Lofrans Ercole Vertical Windlass — Installation & User's Manual
INSTALLATION MANUAL
Performance data, gipsy and chain match, cable sizing, above/below-deck installation, operation, maintenance, troubleshooting and the full parts list for the Lofrans Ercole vertical windlass, with its deck template.
DocumentLofrans Ercole Vertical Windlass Installation & User's Manual
FormatPDF · 47 pages · 5.6 MB
LanguageEnglish
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Technical Data
| 3500 W | 4000 W | 5000 W | 5500 W | 7500 W | 11CC (hydraulic) | |
|---|---|---|---|---|---|---|
| Vessel length, heavy duty | 85–110 ft | 60–80 ft | 70–85 ft | 70–85 ft | 90–145 ft | 70–85 ft |
| Vessel length, light duty | 100–115 ft | 65–85 ft | 75–90 ft | 75–90 ft | 145–155 ft | 75–90 ft |
| Power supply | 24 V | 230 V / 400 V | 230 V / 400 V | 230 V / 400 V | 400 V | Hydraulic |
| Maximum linear pull | 4500 kg 9900 lb |
5500 kg 12100 lb |
6000 kg 13200 lb |
6500 kg 14300 lb |
7500 kg 16534 lb |
6500 kg 14300 lb |
| Maximum lift load | 2250 kg 4950 lb |
2750 kg 6050 lb |
3000 kg 6600 lb |
3250 kg 7150 lb |
3750 kg 8267 lb |
3250 kg 7150 lb |
| Max lift working load | 1075 kg 2365 lb |
1310 kg 2882 lb |
1430 kg 3146 lb |
1550 kg 3410 lb |
2000 kg 4409 lb |
1550 kg 3410 lb |
| Current at working load | 120 A | N/A | N/A | N/A | 20–25 A | N/A |
| Max line speed | 15 m/min 45 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
| Line speed at working load | 8 m/min 24 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
12 m/min 36 ft/min |
| Net weight with drum | 180 kg 396 lb |
185 kg 407 lb |
198 kg 436 lb |
198 kg 436 lb |
225 kg 496 lb |
160 kg 352 lb |
| Hydraulic pressure / flow | N/A | N/A | N/A | N/A | N/A | Min 170 – Max 200 bar Min 35 – Max 40 l/min |
| Gipsy | Chain supported |
|---|---|
| 12 mm | 12 mm ISO; 13 DIN 766; 7/16" G4 |
| 13 DIN 764 | 13 DIN 764 |
| 14 mm | 14 mm, pitch 42 mm |
| 16 mm | 16 mm ISO |
| 16 DIN 766 | 16 mm DIN 766 |
| 18 mm | 18 mm ISO |
| 18 DIN 766 | 18 mm DIN 766 |
| 12,5 | 12,5 stud link |
| 14,5 | 14,5 stud link |
| 16 | 16 stud link |
| 17,5 | 17,5 stud link |
Rope: not supported (N/A on every gipsy). The 4000, 5000 and 5500 W A.C. motors come in 230 V and 400 V with the same figures.
Electrical System
| Model | Motor (W) | Voltage (V) | Contactor (A) | Cable 15–25 m | Cable 50–75 ft | Cable > 25 m | Cable > 75 ft |
|---|---|---|---|---|---|---|---|
| Ercole Verticale | 3500 | 24 | 250 | 70 mm² | 2/0 AWG | 95 mm² | 3/0 AWG |
Cable lengths are the total run, positive plus negative.
- Control box (solenoids): in a dry place near the windlass.
- Circuit breakers: use the Lofrans breakers, chosen for their trip curve rather than a plain rating.
- Remote control panel: where the operator can see the windlass during the manoeuvre (deck, helm or cockpit), sealed so the terminals stay dry.
- The wiring diagrams are in the PDF.
Requirements
- In the box: windlass with motor/gearbox, remote control switch or reverser box, drilling template, handle, screws.
- Tools: drill, 15 mm bit for wood and steel, 65 mm hole saw, 10 mm, 13 mm and 17 mm hex keys.
- Align the windlass precisely with the bow roller.
- Bow roller height must keep the chain inclination below 5 degrees.
- The deck faces must be parallel; shim the difference if they are not.
- With all the chain stowed, leave at least 300 mm between the underside of the deck and the top of the heaped chain.
- Deck: solid enough for the anchor recovery loads. The M14 studs allow a deck thickness of 150 mm; other thicknesses on request.
