Lofrans Lion, Cayman, Tigres & Falkon Windlasses (PDF)

OWNER'S MANUAL

Installation, wiring, operation, maintenance and full spare-parts lists for the Lofrans horizontal windlasses: Lion 1000, Cayman 88, Tigres and Falkon, plus the deck drilling templates for Cayman 88, Tigres and Falkon.

DocumentLofrans Lion, Cayman, Tigres & Falkon Windlasses Installation & User's Manual

FormatPDF · 32 pages · 7.2 MB

LanguageEnglish

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Specifications Installation Electrical Operation Maintenance Troubleshooting Products

Lofrans Lion, Cayman, Tigres & Falkon Windlasses — Installation & User's Manual

This manual is split into 3 pages: Part 1 · Part 2 → · Part 3 →

Technical Data

Lion 1000 & Cayman 88

	Lion 1000	Cayman 88		Cayman 88		Cayman 88
Motor power	700 W	700 W	700 W	1000 W	1000 W	1300 W
Power supply	12 V	12 V	24 V	12 V	24 V	48 V
Vessel length, heavy duty	25–35 ft	25–35 ft	25–35 ft	35–45 ft	35–45 ft	40–50 ft
Vessel length, light duty	35–40 ft	35–45 ft	35–45 ft	40–50 ft	40–50 ft	45–55 ft
Maximum linear load / pull	575 kg / 1268 lb	1050 kg / 2310 lb	1050 kg / 2310 lb	1300 kg / 2860 lb	1300 kg / 2860 lb	1340 kg / 2955 lb
Max lift working load	105 kg / 232 lb	135 kg / 297 lb	135 kg / 297 lb	165 kg / 363 lb	165 kg / 363 lb	170 kg / 375 lb
Amps at work load	60 A	110 A	110 A	117 A	117 A	31 A
Max line speed	26 m/min / 85 ft/min	30 m/min / 90 ft/min	30 m/min / 90 ft/min	35 m/min / 105 ft/min	35 m/min / 105 ft/min	22 m/min / 72 ft/min
Line speed	23 m/min / 75 ft/min	25 m/min / 75 ft/min	25 m/min / 75 ft/min	25 m/min / 75 ft/min	25 m/min / 75 ft/min	16 m/min / 52 ft/min
Net weight with drum	N/A	24 kg / 53 lb	24 kg / 53 lb	25 kg / 55 lb	25 kg / 55 lb	25 kg / 55 lb
Net weight low profile	11 kg / 25 lb	N/A	N/A	N/A	N/A	N/A

Tigres & Falkon

	Tigres			Falkon
Motor power	1500 W	1500 W	1500 W	1700 W	1700 W	2000 W	2200 W
Power supply	12 V	24 V	48 V	12 V	24 V	24 V	48 V
Vessel length, heavy duty	40–50 ft	40–50 ft	40–50 ft	45–55 ft	45–55 ft	45–55 ft	50–60 ft
Vessel length, light duty	50–55 ft	50–55 ft	50–55 ft	55–60 ft	55–60 ft	55–60 ft	60–65 ft
Maximum linear load / pull	1500 kg / 3300 lb	1590 kg / 3900 lb	1000 kg / 2200 lb	1700 kg / 3740 lb	1700 kg / 3740 lb	2640 kg / 5820 lb	2880 kg / 6350 lb
Max lift working load	190 kg / 418 lb	200 kg / 440 lb	120 kg / 264 lb	215 kg / 473 lb	225 kg / 496 lb	330 kg / 727 lb	360 kg / 794 lb
Amps at work load	160 A	90 A	33 A	210 A	100 A	110 A	61 A
Max line speed	33 m/min / 99 ft/min	33 m/min / 99 ft/min	20 m/min / 60 ft/min	32 m/min / 96 ft/min	32 m/min / 96 ft/min	33 m/min / 99 ft/min	21 m/min / 69 ft/min
Line speed	14 m/min / 41 ft/min	16 m/min / 48 ft/min	20 m/min / 60 ft/min	16 m/min / 48 ft/min	16 m/min / 48 ft/min	19 m/min / 57 ft/min	12 m/min / 39 ft/min
Net weight with drum	28 kg / 62 lb	28 kg / 62 lb	28 kg / 62 lb	55 kg / 121 lb	55 kg / 121 lb	57 kg / 125 lb	57 kg / 125 lb

