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INSTALLATION MANUAL

Performance data, gipsy and chain/rope match, cable sizing, installation, operation, maintenance, troubleshooting, dimensions and the parts lists for the Lofrans X3, X3 Alu and Project 1500 vertical windlasses (units built from 2014), with the contents of maintenance kit 72040. The manual for units built before 2014 and the deck template are in the downloads.

DocumentLofrans X3, X3 Alu & Project 1500 Vertical Windlass Installation & User's Manual
FormatPDF · 56 pages · 2.9 MB
LanguageEnglish
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Installation ManualPDF · 56 p.Manual for units built before 2014PDF · 53 p.Deck templatePDF · 1 p.Maintenance kit 72040 (exploded view)PDF · 1 p.
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Lofrans X3, X3 Alu & Project 1500 Vertical Windlass — Installation & User's Manual

Technical Data

1500W 12V 1500W 24V 1700W 12V 1700W 12V (as printed) 2200W 48V
Vessel length, heavy duty 40–50 ft 40–50 ft 50–60 ft 50–60 ft 60–70 ft
Vessel length, light duty 50–55 ft 50–55 ft 60–65 ft 60–65 ft 65–75 ft
Maximum linear load/pull 1200 kg
2640 lb 		1200 kg
2640 lb 		1600 kg
3520 lb 		1600 kg
3520 lb 		1800 kg
3970 lb
Maximum lift load 600 kg
1320 lb 		600 kg
1320 lb 		800 kg
1760 lb 		800 kg
1760 lb 		900 kg
1990 lb
Max lift working load 165 kg
363 lb 		165 kg
363 lb 		200 kg
440 lb 		200 kg
440 lb 		300 kg
660 lb
Amps at work load 150 A 65 A 180 A 90 A 50 A
Max line speed 40 m/min
131 ft/min 		35 m/min
105 ft/min 		32 m/min
96 ft/min 		32 m/min
96 ft/min 		15 m/min
49 ft/min
Line speed at working load 17 m/min
45 ft/min 		17 m/min
45 ft/min 		14 m/min
45 ft/min 		15 m/min
45 ft/min 		9 m/min
29 ft/min
Net weight with drum 35 kg
77 lb 		35 kg
77 lb 		35 kg
77 lb 		38 kg
84 lb 		55 kg
110 lb
Net weight, low profile 32 kg
71 lb 		32 kg
71 lb 		32 kg
71 lb 		35 kg
77 lb 		N/A

The second 1700W column is printed as 12V; its current (90 A) matches a 24V supply, and the cable table lists 1700W at 12V and 24V.

Gipsy Chain supported Rope supported
8 mm 8 mm ISO, 8 mm DIN 766, 5/16" G4, 5/16" BBB 14 mm – 16 mm – 9/16" – 5/8"
10 mm 10 mm ISO, 3/8" G4 16 mm – 5/8"
10 DIN 766 10 mm DIN 766, 3/8" BBB 16 mm – 5/8"
12 mm 12 mm ISO, 13 DIN 766, 7/16" G4 18 mm – 3/4"

Electrical System

Motor (W) Voltage (V) Contactor (A) 0–15 m 0–50 ft 15–25 m 50–75 ft
1500 12 100 35 mm² 2 AWG 50 mm² 1 AWG
1500 24 70 25 mm² 4 AWG 35 mm² 2 AWG
1700 12 125 35 mm² 2 AWG 50 mm² 1 AWG
1700 24 70 25 mm² 4 AWG 35 mm² 2 AWG
2200 48 40 10 mm² 8 AWG 16 mm² 6 AWG

Cable length is the total run, positive plus negative.

  • Control box (solenoids): mount in a dry place near the windlass. The X3 2200W 48V comes from the factory with a 24V command control box.
  • Circuit breakers: use the Lofrans breakers, chosen for their trip curve and not just a plate rating.
  • Remote control panel: mount where the operator can see the windlass and seal it so the terminals stay dry.
  • Wiring diagrams for 4-terminal and 2-terminal motors: deck footswitches UP/DOWN, control box, circuit breaker and a 5 A fuse.
  • Lofrans recommends lead-acid, AGM, gel or similar batteries. Li-ion or LiFePO4 batteries cause rapid deterioration of the motor, control box and transmission if they are not specified correctly.