- Aluminium boats: insulate the windlass from the deck with a non-conductive gasket (not supplied), and insulate anchor and chain from the hull, including chain stopper and fixings.
Fitting
- The windlass separates into an upper part (base, gipsy, drum) on deck and a lower part (gearbox and motor) below deck, joined by the studs.
- With the emergency lever unscrew the wheel; remove drum and spring; remove screws and chain stripper; remove the gipsy, the Belleville springs and the inner clutch disc; unscrew the studs and lift off the base.
- Fit the lower part below deck, join it to the base and reassemble.
- Correctly installed, there is about 5 mm between gipsy and base. If more, add spacers to suit the deck thickness.
- Run silicone around the base to keep water out; wire the motor per the diagram.
- Use calibrated chain matching the gipsy. Feed the chain through the hole and make it fast, wrap it on the gipsy, then motor it in, keeping it aligned. Always fit a swivel between chain and anchor.
- Deck template: print at 100% (1:1) and check it before cutting. It shows the four stud holes, the shaft hole and the chain-pipe cut-out; check the chain-pipe position for your configuration (as printed).
Operation
Lowering
- Electrically: clutch tight, brake off, chain stoppers off; switch on the safety switch and press DOWN; then switch off and re-engage the stoppers.
- By gravity: clutch tight, stopper and brake off, then ease the clutch with the handle. Clockwise brakes the chain (to a full stop), anticlockwise lets it run. Make the chain fast to a strong point.
- A fully released clutch drops the anchor at high speed and can damage the hood and bow roller: control the speed.
- Wait for the windlass to stop before reversing direction.
Recovery, Override and Drum
- Breaker on, clutch tight, brake off, handle removed, stoppers off; press UP until the anchor seats in the bow roller; breaker off and chain on the stopper.
- Do not recover on the batteries alone: run the engine or generator.
- If the hydraulic-magnetic breaker trips on overload, reset it and wait some minutes before running again. It does not protect the motor from overheating on long runs.
- Manual override: clutch engaged, brake and stoppers off, handle in the hand-wheel, turn clockwise against the reducer spring.
- Warping drum: brake on and anchor secured; put the handle in the drum and turn clockwise to release the clutch (drum now independent of the gipsy); three turns clockwise, tail the rope and press UP; make the line fast on a bollard afterwards.
- Never use the windlass as a mooring point; hold the load on a chain stopper or strong point, and never put chain on the warping drum.
- Pay out so the chain lies on the seabed without heaping; motor slowly up over the anchor to ease recovery; slow down as the anchor reaches the bow roller.
Maintenance Programme
| Use of the yacht | Less than 2 months | From 2 up to 6 | More than 6 | Charter |
|---|---|---|---|---|
| Every 3 months | A – B | A – B | ||
| Every 6 months | A – B | |||
| Every 12 months | A – B – C | C | C | C – D |
| Every 24 months | D | D | E | |
| Every 36 months | D – E | E | E |
- A – Rinse all external surfaces and hidden points with fresh water and remove all salt.
- B – Grease the rotating parts, especially the main shaft threads and clutch cones; check for corrosion and mechanical stress.
- C – Check the motor terminals and test the voltage drop at the terminals.
- D – Replace all gaskets.
- E – Remove the windlass from the deck, clean the salt from under the base and re-seal.
Gipsy Service
- Unscrew the wheel with the emergency lever; remove drum and spring.
- Remove the screws and the chain stripper; take off the gipsy, the Belleville springs and the inner clutch disc.
- Wash with running water, never a pressure washer, and check for corrosion or stress.
- Reassemble in reverse order, greasing threads and moving parts.
Disconnect power before any maintenance. Skipping the programme voids the warranty. The English gipsy-service steps 1–4 are printed in French in the manual (as printed); the steps above follow that text.
