drum

Follow similar steps as 5.1, using the drum top cap instead of the drive cap.

1. Engage the circuit breaker/isolator and press the UP button.
2. Release any anchor locks.
3. When safe, insert the Lewmar wrench into the drum top cap. Rotate clockwise to grip the gypsy and anticlockwise to free it, controlling the anchor's descent rate. Lock the clutch by turning the drum cap clockwise, and engage anchor locks.
4. To return to powered operation, lock the clutch by rotating the drum top cap clockwise until tight and remove the wrench handle.
5. Engage the circuit breaker/isolator and press the UP button.
6. NOTE: If the drum cap is not tight, the internal clutch mechanism will rotate freely and not engage the gypsy.

⚠️ WARNING! Always remove the wrench handle after use.

Diagram Description: Illustrates the steps for manual free-fall operation using the gypsy drum.

5.3 HX1 Gypsy Only Operation

To release anchor:

1. Check top cap is tight. If the clutch nut is not tight, the internal clutch will rotate freely and not engage the drive.
2. Release any anchor locks.
3. Engage the circuit breaker/isolator. Press the DOWN button.

To retrieve anchor:

4. Press the UP button continuously to retrieve the anchor.

Note: If the clutch nut is not tight, the internal clutch will rotate freely and not engage the drive.

Diagram Description: Shows steps for releasing and retrieving the anchor using the gypsy only.

5.4 HX1 Gypsy Drum Operation

To release anchor:

1. Check top cap is tight. If the clutch nut is not tight, the internal clutch will rotate freely and not engage the drive to the capstan.
2. Release any anchor locks.
3. Engage the circuit breaker/isolator. Press the DOWN button.

To retrieve anchor:

4. Press the UP button continuously to retrieve the anchor.

Note: If the clutch nut is not tight, the internal clutch will rotate freely and not engage the drive.

Diagram Description: Shows steps for releasing and retrieving the anchor using the gypsy drum.

5.5 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. Vessels at anchor will snub on the rode, causing slippage or excessive loads. Best practice is to use a bollard or strong point when at anchor and use the vessel's engines to break the anchor free. Otherwise, excessive load can seize the free-fall function and damage the gearbox.

• When retrieving anchor, do not overload or stall the windlass. The rode should be secured directly to a bollard, sampson post, or cleat, and chain secured by a chain stopper.
• When anchoring, power rode out, allowing the vessel to move stern away, preventing rode tangling. Use this method for mooring stern first to a jetty.
• To aid recovery, under power, move the vessel towards the anchor but not over and beyond it, as this can cause damage to the topside.
• As the anchor approaches, use careful control adjustments to avoid damaging the 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 stowing, ensure there is at least 300mm (12") of free space below the windlass, especially with rode lines. Check during stowing to determine sufficient space. If the rode pile is too close to the underside of the windlass, redistribute it. This can cause problems with rode recovery and damage the line.

Diagram Description: Illustrates correct and incorrect anchoring and recovery procedures, emphasizing securing the rode and avoiding overloading.

6. Servicing

⚠️ WARNING! Isolate the windlass using the circuit breaker/isolator.

⚠️ WARNING! Ensure rode is adequately secured to an independent strong point.

6.1 Servicing Schedule

Service frequency depends on usage. Professional users may need to perform operations more often.

Bedding-in Period:

Check electrical connections for soundness and corrosion; tighten and protect if necessary. Check mounting studs are firmly clamped and tighten if required.

After Use:

• Wash down the windlass with fresh water.
• Ensure rode is at least 12" (300mm) below the windlass.
• Check anchor locker drain.
• Check rode and splice for wear.

Annually (or more often for frequent users):

• Examine all electrical connections for soundness and corrosion; tighten and protect if necessary.
• Check mounting studs are firmly clamped and tighten if required.
• Check rode and splice for wear.
• Check gypsy for wear (see Section 8.2 for service/replacement).
• Check main case for damage, particularly around the seal and cover.