Before You Drill

  • In the box: windlass with motor/gearbox, remote control switch or reverser box, base gasket, drilling template, handle, screws.
  • Tools: drill, 10 mm bit for wood and steel, 65 mm diameter 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 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 thickness 50–70 mm with the standard studs; other thicknesses on request.
  • Aluminium boats: insulate the windlass from the deck with a non-conductive gasket (not supplied), and insulate anchor, chain, locker and fixings from the hull.

Deck and Under Deck

  1. Place the drilling template on deck, aligned with the bow.
  2. Mark and drill. Leave the hole edges sharp, but radius the forward edge of the chain hole at 45°.
  3. Clean and fit the gasket supplied, then set the upper part on deck. Seal with silicone, never a permanent adhesive.
  4. Below deck: grease the main shaft, join the gearbox with the motor away from the chain hole, fit washers and nuts on the studs and tighten.
  5. Connect the battery cables to the motor following the wiring diagram.

Loading the Chain

  1. Remove the hood (two screws).
  2. Feed the chain through the hole and secure it to a safe point.
  3. Refit the hood.
  4. Wrap the chain round the gipsy.
  5. Recover all the chain under power, checking it enters the gipsy aligned.

Use calibrated chain matching the gipsy and always fit a swivel between chain and anchor.

Operation

Lowering

  • Electrically: clutch tight, chain fixings off; switch on the safety switch and press DOWN; switch off and re-engage the fixings.
  • By gravity: clutch tight, stoppers off, then ease the clutch with the handle. Clockwise brakes the chain (to a full stop), anticlockwise lets it run. Then make the chain (or rope) fast to a strong point.
  • A fully released clutch drops the anchor at high speed and can damage the hood and bow roller: always control the speed.
  • Wait for the windlass to stop before reversing direction.

Recovery, Override and Drum

  • Breaker on, clutch tight, handle removed, stoppers off; press UP until the anchor seats in the bow roller, then breaker off and chain on the stopper.
  • Run the engine or generator while recovering. If the breaker trips on overload, reset it and wait some minutes; it does not protect the motor from overheating on long runs.
  • Manual override: clutch engaged, brake, stopper and safety stops off; handle in the hand-wheel, turn clockwise against the spring in the gearbox. In deep water the effort is significant.
  • Warping drum: anchor secured; handle in the drum, turn clockwise to release the clutch (drum turns independently of the gipsy), three turns of rope clockwise, press UP; make the rope fast to a bollard afterwards.
  • Always remove the handle when not in use.
  • The finger is needed only when the windlass handles a chain-and-rope rode. With all-chain, remove the finger to avoid breaking it.
  • Lay the chain on the seabed without heaping it, motor slowly up over the anchor, and slow down as the anchor reaches the bow roller.

Never use the windlass as a mooring point: hold the load on a chain stopper or strong point.

Maintenance Programme

Use of the yacht (months) Less than 2 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 – Clean all external surfaces and hidden points with fresh water to remove the 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 / Replacement

  1. Remove the hood and the chain pusher by loosening the Allen screws.
  2. Turn the gipsy hand-wheel anticlockwise with the handle to remove it.
  3. Slide the upper clutch cone, gipsy and lower clutch cone off the shaft.
  4. Wash with running water, never pressure-wash, and check for corrosion or mechanical stress.
  5. Reassemble in reverse order, greasing threads and all moving parts.

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

Troubleshooting

Problem Possible cause Solution
Windlass does not run when a control is operated Protection switch OFF; no voltage; control box, control or motor failure Set the switch ON; check battery charge and connections; check/replace the control box or control; measure motor voltage – if OK, check and clean the brushes, otherwise replace the motor
Chain jams frequently Locker too shallow 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 Cables 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 turns neither up nor down Worn or broken wormwheel/worm teeth; broken motor spindle (Service) replace the broken parts, checking no debris has entered the oil; replace the motor, making sure no broken piece is left in the worm bore
Motor runs, shaft turns UP but not DOWN Tangled chain locker, poor chain, chain stowed in a block, worn spring of the emergency mechanism, or stripper fouling the gipsy – the emergency mechanism engages Fit a swivel after the anchor; inspect and free the chain; pay out all the chain in deep water and recover it; (service) replace the spring; re-centre or replace the stripper
Warping drum cannot be used Drum used in the wrong direction, so the emergency mechanism engages Warp with the main shaft turning in the same direction as when the gipsy recovers chain
Motor and shaft turn, gipsy stays still Gipsy not clamped on the clutch cones, or the closing wheel at end of travel; deformed cones with the hubs touching Check clutch tightening, measure for deformation, then replace the clutch and/or gipsy
Shaft runs out of true Shaft bent by excessive load (Service) replace the shaft and worn parts
Oil leak between motor and gearbox Loose motor coupling makes the worm run irregularly (Service) find why the fasteners loosened, check spindle and worm bore, repair and replace seals
Shaft and studs too short on installation Wrong deck thickness specified Adapt the studs if the key engages the gearbox over its full length; otherwise order a longer shaft
Runs slowly and sometimes trips the breaker Cables too small; poor connections; dirty brushes; water in the motor; deck faces not parallel; gearbox lost oil; motor strains; works in one direction only Increase cable section; check connections; clean brushes; replace the motor; shim the faces parallel; (service) inspect gearbox and motor; check the control box relays
The finger is broken Poor lead of the rope or the chain rolling has broken the finger Replace the finger; check the gipsy suits working with the finger