Troubleshooting
| Problem | Possible causes | Solution |
|---|---|---|
| Windlass does not run when a control is operated | Protection switch OFF; no voltage; control box, control or motor failure | Switch ON; check battery charge and connections; check/replace control box or control; measure motor voltage, if OK clean the brushes, otherwise replace the motor |
| Chain jams frequently | Locker not deep enough for the chain carried; chain does not suit the gipsy; chain not calibrated | Fit the windlass over the deepest point of the locker or carry less chain; change the gipsy; replace chain that is out of tolerance |
| Windlass turns slowly | Cable section too small; deck faces not parallel; bad connections; dirty brushes; water in the motor | Increase cable section; shim the faces parallel; check connections; clean brushes; replace the motor |
| Motor runs, shaft does not turn UP or DOWN | Worn or broken wormwheel/worm teeth; broken motor spindle | (Service) remove the windlass, replace the broken parts and check no fragments got into the oil circuit; replace the motor and check no broken piece is left in the worm bore. Replace gaskets, screws, keys, circlips and oil at the same time |
| Motor runs, shaft turns UP but not DOWN | The emergency mechanism engages: tangled chain in the locker, poor chain (burrs, zinc), chain stowed in a block, worn emergency spring, or stripper fouling the gipsy | Fit a swivel joint after the anchor; inspect and free the chain link by link; lower all the chain in deep water and recover it with the windlass; (service) replace the spring; reposition or replace the stripper. The emergency mechanism can be locked (gears always engaged) only with the owner's authorisation: this removes the emergency function |
| Motor runs but the drum will not warp | Drum used the wrong way, so the emergency mechanism engages | Warp with the main shaft turning in the same direction as the gipsy when it recovers chain |
| Motor and shaft run, gipsy stays still with the brake band loose | Gipsy not closed on the clutch cones; clutch or gipsy cones deformed | Check clutch tightening, measure for deformation, shim if needed and replace damaged parts; replace the clutch and/or gipsy |
| Shaft runs out of line with the gipsy and/or drum | Shaft bent by excessive load | Check the windlass is used within its specification; (service) replace the shaft plus worn parts, gaskets, circlips, keys and oil |
| Oil leak between motor and gearbox | Loose motor coupling makes the worm run irregularly and the seal leaks | (Service) find why the fixings loosened, check the spindle and worm bore for ovality and repair on the bench; check for oil in the motor; replace gaskets, keys, circlips, screws, oil and worn parts |
| Shaft and studs too short for the gearbox at installation | Wrong deck thickness given when ordering | If the keyed shaft engages the gearbox along its full length, adapt the studs; otherwise order a longer shaft |
| Runs slowly and sometimes trips the breaker | Cable section, connections, brushes, water in the motor, faces not parallel, oil loss, motor labouring, or works in one direction only | Increase cable section; check connections; clean brushes; replace the motor; restore parallel faces; (service) inspect gearbox and motor; check 12/24 V across B2–C and B3–C on the control box with each button pressed, and replace the control box if a relay does not work |
Spare Parts
Drawing B.14.102 Rev. E, 03-2007. Item numbers are drawing references; only the kits carry Lofrans codes.
Service Kits
| Kit code | Description | |
|---|---|---|
| KA14101 | Kit A – Seals | Ask us to source it → |
| KB14101 | Kit B – Screws & nuts | Ask us to source it → |
| KC14101 | Kit C – Keys | Ask us to source it → |
| KD14101 | Kit D – Circlips | Ask us to source it → |
| KS14101 | Kit S – Sensor & magnet | Ask us to source it → |
