VWC, VWCLP 1200 OWNERS MANUAL

VWC, VWCLP 1200 OWNERS MANUAL
VWC, VWCLP 1200
OWNERS MANUAL
Manual Product
Code No: P19156
Removable Chain Cover
and A Gearbox Ratio Of 56:1
©
COPYRIGHT 1991 MAXWELL WINCHES LTD
ALL RIGHTS RESERVED.
PATENTS PENDING.
PRINTED IN NEW ZEALAND.
MAXWELL WINCHES reserve
the right to make engineering
refinements on all products
without notice.
Illustrations and specifications
not binding as to detail.
VWC, VWCLP 1200
OWNERS MANUAL
Page
Number
1
CONTENTS
INTRODUCTION
2
SPECIFICATIONS
PERSONAL SAFETY WARNING
APPLICATION
INSTALLATION
Location
- Windlass
- Chainstopper
- Footswitches
- Reversing Solenoid
- Breaker Isolator Panel
- Controls
Control Circuits
Main Electrical System
Hydraulic Systems
Preparation of Mounting
Preparation of Windlass
Mounting the Windlass
OPERATION OF THE CONTROL SYSTEM
OPERATING THE WINDLASS
MAINTENANCE
Servicing of Gearbox
Servicing of Motor
ORDERING SPARE PARTS
ASSISTANCE
INSTALLATION DRAWINGS
VWC 1200
B201219
VWCLP 1200
B201220
Wiring Diagram (Dual Direction)
B3424
Wiring Diagram (Single Direction) D3555
Hydraulic Control Diagram
B203101
Hydraulic Schematic
B203103
ASSEMBLY DRAWINGS
VWC 1200 Electric
P100128
VWC 1200 Hydraulic
P100116
VWCLP 1200 Electric
P100111
VWCLP 1200 Hydraulic
P100117
Gearbox
P12427
3-4
5-7
8
WARRANTY
CUSTOMER WARRANTY REGISTRATION
1
9
10
10
11
11
11
11
12-13
13
14
15
15-16
17
18-20
21
22
22
23
23
24
25
26
27
28
29
30-31
32-33
34-35
36-37
38-39
INSTALLATION, OPERATING INSTRUCTIONS AND SERVICE MANUAL
VWC 1200 AND VWCLP 1200 WINDLASSES
INTRODUCTION
You now own a Windlass from MAXWELL’S premier range, designed for automatic
anchor handling.
Used in conjunction with MAXWELL’S Link System Electronic Controls, you will get
system protection and finger-tip control of anchor raising or lowering.
The compact deck saving vertical design allows 180º wrap of the chain ensuring
maximum engagement with the chainwheel. On VWC types a vertical drum allows
working of mooring or docking lines from any direction.
A clutch allows manual control for lowering the anchor under free fall and manual
override when using the emergency crank. The clutch also allows independent
operation of the drum on VWC types.
** IMPORTANT **
FAILURE TO ADHERE TO THE CORRECT APPLICATION, INSTALLATION,
OPERATION AND TO CARRY OUT THE MAINTENANCE SERVICE AS DESCRIBED
HEREIN, COULD JEOPARDISE YOUR SAFETY AND INVALIDATE THE
WARRANTY.
Your MAXWELL Windlass is a precision engineered product. Please read these
instructions carefully.
2
SPECIFICATIONS: MAXWELL VWC/VWCLP 1200 WINDLASS
Maximum chain size
Maximum rated load
at chainwheel
Current (stall load)
10mm (3/8”) short link
1200 lbs (545Kg)
430 amps @ 12volts
210 amps @ 24volts
56:1
Gearbox ratio
Chain haul speed
at no load
Line speed (normal working)
POWER OPTIONS
VWC 1200
10mm (4”) Deck clearance
24 Metres/min (79 Feet/min)
17 Metres/min (56 Feet/min)
150mm (6”) Deck clearance
VWCLP 1200
100mm (4”) Deck clearance
150mm (6”) Deck clearance
SUPPLY CABLES
* HYDRAULIC MODELS
Max. recommended Flow
Max. recommended Pressure
Hydraulic Supply Lines
Hydraulic Motor Ports
Oil
P100110
P100113
P100116
P100128
P100131
P100134
12Volt DC.
24Volt DC.
Hydraulic
12Volt DC.
24Volt DC.
Hydraulic
P100111
P100114
P100117
P100129
P100132
P100135
12Volt DC.
24Volt DC.
Hydraulic
12Volt DC.
24Volt DC.
Hydraulic
See Pages 13-14
P14366
20 Litre/min (5.3 US Gal/min)
138 BAR (2000 p.s.i.)
12mm (½) diameter
¾” U.N.F.
Viscosity ISO 32 - ISO 68 @ 20-50ºC
Minimum of 0.125% zinc anti wear
additive. Suitable
15WPenzoil
SAE
oils: Shell Rimula X
40; Shell Myrina M 15W-40;
SAE 10W-40; Texaco 2109
15W; Texaco 1814 SAE 10W-40.
* Levels of flow/pressure below that specified can be accommodated with a
motor change - see options page 5.
3
Motor
Option
Max Flow/Min
Lt
US Gal
Max Pressure
Bar
P.S.I.
