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OWNER'S MANUAL

Deck preparation, single and multi-station wiring with cable sizes, powered freefall operation, servicing, specifications and service kits for the Lewmar H600 and H900 freefall horizontal windlasses (Horizon 600/900f).

DocumentLewmar H600/900 Freefall Horizontal Windlass Owner's Manual
FormatPDF · 28 pages · 3.0 MB
LanguageEnglish
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Owner's ManualPDF · 28 p.Parts list (Horizon 600/900 Freefall)PDF · 2 p.
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SpecificationsInstallationWiringOperationServicingService KitsProducts
Lewmar H600/900 Freefall Horizontal Windlass — Owner's Manual

Specifications

Model Motor Max pull, chain Max pull, rope Recovery load Line speed at recovery load Current at recovery load
H600f – 12V 400 W output
550 W input 		280 kg
625 lb 		280 kg
625 lb 		50 kg
110 lb 		19 m/min
62 ft/min 		45 A
H900f – 12V 600 W output
750 W input 		410 kg
900 lb 		410 kg
900 lb 		50 kg
110 lb 		24.5 m/min
80 ft/min 		70 A
H900f – 24V 600 W output
750 W input 		410 kg
900 lb 		410 kg
900 lb 		50 kg
110 lb 		30 m/min
98 ft/min 		35 A

Weight: 8.2 kg (18 lb), all three versions. Maximum boat length (LOA): Horizon 600f 10.7 m (35'), Horizon 900f 14.3 m (47').

Preparation & Fitting

  • Make sure the rope/chain feeds correctly and its centre line matches the bow roller; the rode should not come in more than 6° above the gipsy.
  • Leave at least 300 mm (12") between the underside of the deck and the stowed rode.
  • Uneven decks need a mounting pad; reinforce lightweight decks. Decks thicker than 130 mm (5 1/8") need longer studs.
  • Fix the template in line with the rode centre line; drill the 3 stud holes (10 mm, 13/32") and the cable hole, and cut 2 × 45 mm (1 3/4") holes for the rode. Clear the chain pipe hole and seal the cut edges with marine paint, gel coat or two-pack epoxy.
  • Screw the studs in firmly using two plain nuts locked together, then discard the nuts. Bed on silicone – never a permanent adhesive/sealant – part-tighten the nyloc nuts, let the sealant set, then tighten fully without crushing the deck. Trim the studs if they could snag the rode.
  • Allow for the rope to coil below deck without knots or jams that would obstruct freefall.

Safety Notes

  • Neither the windlass nor its mounting is designed for anchoring loads in a storm: ride on an independent strong point and secure the anchor at the bow fitting.
  • Automatic freefall needs the anchor and rode to run freely: knots in the rope restrict or stop it.
  • Always switch off at the breaker/isolator when not in use, or a press of DOWN can freefall the anchor.
  • Rope/chain rodes: three-strand rope only, joined with a tight tapered back splice.
  • Before loading the rode, power the windlass UP so the gipsy is in drive, not freefall.

Wiring & Cable Sizes

  • Plan the wiring so the operator has a full view of the windlass; marine grade copper wire with copper crimp terminals; connect to the starter battery where possible, separate from other wiring.
  • Keep the control box/solenoid and breaker dry; wire all switches in parallel. If the windlass runs the wrong way, swap the cable connections at the motor.
  • Comply with USCG, ABYC, NMMA or local regulations; add a grounding strap between the mounting studs and an earthing point if necessary.
  • Switch wire: 1.5 mm² (14 AWG). Main cable size depends on the total length A + B + C + D + E, battery to windlass and back.
Model Motor Breaker / isolator Contactor
H600f 12V 50A (68000348) 0052531
H900f 12V 70A (68000240) 0052531
H900f 24V 50A (68000348) 0052508

Maximum total cable length (A + B + C + D + E)

Model 6 mm² (8 AWG) 10 mm² (6 AWG) 16 mm² (4 AWG) 25 mm² (2 AWG) 35 mm² (1 AWG)
H600f – 12V 10.7 m (35 ft) 19.8 m (65 ft) 27.4 m (90 ft) – –
H900f – 12V – – 15.2 m (50 ft) 25.9 m (85 ft) 32.0 m (105 ft)
H900f – 24V 22.8 m (75 ft) 33.5 m (110 ft) – – –
Part no. Switchgear item
68000348 Circuit breaker/isolator 50 A (H600f 12V, H900f 24V) View part →
68000240 Circuit breaker/isolator 70 A (H900f 12V) View part →
68000593 Guarded rocker switch View part →
68000598 Deck foot switch set, black Ask us to source it →
68000597 Deck foot switch set, white Ask us to source it →
68000599 Hand held control Ask us to source it →
0052531 Contactor 12V Ask us to source it →
0052508 Contactor 24V Ask us to source it →