Parts
| Item | Description | Kit |
|---|---|---|
| 226 | Washer for screw M8 | Kit B |
| 227 | Nut – M8 | Kit B |
| 231 | Washer for screw M5 | Kit B |
| 242a | Cap nut – M8 | Kit B |
| 250 | Hd cap screw – M5×8 | Kit B |
| 260 | Spring washer for screw M8 | Kit B |
| 272 | Handle | – |
| 293 | Hd cap screw – M5×16 | Kit B |
| 351 | Hd cap screw – M6×20 | Kit B |
| 381 | Key – 8×7×40 | Kit C |
| 386 | Spring washer for screw M10 | Kit B |
| 400 | Circlip – 15 DIN 471 | Kit D |
| 401 | Pivot | Kit B |
| 402 | Hex hd screw – M6×16 | Kit B |
| 403 | Spring | – |
| 412 | O-ring seal – 153 | Kit A |
| 414 | Hex hd screw – M8×30 | Kit B |
| 420 | Hex hd screw – M10×25 | Kit B |
| 566 | Handle | – |
| 567 | Clutch nut | – |
| 568 | Seal – 55×72×10 | Kit A |
| 569 | Drum | – |
| 570 | Spring | – |
| 571 | Clutch cone – outer | – |
| 572 | Circlip – 80 DIN 472 | Kit D |
| 573a | Nylon band | – |
| 573b | Nylon band | – |
| 574a | Gipsy chain 10 | – |
| 574b | Gipsy chain 12 | – |
| 574c | Gipsy chain 1/2 HT | – |
| 574d | Gipsy chain 14 | – |
| 574e | Gipsy chain 16 | – |
| 574f | Gipsy chain 16 DIN 766 | – |
| 574g | Gipsy chain 1/2 stud link | – |
| 574h | Gipsy chain 14 stud link | – |
| 574i | Gipsy chain 13 Italmet | – |
| 574l | Gipsy chain 13 DIN 764 | – |
| 574m | Gipsy chain 16 stud link | – |
| 574n | Gipsy chain 18 | – |
| 574o | Gipsy chain 18 stud link | – |
| 574p | Gipsy chain 19 stud link | – |
| 574s | Gipsy chain 18 DIN 766 | – |
| 575 | Band brake | – |
| 576 | Pivot | – |
| 577 | Spring | – |
| 578 | Brake pivot | – |
| 579 | Hand-wheel | – |
| 580 | Washer for screw M12 | Kit B |
| 581 | Safety nut – M12 | Kit B |
| 582 | Dished plane spring | – |
| 583 | Clutch cone – inner | – |
| 584 | Base | – |
| 585 | Brake pivot support | – |
| 586 | Brake pivot | – |
| 587 | Spacer | – |
| 588 | Seal – 64×80×8 | Kit A |
| 589 | Bearing – 6010 2RS | – |
| 590 | Spacer | – |
| 592 | Hex hd screw – M12×55 | Kit B |
| 593 | Washer for screw M10 | Kit B |
| 598a | Stud – M14×210 | – |
| 599a | Gearcase – upper | – |
| 600 | Nut – M14 | Kit B |
| 601 | Washer for screw M14 | Kit B |
| 602 | Bearing – 6014 2RS | – |
| 603 | Circlip – 18 DIN 471 | Kit D |
| 604 | Pivot | – |
| 605 | Bush | – |
| 606 | Gear | – |
| 607 | Gear flange | – |
| 608 | Key – 12×8×90 | Kit C |
| 609 | Key – 12×8×60 | Kit C |
| 610 | Rack | – |
| 611 | Key – 16×10×60 | Kit C |
| 612b | Main shaft, chain ≤ 16, deck thickness 150 | – |
| 612c | Main shaft, chain ≥ 18, deck thickness 150 | – |
| 613 | Circlip – 88 DIN 471 | Kit D |
| 614 | Pivot | – |
| 615 | Wormwheel – M=3.5/Z=47 | – |
| 617 | Pawl | – |
| 618 | Ratchet wheel | – |
| 619 | Hd cap screw – M6×10 | Kit B |
| 620 | Thrust ring – CP 5578 | – |
| 621 | Thrust bearing – AX5578 | – |
| 622 | Gasket | – |
| 623 | Gearcase – lower | – |
| 624 | Bearing – 6210 2RSR | – |
| 626 | Sightglass | – |
| 631 | Worm | – |
| 632a | Thrust bearing – 51108 | – |
| 633 | Spacer | – |
| 634 | Seal – 40×72×10 | Kit A |
| 637 | Key – 8×7×30 | Kit C |
| 640 | Electric motor 3500 W 24 V | – |
| 641a | Electric motor A.C. ph 1 V 220 kW 5 Hz 50/60 (as printed) | – |
| 641b | Electric motor A.C. ph 3 V 380 kW 4 Hz 50/60 (as printed) | – |
| 642 | Brake cover | – |
| 746 | Stud – M8×55 | Kit B |
| 900a | Stripper, gipsy 574 type c-e-f-g-l | – |
| 900b | Stripper, gipsy 574 type b-d-h-m-n-o-p-s | – |
| 901 | Roller | – |
| 902a | Chain pipe std | – |
| 902b | Chain pipe short | – |
| 994 | Nylon band | – |
| 1030 | Magnet | Kit S |
| 1100 | Combined bearing – 30205A | – |
| 1103 | Sightglass flange | – |
| 1160 | Ratchet wheel – left | – |
| 1174 | Set screw – M8×6 | Kit B |
| 1175 | O-ring seal – 4325 | Kit A |
| 1189 | Washer for screw M12 | Kit B |
| 1190 | Sensor | Kit S |
| 1191 | Sensor holder | Kit S |
Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.
Products in this Manual