Chain and rope by gipsy / drum

Model	Chain supported by gipsy	Rope supported by drum
Lion 1000	6 mm ISO, 6 mm DIN 766	10–12 mm (3/8–1/2")
	8 mm ISO, 8 mm DIN 766	12 mm (1/2")
Cayman 88	6 mm ISO, 6 mm DIN 766	N/A
	8 mm ISO, 8 mm DIN 766, 5/16" G4, 5/16" BBB	14–16 mm (9/16–5/8")
	10 mm ISO, 3/8" G4	N/A
	10 mm DIN 766, 3/8" BBB	N/A
Tigres 12/24 V	8 mm ISO, 8 mm DIN 766, 5/16" G4, 5/16" BBB	14–16 mm (9/16–5/8")
	10 mm ISO, 3/8" G4	16 mm (5/8")
	10 mm DIN 766, 3/8" BBB	16 mm (5/8")
Falkon	10 mm ISO, 3/8" G4	16 mm (5/8")
	10 mm DIN 766, 3/8" BBB	16 mm (5/8")
	12 mm ISO, 13 mm DIN 766, 7/16" G4	18 mm (3/4")

Tigres 48 V with rope kit

Gipsy chain	Rope on gipsy	Rope on drum
8 mm ISO – 5/16 HT	14 mm 3-strand, 8-plait	14–16 mm (9/16–5/8")
10 mm ISO – 3/8 HT	16 mm 3-strand, 8-plait	16 mm (5/8")

Vessel lengths are Lofrans' heavy-duty and light-duty guidance. Warranty is 3 years from purchase; electric motors, controls, seals and units on charter boats are limited to 1 year.

Installation

Package and tools

Package: windlass, control box, handle and this manual.
Tools: drill with 10 mm bit for wood and steel; 10 mm, 13 mm and 17 mm hexagon keys.

Location requirements

Bow roller height must keep the chain inclination under 90 degrees.
Upper and lower deck faces must be parallel; shim the difference if not.
Chain locker: with all chain stowed, leave at least 300 mm between the underside of the deck and the top of the heaped chain.
Insulate anchor and chain from the hull, locker and fixings. Two-terminal motors (Lion 1000, Cayman with 700W motor) must be bonded to the on-board cathodic protection. On aluminium boats insulate every windlass from the deck with a non-conductive gasket (not supplied).

Deck installation

Lay the drilling template on deck aligned with the bow; mark and drill. Leave hole edges sharp, but smooth the chain-hole edge on the bow side at 45°.
Place the upper unit on deck and set the chain stripper pipe so the stripper is aligned and 4–5 mm from the gipsy throat.
Run the battery cables to the motor through the openings in the gearbox body.
Bed the windlass base to the deck with silicone.

Electrical System

Model	Motor	Voltage	Contactor	Cable 15–25 m (50–75 ft)	Cable > 25 m (> 75 ft)
Atlas / Cayman 88 / Lion 1000	600 / 700 / 700 W	12 V	70 A	25 mm² / 3 AWG	–
Cayman 88	700 W	24 V	35 A	16 mm² / 4 AWG	–
Cayman 88	1000 W	12 V	100 A	35 mm² / 2 AWG	50 mm² / 2 AWG
Cayman 88	1000 W	24 V	70 A	25 mm² / 3 AWG	35 mm² / 3 AWG
Cayman 88	1300 W	48 V	35 A	6 mm² / 10 AWG	10 mm² / 8 AWG
Tigres	1500 W	12 V	100 A	50 mm² / 2 AWG	75 mm² / 000 AWG
Tigres	1500 W	24 V	70 A	35 mm² / 3 AWG	50 mm² / 2 AWG
Tigres	1500 W	48 V	35 A	16 mm² / 4 AWG	25 mm² / 3 AWG
Falkon	1700 W	12 V	125 A	50 mm² / 2 AWG	75 mm² / 000 AWG
Falkon	1700 W	24 V	70 A	35 mm² / 3 AWG	50 mm² / 2 AWG
Falkon	2000 W	24 V	100 A	50 mm² / 2 AWG	75 mm² / 000 AWG
Falkon	2200 W	48 V	70 A	10 mm² / 8 AWG	16 mm² / 6 AWG

Cable sizes are for the total length of positive plus negative. Mount the control box in a dry place near the windlass and the remote panel where the operator can see the windlass. The installer must keep motor and control box out of direct water and must ground the windlass. The Lofrans breakers are chosen on their trip curve, not just the plate rating.

