We Ship Worldwide! | FREE SHIPPING! for US Continental orders over $145. Click for details.
OWNER'S MANUAL

Specifications, bulkhead installation, auto-stop set-up, cable sizing, freefall and powered operation, servicing and the spares kits for the Lewmar S900 and S2000 Gen 2 stern (rope) windlasses, plus the drill template and the earlier S900/S2000 manual.

DocumentLewmar S900 / S2000 Gen 2 Stern Windlass Owner's Manual
FormatPDF · 20 pages · 8.3 MB
LanguageEnglish
Download PDF ▾
Owner's ManualPDF · 20 p.Drill template (1:1)PDF · 1 p.Earlier edition (B10500)PDF · 20 p.
View Collection
SpecificationsInstallationAuto-StopElectricalOperationServicingTroubleshootingSpares KitsDrill TemplateProducts
Lewmar S900 / S2000 Gen 2 Stern Windlass — Owner's Manual

Specifications

Model Rope Ø Supply Motor Working load limit Normal current Circuit breaker Weight
S900 12–16 mm
1/2"–5/8" 		12 V 600 W 200 kg
440 lb 		85 A 90 A 11.6 kg
26 lb
S2000 12–16 mm
1/2"–5/8" 		12 V 1000 W 420 kg
924 lb 		100 A 110 A 19.9 kg
44 lb

The gypsy is designed for leaded lines of 12 to 16 mm diameter.

Bulkhead Preparation

  • Choose a position at the stern in line with the anchor roller: the lead from the roller must feed straight back to the pulley and along its centre line.
  • Minimum bulkhead thickness 25 mm (1"). The supplied M8 screws suit bulkhead plus packing of 25–30 mm (1"–1 3/16"); source longer M8 countersunk screws for thicker bulkheads.
  • Foam or balsa-cored bulkheads need reinforcement to spread the recovery torque. Fit a pad if the bulkhead is not flat.
  • Allow clearance behind the bulkhead for the motor/gearbox and at least 300 mm (12") of vertical fall for the line at all times, or it will jam.
  • Tools: marine sealant, drill with 9 mm (3/8") bit, 50 mm (2") hole saw, 5 mm (3/16") Allen key, 13 mm (1/2") spanner, crimping tool.

Fitting

  • Using the template, drill 4 × 9 mm holes for the M8 mounting screws and cut one 50 mm hole for the rode; seal the cut edges.
  • Tighten the M8 screws to 21 Nm (5 mm Allen key, 13 mm spanner).
  • Secure the mounting plate with M10 screws to 43 Nm (8 mm Allen key, 17 mm spanner).
  • Position the 4 gearbox mounting bolts with their hex heads in the housing recesses for the motor/gearbox position you want; secure the main unit with 4 × M8 screws to 21 Nm (6 mm Allen key).
  • Key in the driveshaft, slide the motor/gearbox on and secure with 4 × M8 nuts and washers to 21 Nm.
  • Loading the rode: pass it through the bulkhead roller, pull back the control arm, lead it round the gypsy and down the bottom channel of the rope guide into the locker; release the arm, secure the bitter end, power in the rest.

Auto-Stop Sensor & Brass Coil

  • Isolate the windlass. Fit the sensor to its bracket, feed the cable through the housing grommet and keep it clear of moving parts and the falling rode.
  • With the anchor just below the water, set the sensor within 6 mm of the rode and mark the rode above the sensor.
  • Stow the anchor, cut power, and fit the brass wire coil at the mark: pierce the rope, push the wire through and fold it along the rope, wind the free end 8 times round the rope and over the other end, knot and twist the ends, trim to about 5 mm and tuck under the wrap. The wrap's outside diameter should almost match the rope's.
  • Lower a few metres and haul in: the windlass stops as the anchor breaks the water; pulse it to stow. Re-adjust the sensor height or coil as the rode stretches, and replace the coil when the sheave wears it.
  • On installation, check the motor direction: UP must be up, and it must stop when the sensor connects.