Max
Kg
Pull
Lbs
Normal Rate/Min
Metres
Feet
P14365
15
138
273
600
22
72
Product Code
KGS
LBS
P100110
P100113
P100116
P100128
P100131
P100134
23.8
23.8
16.8
24.2
24.2
17.2
52.4
52.4
37.0
53.2
53.2
37.82
P100111
P100114
P100117
P100129
P100132
P100135
21.8
21.8
14.8
22.2
22.2
15.2
48.0
48.0
32.5
48.8
48.8
33.4
4.0
2000
WEIGHT (Nett including Emergency Crank)
VWC 1200
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
VWCLP 1200
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
4
IMPORTANT
PERSONAL SAFETY WARNINGS
WHEN USING YOUR WINDLASS AT ALL TIMES PRACTICE GOOD SEAMANSHIP
AND AVOID ANY LIKELIHOOD OF INJURY OR ACCIDENT BY ADHERING TO THE
FOLLOWING RULES.
AT ALL TIMES KEEP HANDS, FEET, LOOSE CLOTHING AND HAIR WELL CLEAR
OF THE WINDLASS.
NEVER USE THE WINDLASS UNDER POWER WITH THE LEVER INSERTED IN THE
CLUTCH NUT OR EMERGENCY CRANK COLLAR.
WHEN OPERATING THE CHAINWHEEL PAWL, KEEP FINGERS AWAY FROM THE
INCOMING CHAIN.
WHEN THE WINDLASS IS NOT IN USE, OR WHEN USING THE EMERGENCY
CRANK, MAKE SURE THE WINDLASS IS ISOLATED FROM THE POWER SUPPLY
BY TURNING THE WINDLASS ISOLATOR SWITCH TO “OFF”.
NEVER OPERATE THE WINDLASS FROM A REMOTE STATION WITHOUT A
CLEAR VIEW OF THE WINDLASS AND HAVING MADE SURE THAT EVERYONE IS
WELL AWAY FROM THE WINDLASS.
IF YOUR WINDLASS DOES NOT HAVE A REMOTE CONTROL STATION AND IS
OPERATED FROM THE FOOTSWITCHES ONLY, ALWAYS IMMEDIATELY AFTER
USE, TURN THE WINDLASS ISOLATOR SWITCH TO “OFF”. THIS WILL PREVENT
ACCIDENTAL WINDLASS OPERATION IF YOU OR PASSENGERS ACCIDENTALLY
STAND ON FOOTSWITCHES.
5
**
IMPORTANT HINTS FOR SAFE USE OF WINDLASS **
BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED AND
INSTALLED, YOURS AND OTHERS SAFETY MAY DEPEND ON IT. THE
WINDLASS SHOULD BE USED IN CONJUNCTION WITH A CHAINSTOPPER OF
THE APPROPRIATE SIZE. FOR AUTOMATIC OPERATION TO BE POSSIBLE, THE
ANCHOR MUST BE SELF LAUNCHING.
MAXWELL WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF
A WINDLASS BY OTHERS, INCLUDING DISTRIBUTORS AND AGENTS. IF IN
DOUBT, SEND FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT
FOR APPRAISAL AND WRITTEN RECOMMENDATION.
1. Run the engine whilst raising or lowering the anchor. Not only is this a safety
precaution, it also helps minimise the drain on the batteries.
2. Always motor up to the anchor while retrieving the chain.
Do no use the Windlass to pull the boat to the anchor.
3. If the anchor is fouled, do not use the Windlass to break it out.
With the chainstopper taking the load, use the boats engine to break the
anchor loose.
4. Do not use the Windlass as a Bollard.
In all but the lightest conditions, engage the chainstopper after completing
the anchoring manoeuvre.
5. In heavy weather conditions, always use a heavy anchor snub from the chain
directly to a Bollard or Sampson Post.
6. DO NOT USE THE CHAINSTOPPER OR WINDLASS AS A MOORING POINT.
7. ALWAYS TURN THE ISOLATOR SWITCH TO “OFF” BEFORE LEAVING BOAT.
8. When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE
DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO
STOP AS THIS COULD DAMAGE THE WINDLASS. Abuse is not covered by
Warranty.
9. The Circuit Breaker and Isolator Switch Panel provides high current
protection for the main supply cables and also the means to isolate the
circuit. When the Isolator Switch is “ON” (red indicator light shows) the
system can be activated at either the footswitches or the remote control
station. When the system is not being used, ensure that the Isolator Switch is
turned “OFF”.
10. Never proceed at speed with a bow mounted self launching anchor in
position, without first ensuring that your winch clutches are fully engaged,
and having made fast the anchor and engaged your chainstopper.
DO NOT DEPEND ON THE WINDLASS TO HOLD THE ANCHOR IN ITS BOW
ROLLER. A NYLON LINE SHOULD BE USED TO SECURE THE ANCHOR INTO
6
ITS STOWED POSITION WHEN UNDERWAY AND WILL NEED TO BE
REMOVED BEFORE OPERATION OF THE WINDLASS. ALTERNATIVELY, A
PIN THROUGH THE BOW ROLLER AND THE SHANK OF THE ANCHOR CAN
BE USED FOR SECURING.
Most Windlass models have clutches for the manual pay out of ground tackle
in the event of a loss of power. It is therefore prudent to secure the anchor to
the boat by the means described above.
7
APPLICATION
THE MAXWELL VWC AND VWCLP 1200 WINDLASSES ARE DESIGNED FOR ALL
CHAIN SYSTEMS USING UP TO A MAXIMUM CHAIN SIZE OF 10MM (3/8”) SHORT
LINK CHAIN.
To save weight, a smaller size High Tensile Chain may be used.
** WARNING **
BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED BEFORE
INSTALLATION, YOURS AND OTHERS SAFETY MAY DEPEND ON IT.
