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OWNER'S MANUAL

Install, wire, run and service the Lofrans X1 / X1 ALU vertical windlass (500, 800 and 1000 W, 12 V): technical data, cable sizing, the maintenance schedule, troubleshooting and the parts list. The deck template is the second download.

DocumentLofrans X1 Vertical Windlass Installation & User's Manual
FormatPDF · 98 pages · 15.3 MB
LanguageEnglish
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Owner's ManualPDF · 98 p.Deck template (print at 100%)PDF · 1 p.
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Technical DataInstallationDeck TemplateElectricalOperationMaintenanceTroubleshootingSpare PartsProducts
Lofrans X1 Vertical Windlass — Installation & User's Manual

Technical Data

500 W 800 W 1000 W
Vessel length, heavy duty 20 – 30 ft 25 – 35 ft 30 – 40 ft
Vessel length, light duty 30 – 35 ft 35 – 40 ft 35 – 45 ft
Power supply 12 V 12 V 12 V
Maximum linear load / pull 630 kg / 1386 lb 700 kg / 1540 lb 900 kg / 1980 lb
Maximum lift load / pull 345 kg / 759 lb 380 kg / 836 lb 425 kg / 935 lb
Max lift working load 95 kg / 209 lb 100 kg / 220 lb 125 kg / 275 lb
Amps at work load 60 A 110 A 120 A
Max line speed 26 m/min / 78 ft/min 28 m/min / 84 ft/min 30 m/min / 90 ft/min
Line speed 23 m/min / 69 ft/min 25 m/min / 75 ft/min 20 m/min / 60 ft/min
Net weight with drum 12 kg / 27 lb 14 kg / 31 lb 17 kg / 38 lb
Net weight low profile 11 kg / 25 lb 13 kg / 29 lb 16 kg / 36 lb
Gipsy Chain supported Rope supported
6 mm 6 mm ISO, 6 mm DIN 766, 3/16" BBB 12 mm – 1/2"
7 mm 7 mm ISO, 7 mm DIN 766, 1/4" G4, 1/4" BBB 12 mm – 1/2"
8 mm 8 mm ISO, 8 mm DIN 766, 5/16" G4, 5/16" BBB 12 mm – 1/2"

Use calibrated chain that matches the gipsy fitted. Always fit an articulated joint between chain and anchor so the chain does not twist.

Before You Drill

  • Align the windlass precisely with the bow roller.
  • Upper and lower deck faces must be parallel; shim to compensate if they are not.
  • Chain locker: with all the chain stowed, keep at least 300 mm between the underside of the deck and the top of the heaped chain.
  • Bow roller height must keep the chain inclination below 5 degrees.
  • Standard studs suit a deck 18–30 mm (0.7–1.2") thick. Other thicknesses on request; minimum deck thickness 10 mm.
  • Aluminium boats: insulate the windlass from the deck with a non-conductive gasket (not supplied), and insulate anchor, chain, chain stopper and fixings from the hull.

Fitting

  • Package: windlass with motor reducer, remote control switch / reverser box, base gasket, drilling template, handle, screws.
  • Tools: drill, 10 mm bit for wood and steel, 50 mm hollow drill bit, 10, 13 and 17 mm hex keys.
  • Place the template aligned with the bow, mark and drill. Leave the hole edges sharp, but smooth the bow side of the chain hole at 45°.
  • Clean, fit the gasket and set the upper unit on deck. Bed it with silicone, not permanent glue, so it can be removed for service.
  • Below deck: grease the main shaft, join the reducer with the motor away from the chain hole, fit washers and nuts on the studs.
  • Protect the motor and control box from direct water: water damage to electrical parts voids the warranty.
  • Chain: remove the hood (two screws), feed the chain through and secure it, refit the hood, wrap the gipsy and recover the chain under power.

Drilling Template

The deck template (second download) shows the cut-out line, the overall footprint, the chain line and the stud holes, with the windlass oriented for clockwise rotation and the arrow pointing forward. Print it at 100% (actual size, not "fit to page") and check the printed dimensions against the figures on the drawing before you drill: the template itself warns it may not be to scale once printed.

Electrical System

Motor Voltage Contactor Cable 0–15 m (0–50 ft) Cable 15–25 m (50–75 ft)
500 W 12 V 35 A 16 mm² / 6 AWG 25 mm² / 4 AWG
800 W 12 V 70 A 16 mm² / 6 AWG 35 mm² / 2 AWG
1000 W 12 V 100 A 25 mm² / 4 AWG 50 mm² / 1 AWG

Cable length is positive + negative combined.

  • Control box (solenoids): mount in a dry place near the windlass.
  • Use the Lofrans circuit breakers: they are selected on their trip curve, not just the plate rating. Switch the breaker off whenever the windlass is not in use.
  • Remote panel: mount where the operator can see the windlass (deck, helm or cockpit) and seal it so the terminals stay dry.
  • Wiring diagrams in the manual: E0016-A (2-terminal motor), E0015-A (3-terminal motor), E0017-A (4-terminal motor). Control circuit fused at 5 A; rocker switch type C and Thetis 1002 hand-held remote shown.