Electrical Wiring

Model Supply Normal current Breaker 0–7 m (0–23 ft) 7–15 m (23–50 ft) 15–22 m (50–73 ft)
S900 12 V 85 A 90 A 16 mm² / 6 AWG 25 mm² / 4 AWG 35 mm² / 2 AWG
S2000 12 V 100 A 110 A 16 mm² / 6 AWG 25 mm² / 4 AWG 35 mm² / 2 AWG
  • Cable lengths are the total run from the battery along the cable route; do not confuse cable length with boat length. Voltage drop over the run must not exceed 10%.
  • Fully insulated system, type III stranded tinned copper with copper crimp terminals. Check polarity.
  • Fit the supplied breaker close to the battery in a dry, accessible place; it must be reset manually after a trip.
  • Multi-station: all switches wired in parallel. The wiring diagrams (S900 and S2000 drawn separately) show a 3 A fuse on the control circuit.
Part no. Electrical item
68000349 Circuit breaker 90 A, supplied with S900 View part →
68000350 Circuit breaker 110 A, supplied with S2000 View part →
68000593 Guarded rocker switch (supplied) View part →
68001213 Contactor assembly, S900 (supplied) Ask us to source it →
68001214 Contactor assembly, S2000 (supplied) Ask us to source it →
68000967 Wireless remote, 3 button (windlass only), optional View part →
68000968 Wireless remote, 5 button (windlass & thruster), optional View part →
68001357 Remote handheld control, optional Ask us to source it →
68001289 Y splitter, optional Ask us to source it →

Manual Controlled Freefall

  • Isolate the windlass. Press the plunger button on the drive cap until it stays down, then release the anchor line.
  • Insert the Lewmar handle in the drive cap: clockwise grips the gypsy, anticlockwise frees it to control the rate of descent.
  • Once deployed, lock the clutch clockwise, engage the anchor locks and remove the handle.
  • To return to powered operation, pull the locking button out to disengage the plunger.

Power Up / Down

  • Plunger disengaged (up). Release the anchor line and engage the breaker.
  • Press DOWN for 2 seconds until the anchor freefalls. Holding DOWN over 5 seconds lengthens the clutch re-engagement on the next UP.
  • When enough line is out, press UP continuously until freefall stops; it takes several seconds to re-engage and lock the internal clutch. Unlocked, the rope can creep out.
  • Press UP continuously to retrieve.
  • Never use the windlass as a mooring bollard: secure the rode to a cleat or other strong point.

Servicing

Schedule

  • Bedding-in: check electrical connections and mounting screws frequently while new.
  • After use: fresh-water wash; rode at least 12" (300 mm) below the windlass; check the locker drain and the rode.
  • Annually (or more often): connections, mounting screws, rode wear, and the gypsy – a high-wear item.

Gypsy Replacement

  • Isolate and secure the rode. Remove the drive cap screw and washer (Loctite®-sealed; may need warming).
  • Hold the plunger in and unscrew the freefall mechanism (left-hand thread on a starboard windlass).
  • Remove the stripper screws, pull the control arm clear, move the stripper and lift off the gypsy, noting the rope-tooth direction.
  • Clean without solvent or wire brush, lubricate the freefall plunger, lightly grease mating faces on reassembly.
  • Keep Loctite® off the driveshaft thread or freefall will not work. Tighten the stripper screws then back off 1/2 turn so the stripper lies loose on the gypsy.