6.2 Gypsy Replace/Fitment on Gypsy Only Version

Steps involve releasing clamp nut, removing components, pulling control arm, removing gypsy, and reassembling with grease.

Diagram Description: Shows steps for replacing the gypsy on the Gypsy Only version.

6.3 Gypsy Replace/Fitment on Gypsy Drum Version

Steps involve removing drum top cap, removing components, pulling control arm, removing gypsy, and reassembling with grease.

Diagram Description: Shows steps for replacing the gypsy on the Gypsy Drum version.

6.4 Control Arm Replacement

Steps involve removing gypsy, rear casing, control arm spring, and control arm screw. Inspect gear train and bearings, re-grease if needed, and reassemble, ensuring the gasket is correctly seated.

Diagram Description: Shows steps for replacing the control arm and rear cover.

7. Free-fall Kit

7.1 Fitting

Steps for fitting the HX1 Free-fall actuator include removing the gypsy, ensuring location pins are fitted, push-fitting the actuator, securing with a screw, refitting the gypsy, placing washers/shims, fitting the Free-Fall cap, and securing the cap screw.

Diagram Description: Illustrates the steps for fitting the HX1 Free-fall actuator.

7.2 Power Up/Down

To release anchor:

1. Check unit is not in manual mode (button released, plunger extended).
2. Release any anchor locks.
3. Engage the circuit breaker/isolator. Press the DOWN button until the anchor is under free-fall. If the clutch was locked, the anchor moves immediately; if unlocked, it may take seconds to re-engage.
4. NOTE: Pressing DOWN for over 5 seconds may increase clutch re-engagement time.
5. If using rope/chain, motor astern to create scope. Press UP continuously until free-fall stops. Re-engagement takes seconds.
6. NOTE: Failure to lock the windlass clutch could result in rope/chain creeping out.

To retrieve anchor:

4. Press the UP button continuously to retrieve the anchor.

Diagram Description: Shows steps for releasing and retrieving the anchor using power.

7.3 Manual Controlled Free-Fall

Use for quicker anchor deployment, emergencies, or saving battery power. Observe safety rules.

⚠️ WARNING! Isolate (Turn off) the windlass using the circuit breaker/isolator.

⚠️ WARNING! Trapping, crushing, or entanglement danger whilst operating manually or under power.

1. Disengage the drive by pressing the plunger button on the Free-Fall drive cap and pressing the locking button until the plunger is down.
2. Release any anchor locks.
3. When safe, insert the Lewmar wrench into the capstan drive cap. Rotate clockwise to grip the gypsy and anticlockwise to free it, controlling descent. Adjust scope if needed, lock the clutch by turning the drive cap clockwise, and engage anchor locks. Remove the wrench handle.
4. To return to powered operation, pull the locking button out, disengaging the plunger. Engage the circuit breaker/isolator and press the UP/DOWN button.

⚠️ WARNING! Always remove the wrench handle after use.

Diagram Description: Illustrates the steps for manual controlled free-fall operation.

7.4 Gypsy Replace/Fitment on Gypsy Free-Fall Version

Steps involve undoing a locking screw, removing components, pulling the control arm, removing the gypsy, and reassembling with grease and thread lock.

Diagram Description: Shows steps for replacing the gypsy on the Gypsy Free-Fall version.

7.5 Auto Anchor Fitting

Steps include removing the rear casing, removing the existing sensor, fitting the sensor into the Auto Anchor bracket and mount, inspecting the unit for wear, and reassembling. Note: Gasket is bonded to the cover.

Diagram Description: Illustrates the steps for fitting the Auto Anchor sensor.

8. Specifications

8.1 Parts List

Diagram Description: An exploded view diagram of the windlass with numbered components is provided.

8.2 HX1 Dimensions

Tables and diagrams provide detailed dimensions for the windlass and compatibility with various chain sizes (e.g., 6mm ISO 4565, 8mm Din766, 1/4" G40, 1/4" BBB) and rope sizes.