MAXWELL WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF
A WINDLASS BY OTHERS, INCLUDING DISTRIBUTORS AND AGENTS. IF IN
DOUBT, SEND FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT
FOR APPRAISAL AND WRITTEN RECOMMENDATION.
Your Windlass should have a rating of approximately 3 times total combined weight of
the anchor and chain.
The ground tackle should have been selected taking into account:
a)
Boat size, displacement and windage.
b)
Conditions of operation such as maximum depth of water, type of bottom and
weather conditions.
c)
Holding power and size of anchor, taking special note of the manufacturers’
recommendations.
CHAIN FIT
CORRECT FIT OF CHAIN TO CHAINWHEEL IS ESSENTIAL FOR THE WINDLASS
TO OPERATE PROPERLY.
A range of chainwheels is available to suit your Windlass.
The correct fit can only be guaranteed where a standard chain known to us is used.
Alternatively a 450mm (18”) or 12 links (whichever is longer) sample must be forwarded
to us to match fit. Where patterns to suit are not held by us we are able to manufacture
to instructions and reserve the right to charge cost thereof.
CHAINSTOPPER
THE WINDLASS SHOULD BE USED IN CONJUNCTION WITH A MAXWELL
CHAINSTOPPER OF THE APPROPRIATE SIZE.
8
INSTALLATION
WHERE TO LOCATE THE WINDLASS
The MAXWELL VWC and VWCLP 1200 Windlasses operate in dual direction power
UP/DOWN.
“UP” is clockwise rotation when looking down on the Windlass.
The deckplate should be mounted pointing in the direction of the incoming chain
and with the left hand side parallel to the line of the incoming chain (refer drawing
B201219 VWC types and B201220 VWCLP types). This arrangement allows the chian
to have maximum engagement with the chainwheel.
The Windlass must be positioned to allow the chain to have a clear run from the
fairlead or bow roller on to the chainwheel.
The bow roller should have a vertical groove to suit the profile of the chain. This
will align the chain so that it enters the chainwheel without twisting.
Ideally the outlet from the chainpipe should be directly over the chain locker and
the chain should have at least 500mm (2ft) clear fall to allow the chain to
straighten before passing through the Windlass.
If it can be arranged the chain locker bulkhead should pass between the
chainpipe outlet in the deckplate and the Windlass gearbox. This will keep the
gearbox, motor and wiring or hydraulic hoses dry and away from flaying chain. Access
for servicing from inside the cabin area can usually be arranged through a locker.
The chain must gravity feed into the locker. If the chainpipe cannot be positioned
directly over the locker, heavy wall flexible plastic pipe can be used to direct the chain to
the required area.
It is important that the chain slips through easily, completely unaided. It may be
necessary to provide the pipe with a bell mouth or to bell mouth the entrance to the
chainpipe from the locker to assist the free flow of the chain from the locker.
The chain locker must be of such a size that the chain will heap up and feed out
naturally without fouling.
NOTE: Make sure you securely fasten the end of the chain to the boat.
9
** IMPORTANT **
FOR AUTOMATIC OPERATION TO BE POSSIBLE, THE ANCHOR MUST BE SELF
LAUNCHING. That is, once the Windlass is operated to reverse out the chain, the
anchor must free fall, or the bow roller arrangement be such that the anchor is
automatically launched.
When positioning the Windlass, make sure that there is room to swing the
emergency crank so that it will clear the pulpit and life lines or Bulwark (refer
drawing B201219 VWC types and B201220 VWCLP types).
Allow access for conveniently connecting the supply lines under deck after the
Windlass is bolted in position.
It should be noted that the gearbox can be indexed through 4 different positions
in relation to the deckplate (refer drawing B201219 VWC types and B201220 VWCLP
types). This can be achieved on installation by referring to the appropriate assembly
drawing and indexing at the top end of the spacer tube (item 15 on gearbox assemblyP12427) on bolts (item 15 on windlass assembly). Be sure to select the most
convenient position and allow for the best run for the chain to clear the motor.
WHERE TO LOCATE THE CHAINSTOPPER
The chainstopper should be positioned and aligned in a convenient position between
the Windlass and the bow roller, so that it clears the anchor stock. The chain should
pass through the stopper without being deflected.
WHERE TO LOCATE THE FOOTSWITCHES
Footswitches are not normally fitted on open sports boats as the Windlass can be
seen and operated from the helm, however if footswitches are required the
following should be adhered to.
FOOTSWITCHES SHOULD BE POSITIONED FAR ENOUGH AWAY FROM THE
WINDLASS TO ENSURE OPERATOR SAFETY.
To allow the operator to tail from the warping drum, footswitches should be at least
500mm (20”) from the Windlass.
THE BELOW DECK PORTION OF THE FOOTSWITCH SHOULD NOT BE EXPOSED
TO WATER OR WET ENVIRONMENT AND THE BREATHER HOLES MUST BE
KEPT CLEAR.
Ideally, they should be external to the chain locker.
The arrows on the footswitches should be arranged to indicate the direction of
operation.
10
WHERE TO LOCATE THE REVERSING SOLENOID (Electric Windlass Only)
This unit is used ONLY when a DUAL Direction control system is being installed.
(Refer drawing B3424). The Reversing Solenoid should be located in a dry area in
close proximity to the Windlass.
IT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAINLOCKER.
Locating close by the Windlass considerably shortens the total length of the main power
supply conductors required.
WHERE TO LOCATE THE BREAKER/ISOLATOR PANEL (Electric Windlasses Only)
The Maxwell Breaker/Isolator Panel is used when either the Dual Direction system
(refer drawing B3424) or the Single Direction System (refer drawing B3555) is used.
The Breaker/Isolator Panel is selected to provide limited protection only for the
motor and full protection for the supply cables.
This unit also provides the means for isolating the electrical system from the battery.
This should be mounted in a dry place within 1.8 metres (72”) of cable length
from battery.
This equipment or equivalent is mandatory to meet U.S.C.G. requirements.
WHERE TO LOCATE THE CONTROLS
The remote control stations can be positioned as required, i.e. Bridge, Helm, Cockpit or
Foredeck to suit your requirements.
Mount the panels where the terminals project into a dry area and if mounted in an
area where the face is exposed to the weather, i.e. Fly Bridge, the mounting must be
bedded down with sealant.
They may be wired directly to, or linked together in series to the Reversing Solenoid
(refer B3424).
CONTROL CIRCUITS
Footswitches (if required) and remote control circuits are to be wired using
1.5mm² (16 AWG) cable.
A manually resettable ignition proof fuse or breaker is to be fitted within 1 metre
(40”) of the power source on line 2 of the control cable conductor.
The above requirements are mandatory to meet USCG, ABYC, and NMMA.
After all connections have been made and system tested, seal terminals against
moisture by spraying with CRC2043 “Plasti-Coat”, CRC3013 “Soft Seal” or CRC2049
“Clear Urethane”. Refer to drawing B3384 for wiring details.
11
MAIN ELECTRICAL SYSTEM
The main electrical system is a two cable ungrounded fully insulated negative return
system.
The motor is of the isolated earth type.
This system is used to minimise electrolytic and corrosion problems.
The system should be wired as per drawing B3424 or D3555 having taken into
consideration the best location for the main elements as previously discussed.
After all connections have been made and system tested, seal terminals against
moisture by spraying with CRC2043 “Plasti-Coat”, CRC3013 “Soft Seal” or CRC2049
“Clear Urethane”.
The main supply cables should be selected from the following table:
RECOMMENDED MAIN CABLE CONDUCTOR SIZE
12 VOLT D.C. SYSTEMS
Conductor Length
Conductor Size
Engine Room
Battery to Winch
Size Correction
____________________________________________________________________
Metres
3.1
4.6
6.2
7.7
9.2
10.8
12.3
15.4
Feet
10
15
20
25
30
35
40
50
MM²
26
26
26
34
42
54
54
67
A.W.G
3
3
3
2
1
0
0
00
MM²
34
34
34
-
A.W.G
2
2
2
-
MM²
14.0
14.0
14.0
14.0
14.0
14.0
22.0
22.0
A.W.G
6
6
6
6
6
6
4
4
MM²
14
14
14
-
A.W.G
6
6
6
-
24 VOLT D.C. SYSTEMS
Metres
3.1
4.6
6.2
7.7
9.2
10.8
12.3
15.4
Feet
10
15
20
25
30
35
40
50
12
NOTE
a) Conductor length means the actual length of the conductor between the battery and
Windlass.
b) Recommendations allow for a maximum 10% voltage drop approximately over the
conductor length.
c) Where portion of cable runs through the engine room a size increase should be made
as indicated.
d) Recommendations assume cable insulation has a minimum thermal rating of 90ºC.
e) The above recommendations are in accordance with the requirements of
USCG, ABYC AND NMMA.
HYDRAULIC SYSTEMS
Pressure/flow quoted in specification on page 4 assumes operation at rated capacity
with standard motor fitted. Levels below that specified can be accommodated, by a
motor change, with a corresponding change to stall torque and/or speed. (Refer chart
page 5).
Several levels of supply and control are possible.
BASIC SYSTEM (Refer drawing B203101 and B203103).
This covers applications where the Windlass is supplied from an engine driven pump or
single function power pack. Control of the Windlass is via a hydraulic bi-directional
solenoid valve which is operated by a self centering UP/DOWN toggle switch type
remote control or the footswitches.
Use of MAXWELL’S Hydraulic Single Function Controller will enhance the system
and allow the interfacing of self centering UP/DOWN toggle switch control and
footswitches, with the hydraulic bi-directional solenoid valve controlling the oil flow to the
Windlass. This unit also provides for remote controlling the oil flow to the Windlass.
This unit also provides for remote controlling the electric clutch of a main engine pump
or the hydraulic power pack motor starter.
The controller must be located in a dry area.
IT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAIN
LOCKER.
MAXWELL LINK-SYSTEM MULTI-FUNCTION ELECTRO-HYDRAULIC POWER
PACKS
See separate manual for these multi-function, multi-purpose systems
.
13
PREPARATION OF MOUNTING
Standard units will accommodate deck thickness up to 100mm (4”). Extra clearance
models are available to accommodate deck thickness in the range of 100mm to 150mm
(6”).
It should be noted that keeping the thickness to no more than 100mm (4”) and 150mm
(6”) respectively, will considerably enhance serviceability. This will allow access to the
gearbox mounting bolts, allowing the gearbox to be removed as a sealed unit, without
dismantling the top works.
** IMPORTANT **
1. IT IS IMPERATIVE THAT THE DESIGNER/INSTALLER ENSURES THAT THE
DECK AND UNDERDECK PAD ARE OF SUFFICIENT THICKNESS AND
STRUCTURAL STRENGTH TO SUSTAIN THE LOADS CAPABLE OF BEING
IMPOSED ON OR BY THE WINDLASS. THE UNDERDECK PAD SHOULD
SPREAD THE LOADS AS WIDELY AS POSSIBLE AND IF USE CAN BE MADE
OF A BULKHEAD OR CROSS MEMBER TO PROVIDE STIFFENING, THIS
SHOULD BE DONE.
2. IT IS VERY IMPORTANT THAT THE ABOVE DECK PAD TOP SURFACE OR
DECK AREA COVERED BY THE GASKET SUPPLIED, AND THE UNDERDECK
AREA AGAINST WHICH THE LOAD WASHERS SEAT, ARE SMOOTH, FLAT
AND GENERALLY PARALLEL.
3. The gasket item 22 supplied with the Windlass can be used for accurately spotting
the mounting holes and marking the cut outs. After spotting, bore the necessary
holes. These must be drilled parallel to each other and square to the mounting
face.
DON’T SPOT THROUGH THE GASKET WITH THE DRILL. THIS WILL DAMAGE
THE GASKET.
NOTE: For boats of steel or aluminium construction, it is very important that the
deckplate is insulated from the deck with the non conductive gasket provided that the
mounting studs pass through insulators and that the underdeck fixings are insulated
from the deck. It is also important that the anchor and chain is insulated from the hull,
including rubber lining, the chain locker and insulating the fixing for the end of the chain
to the hull.
Without these precautions severe electrolysis can occur.
It is not necessary to separately earth the Windlass, as the electric motor is of the
isolated earth type.
14
PREPARING THE WINDLASS
Remove the Windlass from the packaging.
Subject to the type of packaging used, the Windlass will be either completely assembled
or with the motor separated from the gearbox.
Refer to the appropriate assembly drawing provided for the Windlass being
installed and proceed as follows:
4. If the motor is not fitted to gearbox assemble it as follows:
For Electric Motors
Offer motor up to gearbox aligning drive pin with slot in the worm item 2 (refer to
drawings P12427).
Insert and tighten two bolts item 32 and washer items 33, 34 provided (refer to
Assembly Drawings P100110 and P100111).
For Hydraulic Motors
Offer motor up to gearbox aligning drive pin with slot in the worm item 2 ( refer to
drawings P12427).
Insert and tighten two bolts item 32, washers items 33, 34 and nuts item 39
provided
(refer to Assembly Drawings P100116 and P100117).
5. With a pen knife, or similar, carefully remove cap, item 1.
Remove screw, item 2 and retaining washer, item 3.
Unscrew clutch nut, item 5.
Lift drum, item 28 from shaft (VWC models only).
Undo cap screw item 9 with washer item 33 & 34 .
Remove chain cover item 10 & stripper item 25 from deckplate item 14.
Lift clutch cones, and chainwheel, items 6, 7 and 8 from the shaft.
Remove two keys, item 29 (VWC models), one key (VWCLP models), item 29 from
shaft item 27.
Remove Wave spring washer, item 11 and Emergency Crank Collar, item 12 from
the shaft item 27
6. Remove four bolts item 15 with spring washers item 16 and lift deckplate 14 from
gearbox assembly.
With gearbox held horizontally, check that oil is showing half way up the sight
glass. If necessary, top up with SAE 90 (Shell Omala 320, Castrol Alpha SP320
or equivalent). DON’T OVER FILL.
7. Remove washers items16 and 24, by undoing four nuts item 26.
MOUNTING THE WINDLASS
8. Clean the underside of the deckplate item 14.
Make sure the mounting area on the deck is properly prepared, as per step 3
above and is clean.
Using the gasket item 22 between the deckplate and the deck, lower the deckplate
to the deck, guiding the mounting studs 23 through the pre drilled mounting holes
and bed the deckplate down.
9. From the underside of the deck offer up the four load washers item 24 and replace
four washers and nuts, items 16 and 26.
15
IMPORTANT
Tighten the nuts progressively and evenly.
DO NOT USE POWER
10. Lightly grease shaft item 27, using Shell Alvania R2, Castrol AP2 or equivalent
grease.
Holding the gearbox assembly, feed the shaft through the deckplate from below
and locate the spacer tube item 15 (refer to drawings P12427) on the spigot of the
deckplate item 14. Rotate the gearbox assembly to the most appropriate of the
four positions available.
Replace four bolts and spring washers items 15 and 16 removed in step 6 above.
Tighten bolts evenly and firmly - DON’T USE POWER TOOLS.
11. Ensure parts removed in step 5 above are clean along with the top area of the
deckplate.
12. Use grease (specified in step 10 above) and with the aid of a clean brush or nonfluffy rag, lightly grease the thread on the top end of shaft item 27 and the bores
and clutch faces of the parts removed in step 5 above, reassemble them as you
go in reverse order.
IMPORTANT - care must be taken to ensure that the key/keys, item 29 are
properly seated in shaft.
IMPORTANT NOTE TO BOAT BUILDERS
After completing installation we suggest that you spray the top works of the winch with
CRC3097 “Long Life”.
Also protect the winch by wrapping with plastic film and tape.
Experience has shown that on long ocean deliveries as deck cargo sulphur from the
ship’s exhausts settles and severely damages the chrome plating and stainless steel by
breaking down the chrome oxide protective film.
PLEASE LET YOUR CUSTOMER RECEIVE THE WINDLASS FROM YOU IN THE
SAME TOP QUALITY CONDITION THAT YOU RECEIVED IT FROM US
.
16
OPERATION OF THE CONTROL SYSTEM
DUAL DIRECTION SYSTEM (Refer drawing B3424)
This system provides means of controlling the Windlass via a Reversing Solenoid which
is actuated by a self centering UP/DOWN toggle switch type remote control or the
footswitches.
An indicator light on the remote control glows when the power is “ON” and the system
can be operated.
WARNING: When using the Windlass DO NOT SWITCH IMMEDIATELY FROM
ONE DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO
STOP AS THIS COULD DAMAGE THE WINDLASS. Abuse is not covered by
Warranty.
The Breaker/Isolator Panel provides protection for the main supply cables and
means to isolate the circuit.
WARNING: When the Isolator Switch is “ON” the system can be activated at
either the footswitches or the remote.
When the system is not being used, ensure that the Isolator Switch is turned
“OFF”.
WARNING: This system provides protection for the motor from excessive current
and short circuit. It does not provide protection against excessive heat build up
due to prolonged operation or repeated operation under overload conditions.
Make sure you give the motor time to cool. Abuse is not covered by Warranty.
17
OPERATING THE WINDLASS
LOWERING THE ANCHOR UNDER POWER
Proceed as follows:
1. Insert the lever item 30 into the clutch nut item 5 and check that the clutches are
tightened down firmly by turning the nut clockwise.
REMOVE THE LEVER.
2. Check that the chainstopper is open and the pawl item 19 is disengaged from the
chainwheel.
NOTE: This may require jogging the Windlass “UP” by momentarily operating the
footswitch.
3. If clutches are tightened down and the chainstopper and pawl are disengaged, the
Windlass may be operated under power by either using the “DOWN” footswitch or
the “DOWN” button on the remote control station. Hold until the required amount of
chain is out.
RAISING THE ANCHOR UNDER POWER
Proceed as follows:
1. Carry out step 1 above.
2. If the clutches are tightened down, the Windlass may be operated under power by
either using the “UP” footswitch or the “UP” button on the remote control station.
Hold until the required amount of chain has been brought in.
Care should be taken when docking the anchor. Jog in the last metre (few feet)
carefully seating the anchor home.
NOTE: It is not necessary to disengage the pawl or open the chainstopper to
operate the Windlass in the “UP” direction.
LOWERING THE ANCHOR UNDER MANUAL CONTROL
This method is generally used in tight anchorages or an emergency situation, where a
fast dump is required.
Proceed as follows:
1. Insert the lever item 30 into the clutch nut item 5 and check that the clutches are
tightened down firmly by turning the nut clockwise.
REMOVE THE LEVER.
18
2. Check that the chainstopper is open and the pawl item 19 is disengaged from the
chainwheel.
NOTE: This may require jogging the Windlass “UP” under power or in an
emergency by using the emergency crank lever.
IF JOGGING UNDER POWER, MAKE SURE THAT THE LEVER IS REMOVED
FIRST.
3. Standing well clear, insert the lever into the clutch nut.
Slowly back off the clutch nut.
This will release the chain.
Regulate the speed at which the chain goes out by tightening to slow, or easing to
increase.
** CAUTION **
DO NOT ALLOW THE CHAINWHEEL TO FREE WHEEL AS THIS WILL ALLOW
DANGEROUSLY HIGH CHAIN SPEEDS TO BUILD UP.
4. When the required amount of chain is out, tighten the clutch nut firmly, remove
the lever and stow.
RAISING THE ANCHOR MANUALLY IN AN EMERGENCY
An emergency crank facility for raising the anchor is provided.
To use proceed as follows:
1. Check that the chainstopper is engaged.
If a chainstopper is not fitted ensure that the pawl item 19 is engaged with the
chainwheel.
2. Insert the lever in the clutch nut and release clutches by backing off the clutch nut in
a counter clockwise direction.
3. Insert the lever into the emergency crank collar item 12, pin end first, with pin
uppermost, until the pin engages with one of the dogs in the chainwheel in the
furthermost counter clockwise position.
4. Take the weight by pulling the lever in a clockwise direction as far as possible,
bring in the chain.
Ease off and the chainstopper will take the load.
Pull the lever out until the pin disengages the chainwheel dog.
Push lever to furthermost counter clockwise position and re-engage with the
chainwheel.
Repeat cycle, progressively bring in the anchor.
NOTE: If a chainstopper is not fitted, or if found more convenient, the pawl item 19
may be engaged with the chainwheel after each upward (clockwise) movement to
hold the chainwheel from reversing.
19
CHAINPIPE
Chainpipe Cover can be swung out of position to relieve chain jam if necessary.
1. Loosen the cap screw (item 9) & rotate cover (item 10) clockwise,
2. Relieve chain jam
3. Replace cover in reverse order to point 1.
USING THE WARPING DRUM (VWC Models only)
The vertical capstan can be used independently of the chainwheel.
This is ideal for handling mooring lines, docking lines or a second anchor.
To use proceed as follows:
1. Check that the pawl item 19 is engaged with the chainwheel.
2. Insert the lever item 30 in the clutch nut item 5 and back off in a counter clockwise
direction until it stops.
The capstan will now operate whilst the chainwheel remains stationary.
3. Take several turns of line around the drum in a clockwise direction.
Whilst pulling on the tail press the “UP” footswitch. The Capstan will rotate in a
clockwise direction.
Increasing or decreasing the load on the tail, whilst holding the footswitch down will
increase/decrease the rate at which the line will be hauled in.
Extra turns around the drum will increase the grip and require less load on the tail.
DON’T PUT SO MANY TURNS ON THE DRUM THAT EASING THE LOAD ON
THE TAIL WILL NOT ALLOW THE ROPE TO SLIP ON THE DRUM.
20
MAINTENANCE
** IMPORTANT **
Failure to carry out the maintenance and service as described herein will
invalidate warranty.
Recommended Lubricants:
Gearbox Oil:
SAE 90, e.g. Shell Omala 320, Castrol Alpha SP 320.
Mainshaft & Bearing:
Marine Grease, Lithium based or Lithium complex based,
e.g. Duckhams ‘Keenol’; ‘Castrol LMX’. Do not use soap
based grease.
Above Deck Components: CRC 3097 Spray.
1. Prior to Season - the above deck components should be removed and greased
following the instructions under steps 5, 11 and 12 of the installation instructions.
Check level of oil in gearbox. If necessary top up as per step 6 of preparing the
windlass instructions.
The underdeck components should be sprayed, preferably with CRC3097 “Long
Life” or alternatively, CRC6-66 or WD40.
Particular attention should be paid to the motor on electric units, including the
motor terminals, footswitch terminals, terminals on the Reversing Solenoid Pack or
the Overload/Control Box plus the battery and isolator terminals.
2. Six-monthly - repeat procedure under item 1 above.
3. End of Season - before storage carry out procedure under item 1.
4. Above deck components - clean the Windlass with a cloth damp with Kerosene
(paraffin). Spray preferably with CRC3097 “Long Life” or alternatively, CRC6-66
WD40. Polish off with a clean non-fluffy cloth.
Regular use of CRC3097 “Long Life” will assist maintaining the bright chrome
finish.
Natural lustre of bronze units can be restored by polishing with mild abrasive liquid
polish. Don’t use on chrome units.
21
SERVICING OF GEARBOX
The gearbox is a totally self contained unit. Providing the Windlass is not abused this
unit should give years of trouble free service.
Every three years the gearbox should be removed, oil drained, cleaned and oil replaced
with SAE 90, eg Shell Omala 320, Castrol Alpha SP 320.
If further maintenance is required, refer to the appropriate assembly drawing and
accompanying parts list, for disassembly.
SERVICING OF MOTOR - Electric Units
If necessary, the motor can be removed from the gearbox without draining the gearbox
oil as the gearbox is a sealed unit.
The motor is removed by undoing two bolts item 32 and washes items 33 and 34 (refer
to assembly drawing P100110 for VWC types and P100111 for VWCLP types).
A replaceable drive pin item 38 is a press fit in the output end of the drive shaft. This
pin engages the slot in the worm item 2.
Providing the Windlass is properly installed with the Maxwell Overload Control Box and
Breaker Panel, and the Windlass is not abused, trouble free operation can be expected.
Replacement brush sets are available - order Part No. SP 1383 - 12 Volt, Part No.
SP1384 - 24 Volt.
SERVICING OF MOTOR - Hydraulic Units
If necessary, the motor can be removed from the gearbox without draining the gearbox
oil as the gearbox is a sealed unit.
The motor is removed by undoing two bolts, item 32, washers items 33 and 34, and
nuts item 39.
(Refer to drawing P100116 for VWC types and P100117 for VWCLP types)
.
22
ORDERING SPARE PARTS
When ordering spare parts, please quote the following:
Windlass Model…………………………….
Serial Number………………………………
Power Supply 12V, 24V or Hydraulic
Drawing Reference Number……………..
Item No………………………………………
Part No………………………………………
Description…………………………………
Quantity Required…………………………
TECHNICAL ASSISTANCE
We are always at your service. If you require information or assistance contact:
Head Office:
MAXWELL MARINE LTD
Street Address:
16 –18 William Pickering Drive
Albany
Auckland
NEW ZEALAND
Postal address:
P O Box 100-703
North Shore Mail Centre
Auckland
NEW ZEALAND
PHONE: +(64) 9-477-0900
FAX: +(64) 9-476-0555
EMAIL: [email protected]
WEBSITE: www.maxwellmarine.com
Australia
MAXWELL MARINE AUSTRALIA
Street Address:
Unit 1
10 Neumann Street
Capalaba 4157
Queensland
AUSTRALIA
Postal Address:
P O Box 1292
Capalaba 4157
Queensland
AUSTRALIA
PHONE: +(61) 7-3245-4755
FAX: +(61) 7-3245-5906
America
MAXWELL MARINE INC:
Street Address:
2907 South Croddy Way
Santa Ana, CA 92627-6302
USA
PHONE: +(1) 714 689 2900
FAX: +(1) 714 689 2910
23
24
25
26
27
28
29
30
VWC 1200 ELECTRIC
P100110 / P100113 / P100128 / P 100131
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23/A
23/B
24
25
26
27/A
27/B
28
29
30
31
32
33
34
35/A
35/B
36
37
38
PART NO.
3465
SP40
3467
3470
3438
3446
3173
3447
SP70
4528
SP472
3441
SP663
3442
SP287
SP457
3480
SP871
3372
SP463
3461
3473
3174
3471
3843
4445
SP322
3448
3453
3436
3462
P20041
SP878
SP288
SP413
SP467
P10156
P10157
3205
SP530
DESCRIPTION
QTY
CAP
SCREW
RETAINING WASHER
LABEL 1200
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
CLUTCH CONE
CAP SCREW
CHAIN COVER
WAVE SPRING WASHER
EMERGENCY CRANK COLLAR
BUSH
DECKPLATE
BOLT
WASHER
STOP PIN
SPIRAL RETAINING WASHER
PAWL
WAVE SPRING WASHER
PAWL PIN
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
DRUM
KEY
LEVER
CIRCLIP
BOLT
WASHER
WASHER
ELECTRIC MOTOR 12V
ELECTRIC MOTOR 24V
PLUG
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
8
1
1
1
1
1
1
4
4
4
1
4
1
1
ROL PIN
Fill the gearbox with
1
3
1
2
2
4
4
1
1
1
1
Castrol Alpha SP 320 Oil 65 mils
31
32
VWC 1200 HYDRAULIC
P100116 / P100134
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23/A
23/B
24
25
26
27/A
27/B
28
29
30
31
32
33
34
35
36
37
38
39
40
PART NO.
3465
SP40
3467
3470
3438
3446
3173
3447
SP70
4528
SP472
3441
SP663
3442
SP287
SP457
3480
SP871
3372
SP463
3461
3473
3174
3471
3843
4445
SP322
3448
3453
3436
3462
P20041
SP878
SP288
SP413
SP467
3205
SP530
SP366
P14366
Fill the gearbox with
DESCRIPTION
CAP
SCREW
RETAINING WASHER
LABEL 1200
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
CLUTCH CONE
CAP SCREW
CHAIN COVER
WAVE SPRING WASHER
EMERGENCY CRANK COLLAR
BUSH
DECKPLATE
BOLT
WASHER
STOP PIN
SPIRAL RETAINING WASHER
PAWL
WAVE SPRING WASHER
PAWL PIN
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
DRUM
KEY
LEVER
CIRCLIP
BOLT
WASHER
WASHER
PLUG
QTY
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
8
1
1
1
1
1
1
4
4
4
1
4
1
1
1
3
1
2
2
6
4
1
ROL PIN
HEX NUT
HYDRAULIC MOTOR
Castrol Alpha SP 320 Oil 65 mils
33
1
2
1
34
VWCLP 1200 – ELECTRIC
P100111 / P100114 / P100129 / P100132
ITEM
PART NO.
DESCRIPTION
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23/A
23/B
24
25
26
27/A
27/B
28
29
30
31
32
33
34
35/A
35/B
36
37
38
3465
SP40
3467
3470
3438
3446
3173
3447
SP70
4528
SP472
3441
SP663
3442
SP287
SP457
3480
SP871
3372
SP463
3461
3473
3174
3471
3483
4445
SP322
3449
3454
3462
P20041
SP878
SP288
SP413
SP467
P10156
P10157
3205
SP530
CAP
SCREW
RETAINING WASHER
LABEL 1200
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
CLUTCH CONE
CAP SCREW
CHAIN COVER
WAVE SPRING WASHER
EMERGENCY CRANK COLLAR
BUSH
DECKPLATE
BOLT
WASHER
STOP PIN
SPIRAL RETAINING WASHER
PAWL
WAVE SPRING WASHER
PAWL PIN
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
8
1
1
1
1
1
1
4
4
4
1
4
1
1
Fill the gearbox with
KEY
LEVER
CIRCLIP
BOLT
WASHER
WASHER
ELECTRIC MOTOR - 12V
ELECTRIC MOTOR - 24V
PLUG
ROL PIN
2
1
2
2
4
4
1
1
1
1
Castrol Alpha SP 320 Oil 65 mils
35
36
VWCLP 1200 - HYDRAULIC
P100117 / P100135
ITEM
PART NO.
DESCRIPTION
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23/A
23/B
24
25
26
27/A
27/B
28
29
30
31
32
33
34
35
36
37
38
39
40
3465
SP40
3467
3470
3438
3446
3173
3447
SP70
4528
SP472
D3441
SP663
3442
SP287
SP457
3480
SP871
3372
SP463
3461
3473
3174
3471
3843
4445
SP322
3449
3454
3462
P20041
SP878
SP288
SP413
SP467
3205
SP530
SP366
P14366
CAP
SCREW
RETAINING WASHER
LABEL 1200
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
CLUTCH CONE
CAP SCREW
CHAIN COVER
WAVE SPRING WASHER
EMERGENCY CRANK COLLAR
BUSH
DECKPLATE
BOLT
WASHER
STOP PIN
SPIRAL RETAINING WASHER
PAWL
WAVE SPRING WASHER
PAWL PIN
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
8
1
1
1
1
1
1
4
4
4
1
4
1
1
KEY
LEVER
CIRCLIP
BOLT
WASHER
WASHER
2
1
2
2
6
4
Fill the gearbox with
PLUG
1
ROLL PIN
HEX NUT
HYDRAULIC MOTOR
Castrol Alpha SP 320 Oil 65 mils
37
1
2
1
38
P12427
GEARBOX ASSEMBLY
ITEM
PART NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15/A
15/B
3223
3400
SP643
3133
3584
SP720
SP838
SP642
SP844
SP726
3145
SP721
SP724
SP159
3183
3418
Fill the gearbox with
DESCRIPTION
SIGHT GLASS
WORM
BALL BEARING 12x28x8
WORM BOX
WORMWHEEL 56T
20x2 O-RING
1in EXT CIRCLIP
BALL BEARING 25x12x47
47 x 1.85 INT CIRCLIP
O-RING ID 90MM X2MM
BUSH
25x47x7 OIL SEAL
40x55x8 OIL SEAL
M6x40 CAP SCREW
SPACER TUBE 4 -IN
SPACER TUBE 6 -IN
Castrol Alpha SP 320 Oil 65 mils
39
QTY
1
1
1
1
1
1
1
1
1
1
2
1
2
4
1
1
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