Troubleshooting

Problem Check / remedy
Rode pays out when not in use Rope not secured and drive cap slack: tighten the drive cap with the handle and always secure the rope independently
Failure to operate or sluggish Mostly electrical. A 12 V system should hold 13.5 V; constant low voltage damages the motor. Check cable size, switches, connections, battery, isolator, fuse and motor
Failure to operate Voltage at contactor and switch inputs (breaker, fuses); voltage at the solenoid switch terminal when operated (else switch/wiring); voltage at the contactor main output (else coil ground, then contactor); at least 12.5 V at the motor and no rotation = motor defective

Spares Kits

Lewmar S900 and S2000 Gen 2 stern windlass exploded parts view

Gen 2 (ref B17416)

Kit no. Description Items included (qty)
66000842 Gen 2 port control arm kit 7(1), 17(1), 18(1), 19(1), 21(1) Ask us to source it →
66000843 Gen 2 stbd control arm kit 36(1), 17(1), 18(1), 19(1), 21(1) Ask us to source it →
66000099 Clutch lever 20(1) View part →
66000833 Gen 2 port drive cap 16(1) Ask us to source it →
66000832 Gen 2 stbd drive cap 37(1) Ask us to source it →
66000834 Gen 2 bulkhead unit 22(1), 44(4) Ask us to source it →
66000835 Gen 2 mounting bracket kit 8(1), 32(2), 35(4) Ask us to source it →
66000844 Gen 2 port stopper cam / rope guide kit 6(1), 10(1), 33(1), 35(4) Ask us to source it →
66000845 Gen 2 stbd stopper cam / rope guide kit 38(1), 6(1), 33(1), 35(4) Ask us to source it →
66000810 Gypsy 23(1) Ask us to source it →
66000811 Stripper kit 11(1), 28(2) Ask us to source it →
66000836 Gen 2 port drive cone kit 3(1), 12(1), 27(1), 39(1) Ask us to source it →
66000837 Gen 2 stbd drive cone kit 40(1), 41(1), 3(1), 27(1) Ask us to source it →
66000839 S900 port driveshaft kit 1(1), 5(1), 13(1), 15(1) Ask us to source it →
66000838 S900 stbd driveshaft kit 42(1), 1(1), 5(1), 13(1) Ask us to source it →
66000841 S2000 port driveshaft kit 1(1), 4(1), 43(1), 13(1) Ask us to source it →
66000840 S2000 stbd driveshaft kit 4(1), 9(1), 1(1), 13(1) Ask us to source it →
66001190 Autostop 24(1) Ask us to source it →
66000816 S900 motor / gearbox 25(1), 35(4), 29(4), 31(4), 34(4) Ask us to source it →
66000817 S2000 motor / gearbox 26(1), 35(4), 29(4), 31(4), 34(4) Ask us to source it →

Earlier S900/S2000 (ref B10500)

Kit no. Description Items included (qty)
66000097 Control arm kit 7(1), 17(1), 18(1), 19(1), 21(1) View part →
66000099 Clutch lever 20(1) View part →
66000620 Pro-Fish drive cap 16(1) View part →
66000807 Bulkhead unit 23(1) Ask us to source it →
66000808 Mounting bracket kit 8(1), 14(1), 30(3), 31(3), 32(3), 33(1), 36(3) Ask us to source it →
66000809 Stopper cam / rope guide kit 6(1), 10(1), 34(1), 35(4) Ask us to source it →
66000810 Gypsy 24(1) Ask us to source it →
66000811 Stripper kit 11(1), 29(2) Ask us to source it →
66000812 Drive cone kit 3(1), 12(1), 28(1) Ask us to source it →
66000813 600 W driveshaft kit 1(1), 5(1), 13(1), 15(1) Ask us to source it →
66000814 1 kW driveshaft kit 1(1), 4(1), 9(1), 13(1) Ask us to source it →
66001190 Autostop 25(1) Ask us to source it →
66000816 600 W motor / gearbox 2(4), 22(4), 26(1), 37(4) Ask us to source it →
66000817 1 kW motor / gearbox 2(4), 22(4), 27(1), 37(4) Ask us to source it →

Item numbers refer to the exploded view of each edition; the two editions number their parts differently.

Drill Template

Bulkhead drill template for the mounting screw holes and the 50 mm rode hole. Download the PDF and print it at 100% (1:1, no "fit to page"), then check a dimension with a ruler before drilling.

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

Products in this Manual