Safety, Use & Freefall

  • Check for swimmers and keep clear of the moving rode. Do not overload or stall the windlass; the splice should not sit in the windlass with the anchor raised.
  • Freefall: press DOWN for 2 seconds until the anchor is in freefall. Pressing DOWN for 5+ seconds gives a clutch re-engagement time of up to 30 seconds on the next UP.
  • Once the scope is out, press UP continuously until freefall stops; about 10 seconds fully re-engages the internal clutch and locks the windlass, otherwise the rode can creep out.
  • Motor astern or drift to set the anchor; press UP continuously to recover.
  • With rope/chain rodes the rope must be free of knots and hockles: periodically pay the rode out while motoring astern in deep water to clear them.
  • Secure the anchor at the bow fitting and ride on an independent strong point; isolate the windlass when not in use.

Servicing

  • Regularly: wash down with fresh water; check mounting bolts and nuts; clean and lightly grease the electrical connections.
  • Annually: check the electric cables; strip, clean and lightly grease the above-deck components.
  • Motor removal: isolate; disconnect the motor cables; remove the 3 under-deck nuts and take the windlass to the workshop; remove the 7 (4 mm AF) gear case socket screws and the gear train cover, the 3 (4 mm AF) motor cover screws, then the 3 (5 mm AF) motor screws. Reverse to refit, re-greasing and sealing the maincase to the covers.

Service Kits

Lewmar H600/900 freefall windlass exploded view

Kit no. Description Parts included
60540K01 Maincase assembly 1, 13, 14, 22 & 49 Ask us to source it →
60540K02 Motor cover assembly 3 & 23 (×3) Ask us to source it →
60540K03 Mainshaft gear 4 Ask us to source it →
60540K04 2nd compound gear assembly 5, 14, 16 (×2) & 20 (×2) Ask us to source it →
60540K05 1st compound gear assembly 6, 13, 15 (×2) & 43 (×2) Ask us to source it →
60540K08 Motor drive shaft assembly 10 Ask us to source it →
60540K09 Bearing kit 13, 14, 15 (×2), 16 (×2), 17, 19, 20 (×2), 21, 22 & 43 (×2) Ask us to source it →
60540K10 Fastener kit 23 (×3), 24, 30 (×2), 50, 51 (×3), 52 (×8) & 73 Ask us to source it →
60540K12 H600 12V/400W electric motor assembly 35, 19 & 51 (×3) Ask us to source it →
60550K13 H900 12V/600W electric motor assembly 36, 19 & 51 (×3) Ask us to source it →
60550K14 H900 24V/600W electric motor assembly 37, 19 & 51 (×3) Ask us to source it →
60540K16 Chain only (C0671) 6 mm gipsy assembly 40, 44 & 52 Ask us to source it →
60541K37 Rope/chain (RC0670) 6 mm gipsy assembly 40, 52 & 73 Ask us to source it →
60541K38 Rope/chain (RC0761) 7 mm gipsy assembly 40, 52 & 73 Ask us to source it →
60550K19 Rope/chain (RC0860) 8 mm gipsy assembly 40, 52 & 73 Ask us to source it →
60550K31 Chain only (C0860) 8 mm gipsy assembly 40, 52 & 73 Ask us to source it →
60540K20 Fleming, chain only kit 44 & 52 Ask us to source it →
60540K21 Guide pillar kit 30, 41 & 72 Ask us to source it →
60540K22 Control arm kit 45, 46 & 47 Ask us to source it →
60540K24 Seal kit 29, 49 & 72 Ask us to source it →
60540K25 Mounting kit 60 (×3), 61 (×3), 62 (×3) & 74 (×3) Ask us to source it →
60540K26 G gear train cover assembly 2, 17, 21, 38, 39 & 52 (×7) Ask us to source it →
60541K32 Mainshaft kit 14 & 109 Ask us to source it →
60541K33 Drive cone kit 111 & 112 Ask us to source it →
60541K34 Freefall housing 113 Ask us to source it →
60541K35 Housing location kit 114, 115, 116, 117, 122, 124, 125 & 126 Ask us to source it →
60541K36 Horizon 600/900f nameplate kit 120 & 121 Ask us to source it →
6044111 Pawl & spring set 118 (×3) & 119 (×3) Ask us to source it →

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual