Lofrans X5 Vertical Windlass — Installation & User's Manual
INSTALLATION MANUAL
Performance data, gipsy and chain match, cable sizing, installation, operation, maintenance, troubleshooting, dimensions and the parts list for the Lofrans X5 vertical windlass (3000W 24V DC, 3600W 230/400V AC and 9cc hydraulic), with the deck template.
DocumentLofrans X5 Vertical Windlass Installation & User's Manual
FormatPDF · 47 pages · 2.3 MB
LanguageEnglish
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Technical Data
| 3000W | 3600W | 9cc | |
|---|---|---|---|
| Vessel length, heavy duty | 85–95 ft (electric versions) | ||
| Vessel length, light duty | 90–100 ft (electric versions) | ||
| Power supply | 24V | 230/400V | N/A |
| Maximum linear load/pull | 2800 kg 6160 lb |
3000 kg 6600 lb |
3000 kg 6600 lb |
| Maximum lift load | 1400 kg 3080 lb |
1500 kg 3300 lb |
1500 kg 3300 lb |
| Max lift working load | 760 kg 1672 lb |
815 kg 1793 lb |
815 kg 1793 lb |
| Amps at work load | 250 A | N/A | N/A |
| Max line speed | 30 m/min 90 ft/min |
20 m/min 60 ft/min |
20 m/min 60 ft/min |
| Line speed at working load | 12 m/min 36 ft/min |
20 m/min 60 ft/min |
20 m/min 60 ft/min |
| Net weight with drum | 100 kg 220 lb |
105 kg 231 lb |
105 kg 231 lb |
The vessel-length rows span the 3000W and 3600W columns in the printed table. The technical data are printed as an image; values are copied from it.
| Gipsy | Chain supported |
|---|---|
| 12 mm | 12 mm ISO, 13 DIN 766, 7/16" G4 |
| 13 DIN 764 | 13 DIN 764 |
| 14 mm | 14 mm ISO |
| 1/2" HT | 1/2" G4 |
| 1/2" BBB | 1/2" BBB |
Rope supported: N/A for all gipsies.
Electrical System
| Motor (W) | Voltage (V) | Contactor (A) | Cable 15–25 m / 50–75 ft | Cable >25 m / >75 ft |
|---|---|---|---|---|
| 3000 | 24 | 125 | 50 mm² / 2 AWG | 75 mm² / 000 AWG |
Cable length is the total run, positive plus negative.
- Contactor (control box): mount in a dry place near the windlass.
- 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.
- The wiring diagram shows deck footswitches UP/DOWN, the solenoids and the motor terminals.
Before You Drill
- In the box: windlass with motor/gearbox, remote control switch or reverser box, drilling template, handle, screws.
- Tools: drill, 10 mm bit for wood and steel, 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: 100 mm with the standard series studs (the dimension drawing gives min 60 – max 90 mm, as printed); other thicknesses on request.
- 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.
Deck and Under Deck
- Place the drilling template on deck, aligned with the bow.
- Mark and drill. Leave the hole edges sharp, but radius the forward edge of the chain hole at 45°.
- Set the upper part on deck. Seal with silicone, never a permanent adhesive.
- 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.
- Connect the battery cables to the motor following the wiring diagram.
Loading the Chain
- Feed the chain through the hole and secure it to a safe point.
- Wrap the chain round the gipsy.
- 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, brake off, chain fixings off; switch on the safety switch and press DOWN; switch off and re-engage the fixings.
- 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. 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 and Warping Drum
- Breaker on, clutch tight, brake off, 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.
- Warping drum: brake on and 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.
- Never put chain on the warping drum. Always remove the handle when not in use.
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
- Turn the gipsy hand-wheel anticlockwise with the handle to remove it.
- Slide the upper clutch cone, gipsy and lower clutch cone off the shaft.
- Wash with running water, never pressure-wash, and check for corrosion or mechanical stress.
- 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 with the brake band loose | 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 | Check use is within the specification; (service) replace the shaft and worn parts, gaskets, circlips, keys and oil |
| 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 on the bench, check for oil in the motor; replace seals and oil |
| 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 for 12/24V between B2–C and B3–C on the control box when each button is pressed – if present and a relay does not work, replace the control box |
Spare Parts
Item numbers refer to the exploded view (B.59.101). The kit letter shows which kit includes each part, as printed.
| Item | Description | Kit |
|---|---|---|
| 216 | Nylon bush | – |
| 217 | Hex hd screw M8×20 | Kit B |
| 226 | Washer for screw M8 | Kit B |
| 231 | Washer for screw M5 | Kit B |
| 234 | Hd cap screw M8×20 | Kit B |
| 250 | Hd cap screw M5×8 | Kit B |
| 255 | Key 6×6×25 | Kit C |
| 260 | Spring washer for screw M8 | Kit B |
| 272 | Handle | – |
| 293 | Hd cap screw M5×16 | Kit B |
| 336 | Oil cap | – |
| 361 | Seal 40×50×5 | Kit A |
| 395 | Seal 50×70×10 | Kit A |
| 396 | Bearing 16010 | – |
| 400 | Circlip 15 DIN 471 | Kit D |
| 407 | Sightglass | – |
| 414 | Hex hd screw M8×30 | Kit B |
| 415 | Nut M12 | Kit B |
| 449 | Pivot | – |
| 453 | Bearing 6206 | – |
| 567 | Clutch nut | – |
| 568 | Seal 55×72×10 | Kit A |
| 575 | Band brake | Kit B |
| 576 | Pivot | Kit C |
| 577 | Spring | Kit D |
| 580 | Washer for screw | Kit B |
| 581 | Safety nut M12 | Kit B |
| 582 | Dished plane spring | – |
| 583 | Clutch cone – inner | – |
| 585 | Brake pivot support | – |
| 586 | Brake pivot | – |
| 609 | Key 12×8×60 | – |
| 642 | Brake cover | – |
| 671 | Bearing 6011 | – |
| 730 | Conic screw M10×30 | Kit B |
| 741 | Key 12×8×150 | – |
| 746 | Stud M8×40 | Kit B |
| 874 | Gearcase – upper | – |
| 875 | O-ring seal 4800 | Kit A |
| 877 | Ratchet | – |
| 878 | Gearcase – lower | – |
| 879 | O-ring seal 159 | Kit A |
| 880 | Oil level flange | – |
| 881 | Coupling flange | – |
| 883 | Spacer | – |
| 884 | Handle | – |
| 1024 | Spring | – |
| 1031 | Sensor | – |
| 1174 | Screw M8×6 | Kit B |
| 1256 | Electric motor 3000W 24V | – |
| 1260 | Wormwheel | – |
| 1261 | Worm | – |
| 1262 | Motor flange for B14 | – |
| 1263 | Hd cap screw M12×30 | Kit B |
| 1264 | Spacer | – |
| 1265 | Base | – |
| 1266 | Hand-wheel shaft | – |
| 1267 | Gimbal | – |
| 1268 | Brake shaft | – |
| 1269 | Support; support sensor (two rows, as printed) | – |
| 1270 | Hand-wheel | – |
| 1272 | Drum | – |
| 1273 | Clutch cone – outer | – |
| 1274 | Chain pipe | – |
| 1275 | Stripper | – |
| 1276 | Stripper base | – |
| 1277 | Seal 55×90×10 | Kit A |
| 1278 | Spiral retaining ring 55mm | Kit D |
| 1279 | Circlip 90 DIN 472 | Kit D |
| 1280 | Main shaft | – |
| 1297 | Stud M12×160 | – |
| 1313 | Gipsy chain 12 ISO – 13 DIN 766 – 1/2" DIN 766 | – |
| 1323 | Key 6×7×40 | Kit C |
| 574d | Gipsy chain 14 ISO | – |
| 574g | Gipsy chain 12,5 stud link | – |
| 632b | Bearing 51108 | – |
| 641ai | A.C. electric motor 4KW B14 | – |
Overall Dimensions & Deck Template
| Ref. | mm |
|---|---|
| A | 385 |
| B (deck) | min 60 – max 90 |
| C | 200 |
| D | Ø132 |
| E | – |
| F | 332 |
| G | 140 |
| H | 445 |
| I | 264 |
| J | Ø152 |
| K | 339 |
| L | 190 |
Letters refer to the dimension drawing C.59.101 (X5 3000W) in the manual.
- Deck template (separate download): base cut-out with four Ø16 stud holes, Ø60 shaft hole, chain pipe cut-out and the chain-line offset A for 12.5 stud link, 14.5 stud link and 14 short link chain.
- 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.
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