Anchoring

  • Never reverse direction while the windlass is turning: let it stop first.
  • Lowering electrically: clutch tight, chain stoppers off, safety switch on, press DOWN; switch off and re-engage the stoppers when done.
  • Lowering by gravity: clutch tight, stoppers off, then slack the clutch gradually with the handle. Clockwise brakes the chain harder, anticlockwise eases it. A fully open clutch drops the anchor fast and can damage hood and bow roller.
  • Weighing: breaker on, clutch tight, handle out, stoppers off, press UP until the anchor seats in the bow roller; breaker off and chain on the stopper.
  • Run the engine or generator while recovering; do not rely on the batteries alone. Give the motor time to cool after long runs.

Warping Drum & Notes

  • Secure the anchor, insert the handle in the drum and turn clockwise to free the drum from the gipsy.
  • Take three turns of rope clockwise round the drum, hold the tail and press UP. Then make the line fast on a bollard and switch off.
  • Never put chain on the warping drum. Never use the windlass as a mooring point: hold the load on a chain stopper.
  • The finger is only needed for a chain-and-rope rode; with all-chain, remove it to avoid breaking it.
  • If the breaker trips on overload, reset it and wait some minutes before running again. Always remove the handle when not in use.

Maintenance

Interval Use under 2 months/yr 2 to 6 months Over 6 months 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

Tasks

  • A – Rinse all surfaces with fresh water and remove salt. Dark Version: fresh-water rinse weekly, and cover with waterproof material for winter storage.
  • B – Grease rotating parts, especially the main shaft threads and clutch cones; check for corrosion and stress.
  • C – Check motor terminals and test voltage drop at the terminals.
  • D – Replace all gaskets.
  • E – Remove the windlass from the deck, clean the salt under the base and reseal.

Gipsy Service

  • Remove the hood and chain pusher (Allen screws).
  • Undo the gipsy hand-wheel anticlockwise with the handle.
  • Slide off the upper clutch cone, the gipsy and the lower clutch cone.
  • Wash with running water – not 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 maintenance programme voids the warranty.

Troubleshooting

Problem Check / fix
No response to the controls Breaker ON; battery charge and connections; control box; control; motor voltage, then brushes, else replace the motor.
Chain jams often Locker not deep enough (move the windlass over the deepest point or carry less chain); chain does not suit the gipsy; chain out of tolerance.
Runs slowly, trips the breaker Cable section too small; poor connections; dirty brushes; water in the motor; decks not parallel (shim); gearbox oil loss; check B2-C and B3-C contacts get 12/24 V when pressed.
Motor runs, shaft does not turn Worn or broken wheel / worm teeth, or broken motor spindle: service job; replace gaskets, screws, tabs, seeger and oil at the same time.
Turns UP but not DOWN Tangled locker; poor-quality chain with burrs or zinc; chain stowed in a block with links stuck together.
Motor and shaft turn, gipsy does not Gipsy not clamped on the clutch cones or hand-wheel at end of stroke; deformed cones or gipsy: replace.
Shaft bent / out of line Overload. Replace the shaft and worn parts.
Oil between motor and gearbox Loose motor coupling; check spindle and worm bore for ovality, check for oil in the motor.
Shaft and studs too short at install Wrong deck thickness ordered: adapt the studs if the key engages its full length, otherwise order a longer shaft.
Finger broken Replace the finger, or fit the replacement cap if the gipsy cannot work with a finger.

X1 500 W / 800 W Spare Parts

Item numbers from the X1 500W / 800W IP67 parts list (the manual gives item references, not order codes). Parts marked with a kit letter come in that Lofrans kit.

Item Description Kit
208 Ring
216 Bush
223 Circlip – 18 Din 471 Kit D
224 Key – 6x6x45 Kit C
226 Washer for M8 screw Kit B
227 Nut – M8 Kit B
230 Spring washer for M5 screw Kit B
231 Washer for M5 screw Kit B
232 Key – 4x4x15 Kit C
252 O Ring 2325
293 Hd cap screw M5x16 Kit F
619 Hd cap screw M6x10 Kit B
906 Spacer Kit F
909 Spring Kit F
945 Cap Kit F
964 Magnet Kit S
965 Sensor Kit S
1008 Pivot 7x14 Kit F
1011 Hd cap screw M6x40 Kit B
1043 Support
1044 Stripper
1046 Seal 18-30-7 Kit A
1047 Ring
1048 Clutch cone – outer
1049 Clutch cone – inner
1050 Gipsy cap
1053 Nut
1054 Gasket
1083 O Ring 3250 Kit A
1225 PG9
1226 Gearbox
1228 O Ring 2250
1231 Electric motor 500W 12V
1303 Complete motor cover kit Kit Cover
1041a Base
1042a Cover
1045a Main shaft without drum
1051a Main shaft with drum
1052a Drum
1232a Electric motor 700W 12V (as printed)
206b Gipsy chain 6 – 5 pockets
206c Gipsy chain 7 – 6 pockets
206d Gipsy chain 8 – 5 pockets
225a Stud M8x58
842a Handle
905a Finger Kit F
905b Stainless steel finger Kit F

The X1 ALU list differs: it adds 203 Seal 35x45x7 (Kit A), 2004 Clutch nut and 2005 Drum, uses 1041b Base, 1042b Cover and 842b Handle, has no 1052a, 1053, 1083 or 206d, and puts 252 and 1228 in Kit A. Check the PDF for your version.

Lofrans X1 500W / 800W exploded view

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

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