Falkon 2000W

Lion 1000 (2-terminal motor)

Tigres 48V (3-terminal motor)

Cayman 48V (3-terminal motor)

Operation

Lowering

Electrically: clutch tight, brake off, chain stoppers off; switch on, press DOWN; switch off and set the stopper.
By gravity: clutch tight, release the stopper and brake, then ease the clutch with the handle. Clockwise brakes the chain (to full stop), anticlockwise frees it.
Never reverse direction until the windlass has stopped. A fully released clutch lets chain run very fast and can damage hood and bow roller.

Weighing and warping

Breaker on, clutch tight, brake off, handle out; press UP until the anchor seats in the bow roller; breaker off and set the chain stopper.
Manual override: clutch engaged, brake and stoppers off; handle in the hand-wheel and turn clockwise against the spring.
Warping drum: brake on and anchor secured, clutch off, three turns of rope clockwise, press UP. Never put chain on the drum.
Run the engine or generator while weighing. The breaker does not protect against motor overheating from long runs – let it cool. After an overload trip, reset and wait a few minutes.

Never use the windlass as a mooring point: hold the anchor load on a chain stopper or strong point, and secure the anchor for passage.

Maintenance Programme

Interval	Use < 2 months/yr	2–6 months/yr	> 6 months/yr	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	F

A – Rinse all surfaces with fresh water to remove salt; soapy water only, no chlorine.
B – Grease rotating parts, especially main shaft threads and clutch cones; check for corrosion and stress. With galvanic corrosion, check for stray currents.
C – Check motor terminals and test voltage drop at the terminals; keep the control box dry.
D – Replace all gaskets and oil.
E – Lift the windlass, clean salt from under the base, reseal; check for corrosion.
F – Pull the stainless deck screws and stripper screws and refit with a chromate-free jointing compound.

Gipsy service

Turn anticlockwise with the handle to remove the gipsy; slide off upper clutch cone, gipsy and lower clutch cone.
Wash in running water – no pressure washer; check for corrosion and stress; reassemble in reverse with grease on threads and moving parts.

Disconnect power before any maintenance. Skipping the programme voids the warranty.

Troubleshooting

Problem	Possible cause	Solution
Windlass does not work when a control is operated	Protection switch OFF; no voltage; failed control box, control or motor	Set the switch ON; check battery charge and connections; check/replace the control box or control; measure motor voltage – if OK, clean the brushes, otherwise replace the motor
Chain jams frequently	Chain locker not deep enough for the chain carried; chain not suited to the gipsy; chain not calibrated	Mount the windlass over the deepest point of the locker or carry less chain; change the gipsy; check the chain against tolerances and replace if out
Windlass turns slowly	Cable section too small; deck faces not parallel; bad connections; dirty brushes; water in the motor	Increase cable section; shim to parallel; check connections; clean brushes; replace the motor
Motor runs, shaft turns UP but not DOWN	Tangled locker, burred/zinc-encrusted chain or links stuck together trip the emergency mechanism; worn emergency spring; stripper fouling the gipsy	Fit a joint right after the anchor; inspect the chain link by link; lower all chain in deep water and retrieve with the windlass; (service) replace the spring; re-centre or replace the stripper
Motor runs but the bell cannot warp	Bell used in the wrong direction (emergency mechanism trips)	Warp with the main shaft turning the same way as the gipsy when weighing chain
Motor and shaft run, gipsy stays still with band brake loose	Gipsy not closed on the clutch cones, or deformed cones/gipsy	Check clutch tightening, measure for deformation, shim if needed; replace clutch and/or gipsy
Oil leak between motor and gearbox	Loose motor coupling makes the worm turn irregularly	(Service) find why fasteners loosened, inspect spindle and worm bore, repair on the bench, replace gaskets, tabs, seeger, screws and oil
Shaft and studs too short on installation	Deck thickness given at order was wrong	Studs can be adapted if the key shaft engages the gearbox along its full length; otherwise order a longer shaft
Runs slowly and sometimes trips the breaker	Cable section, connections, brushes, water in motor, deck faces not parallel, gearbox oil loss, motor straining	Increase section; check connections; clean brushes; replace motor; shim; (service) inspect gearbox and motor. If it works one way only, check for 12/24 V between B2-C and B3-C on the control box when each button is pressed
Finger broken	Poor cable-top layout or chain rolling broke the finger	Replace the finger; if the gipsy cannot work with the finger, fit the replacement kit (cap)