Spare Parts

Project 1500 (B.32.101 Rev. B)

Lofrans Project 1500 exploded view

X3 1500W

Lofrans X3 1500W exploded view

X3 Alu 1500W

Lofrans X3 Alu 1500W exploded view

X3 1700W (B.37.101 Rev. C)

Lofrans X3 1700W exploded view

Item numbers refer to the exploded views. Kit letters show which kit includes each part; Kit S is the magnet and sensor, Kit Cover the complete motor cover kit.

Item Description Kit Project 1500 X3 1500W X3 Alu 1500W X3 1700W
209 Key 6×6×30 Kit C ✓ ✓
226 Washer for M8 screw Kit B ✓ ✓
227 Nut M8 Kit B ✓ ✓ ✓ ✓
255 Key 6×6×25 Kit C ✓
272 Handle – ✓ ✓ ✓ ✓
284 Key 8×7×60 Kit C ✓ ✓
293 Hd cap screw M5×16 Kit F ✓ ✓ ✓ ✓
304 Seal 40-55-7 Kit A ✓ ✓
307 Spring washer for M6 screw Kit B ✓ ✓ ✓ ✓
308 Washer for M6 screw Kit B ✓ ✓ ✓ ✓
309 Bearing 6203 – ✓ ✓ ✓ ✓
311 Thrust bearing 51105 – ✓ ✓ ✓ ✓
312 Circlip 43 DIN 472 Kit D ✓ ✓ ✓ ✓
313 Seal 25-43-8 Kit A ✓ ✓
314 Key 5×5×15 Kit C ✓ ✓
351 Hd cap screw M6×20 Kit B ✓ ✓ ✓ ✓
450 Key 8×7×80 Kit C ✓ ✓
524 Seal 30×55×10 Kit A ✓ ✓ ✓ ✓
526 Circlip 30 DIN 471 Kit D ✓ ✓ ✓ ✓
534 Gearcase – upper – ✓ ✓
535 O-ring 4500 Kit A ✓ ✓
536 Seal 45×60×7 Kit A ✓ ✓
537 Bearing 16009 – ✓ ✓
538 Circlip 100 DIN 472 Kit D ✓ ✓
539 Key 8×7×35 Kit C ✓ ✓
540 Sleeve – ✓ ✓
541 Spring – ✓ ✓
542 Dog clutch – ✓ ✓
543 Wormwheel – ✓
546 Seal 25×45×10 Kit A ✓ ✓
619 Hd cap screw M6×10 Kit B ✓ ✓ ✓ ✓
639 Washer for screw M8 Kit B ✓ ✓
870 Bearing 6008 – ✓ ✓
906 Spacer Kit F ✓ ✓ ✓ ✓
907 Hd cap screw M6×50 Kit B ✓ ✓ ✓ ✓
909 Spring Kit F ✓ ✓ ✓ ✓
912 Clutch nut – ✓ ✓ ✓ ✓
913 O-ring 3287 Kit A ✓ ✓ ✓ ✓
920 Gearcase – upper – ✓ ✓
921 O-ring 4375 Kit A ✓ ✓
922 Sleeve – ✓
923 Washer – ✓
924 Spring – ✓
925 Dog clutch – ✓
926 Wormwheel – ✓
927 Circlip 40 DIN 471 Kit D ✓
945 Cap Kit F ✓ ✓ ✓ ✓
964 Magnet Kit S ✓ ✓ ✓
965 Sensor Kit S ✓ ✓ ✓
981 Support – ✓ ✓ ✓ ✓
982 Stripper – ✓ ✓ ✓ ✓
984 Hd cap screw M8×50 Kit B ✓ ✓ ✓ ✓
985 Std main shaft – ✓ ✓
986 LP main shaft – ✓ ✓
987 Stainless steel bearing 6006 2RS – ✓ ✓ ✓ ✓
988 Clutch cone – ✓ ✓ ✓ ✓
990 Spacer – ✓ ✓ ✓ ✓
992 Gasket – ✓ ✓ ✓ ✓
997 Circlip 55 DIN 472 Kit D ✓ ✓ ✓ ✓
1008 Pivot 8×14 Kit F ✓ ✓ ✓ ✓
1026 Plastic cap for sensor – ✓
1033 Stud M8×105 – ✓ ✓ ✓ ✓
1035 O-ring 2375 Kit A ✓
1077 Wormwheel – ✓
1243 O-ring 2287 Kit A ✓ ✓
1252 Std main shaft – ✓ ✓
1253 LP main shaft – ✓ ✓
1302 Hd cap screw M6×25 Kit B ✓
1304 Complete motor cover kit Kit Cover ✓ ✓
1305 O-ring 2375 Kit A ✓ ✓
1306 PG13 – ✓ ✓
1307 Gearcase – lower – ✓ ✓
1308 Worm – ✓ ✓
1317 Worm – ✓ ✓
1319 Gearcase – lower – ✓ ✓
1325a Electric motor 1500W 12V, built-in solenoid, B14 flange – ✓
1325b Electric motor 1500W 24V, built-in solenoid, B14 flange – ✓
1250a Electric motor 1500W 12V – ✓ ✓
1250b Electric motor 1500W 24V – ✓ ✓
1320a Electric motor 1700W 12V B14 – ✓
1320b Electric motor 1700W 24V B14 – ✓
980a Base – ✓ ✓ ✓
980b Base – ✓
983a Cover – ✓ ✓ ✓
983b Cover – ✓
989a Gipsy Ø8 ISO – ✓ ✓ ✓ ✓
989b Gipsy Ø10 ISO – Ø3/8" G40 – ✓ ✓ ✓ ✓
989c Gipsy Ø10 DIN 766 – ✓ ✓ ✓ ✓
989d Gipsy Ø12 ISO – Ø13 DIN 766 – ✓ ✓ ✓ ✓
991a Drum – ✓ ✓ ✓
991b Drum – ✓
993a Gipsy cap – ✓ ✓ ✓ ✓
998a Finger Kit F ✓ ✓ ✓ ✓
998b Stainless steel finger (option) Kit F ✓ ✓ ✓ ✓