Diagram Description: Shows diagrams illustrating windlass dimensions (W, P, D) and chain center line.

8.3 HX1 Deck Mounting Detail

Diagram provides details for deck mounting, including hole sizes, spacing, and anchor rode centerline.

Diagram Description: Shows deck mounting details with dimensions and hole placements.

8.4 Electric Specifications

Tables detail electrical specifications including power options, motor ratings, typical pull, maximum line speed, typical working load, current draw, weight, and required circuit breakers.

*Values tested at +/- 10% on 12/24V system typical of electric systems installed on boats.

9. Troubleshooting

1. Anchor rode pays out independently while windlass is not in use: This is due to not securing the anchor rode and a slack gypsy drive cap. Tighten the gypsy drive cap with the winch handle and always secure the anchor rode independently when not in use.
2. Failure to operate or sluggish operation: Most problems are electrical. Ensure proper voltage (13.5V for 12V systems) is maintained; low voltage can damage the motor. Ensure electrical cable size is adequate for current draw and keeps voltage drop within limits. Check control switches, connections, battery condition, isolator switch, fuse, and motor.
3. Failure to operate:
   • Check for voltage at input terminals to contactor and switches. Check circuit breaker/isolator and fuses.
   • Operate the switch. Check for voltage at the solenoid's positive switch terminal. If absent, the switch or wiring is defective.
   • Keep the switch activated. Check for voltage at the contactor's main output terminal. If absent, check the contactor coil ground circuit; if okay, replace the contactor.
   • Check voltage at the motor. If voltage of at least 12.5V is present and the motor doesn't operate, the motor is defective.

10. Warranty

Lewmar warrants products for three years from purchase date for normal private pleasure boat usage with proper maintenance. Defects will be repaired or replaced at Lewmar's option.

Conditions and Limitations:

• Liability limited to repair or replacement of defective parts.
• Buyer is responsible for product selection appropriate for intended use.
• Lewmar is not liable for failure arising from: improper application, corrosion/wear, failure to service, faulty installation (unless by Lewmar), modification, exceeding specifications, or abuse.
• Warranty claims require returning the product to the Lewmar outlet that supplied it, unless otherwise approved.
• Warranty does not cover incidental costs for investigation, removal, carriage, or installation.
• Service by unauthorized personnel voids warranty.
• Products are intended for marine environments only.

Exceptions:

Warranty is limited to one year for electric motors, electronic controls, hydraulic pumps/valves/actuators, hatch/portlight seals, products used in racing, commercial, or charter applications, and anchor rodes.

Liability:

Lewmar's liability is exclusive of other warranties. It does not cover loss of profit, consequential damages, third-party expenses, damage to yachts/equipment, or death/personal injury (unless caused by Lewmar's negligence).

Some regions may not allow limitations on incidental or consequential damages.

No other warranties are granted regarding fitness for purpose, use, nature, or satisfactory quality.

Implied warranties, if not excludable by law, are limited to one year.

Procedure:

Claims must be made promptly and in writing to the Lewmar outlet or Lewmar Limited, Southmoor Lane, Havant, Hampshire PO9 1JJ, England.

Severance Clause:

If any clause is held invalid, the rest remain effective.

Other Rights:

This warranty grants specific legal rights, which may vary by location. Consumer rights under national law are unaffected.

Law:

Governed by the laws of England or the buyer's domicile country.

Disputes:

Disputes may be referred to alternative dispute resolution or the courts of the governing state/country.

Contact Information

UK & International Distribution

Lewmar
Southmoor Lane
Havant
Hampshire
PO9 1JJ
England
Tel: +44 (0)23 9247 1841
Fax: +44 (0)23 9248 5720
Email: info@lewmar.com

USA

Lewmar
351 New Whitfield Street
Guilford, CT
06437
USA
Tel: +1 203 458 6200
Fax: +1 203 453 5669
Email: info@lewmarusa.com

Website: www.lewmar.com

Part No: 65140050 iss.2

Copyright 2017 Lewmar Ltd. All rights reserved.