Maintenance Kit 72040 for X3, X3 Alu & Project 1500

Lofrans maintenance kit 72040 exploded view with included parts highlighted

Code Description
72040 Maintenance kit for X3, X3 Alu & Project 1500 View kit →
Code Description
203 Seal 35×45×7
226 Washer for M8 screw
227 Nut M8 DIN 934
252 O-ring 2325
260 Spring washer for screw M8
304 Seal 40×55×7
312 Circlip 43 DIN 472
313 Seal 25×43×9
350 Round key 4×6,5
351 Hd cap screw M6×20
417 Hex cap screw M8×30
450 Key 8×7×80
524 Seal 30×55×10
526 Circlip 30 DIN 471
535 O-ring 4500
536 Seal 45×60×7
538 Circlip 100 DIN 472
539 Key 8×7×35
546 Seal 25×45×10
619 Hd cap screw M6×10
639 Washer for screw M8
830a Seal 30×50×7
907 Hd cap screw M6×50
913 O-ring 3287
921 O-ring 4375
927 Circlip 40 DIN 471
950a Circlip 48 DIN 472
984 Hd cap screw M8×50
997 Circlip 55 DIN 472
1243 O-ring 2287
1305 O-ring 2375

Overall Dimensions & Deck Template

Model A B (deck) C D E* F G H I J L
1500 W 195 50–70 165 Ø92 110 270 80 270 192 Ø114 135
1700 W 195 50–70 165 Ø92 110 270 80 300 192 Ø126 135
2000 W (as printed) 195 50–70 165 Ø92 110 270 80 320 192 Ø126 135

Dimensions in mm. * Low-profile height. Letters refer to the dimension drawing in the manual.

  • Deck template (separate download): four 9 mm (3/8") stud holes, the shaft and chain cut-outs, the hole for the sensor and the chain line.
  • Lofrans warns the drawing may not be to scale once printed: print at 100% and verify the printed dimensions before you start the installation.

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

Products in this Manual