Maxwell-Windless Manual-800VWC

Maxwell-Windless Manual-800VWC
VWC, VWCLP 800
OWNERS MANUAL
©
COPYRIGHT 1991 MAXWELL MARINE LTD
ALL RIGHTS RESERVED.
PATENTS PENDING.
PRINTED IN NEW ZEALAND.
Manual Product
Code No: P19086
02/05/06
Removable Chain Cover
Gearbox Ratio of 44:1
MAXWELL MARINE reserve
the right to make engineering
refinements on all products
without notice.
Illustrations and specifications
not binding as to detail.
VWC 800
OWNERS MANUAL
CONTENTS
INTRODUCTION
SPECIFICATIONS
PERSONAL SAFETY WARNINGS
APPLICATION
INSTALLATION
Location
- Windlass
- Chainstopper
- Footswitches
- Reversing Solenoid Pack
- 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 AND TECHNICAL SUPPORT
INSTALLATION DRAWINGS
VWC 800
D200828
VWCLP 800
D200829
Deck Cutout Details
3484
Wiring Diagram (Dual Direction)
P101840
Wiring Diagram (Single Direction) P101844
Hydraulic Control Diagram
B203101
Hydraulic Schematic
B203103
ASSEMBLY DRAWINGS
VWC 800 Electric
B200834
VWC 800 Hydraulic
B200835
VWCLP Electric
B200836
VWCLP 800 Hydraulic
B200837
WARRANTY
1
Page
Number
1
2
3-4
5-7
7-8
9
10
10
11
11
11
11
12-13
13
14
15
15-16
17
18-20
21
22
22
23
24
25
26
27
28
29
30
31-32
33-34
35-36
37-38
INSTALLATION, OPERATING INSTRUCTIONS AND SERVICE MANUAL
VWC 800 AND VWCLP 800 WINDLASSES
INTRODUCTION
You now own a Windlass from MAXWELL’S premier range, designed for automatic
anchor handling.
Used in conjunction with MAXWELL’S remote control, you will have complete command
of the anchor raising or lowering.
The compact deck saving vertical design allows 180 degree 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 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
PULL AT CHAINWHEEL
STATIC LOAD CAPACITY
CHAIN SIZE
RATE AT NORMAL WORKING LOAD
POWER OPTIONS
364 kg Max (800 lbs)
682 kg Max (1500 lbs)
Short Link Max 8mm (5/16”)
20 Metres/min (65 Feet/min)
Product Code
VWC800
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
VWCLP 800
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
ELECTRIC MODELS
Current at Normal Working Load
Current at Stall
SUPPLY CABLES
* HYDRAULIC MODELS
Max. recommended Flow
Max. recommended Pressure
Hydraulic Supply Lines
Hydraulic Motor Ports
Oil
P12335
P12336
P14383
P12375
P12376
P12399
12 Volt D.C.
24 Volt D.C.
Hydraulic
12 Volt D.C.
24 Volt D.C.
Hydraulic
P12345
12 Volt D.C.
P12346
P14387
P12385
P12386
P14403
24 Volt D.C.
Hydraulic
12 Volt D.C.
24 Volt D.C.
Hydraulic
12 Volt
24 Volt
12 Volt
24 Volt
See Pages 12-13
80-120 Amps
40-60 Amps
305 Amps
150 Amps
20 Litre/min (5.3 US Gal/min)
100 BAR (1450 p.s.i.)
12mm (½”) diameter
¾” U.N.F.
Viscosity ISO 32 - ISO 68 @ 20-50ºC
Suitable oils: Shell Rimula X 15W-40;
Shell Myrina M 15W-40; Penzoil SAE
10W-40; Texaco 2109 SAE 15W;
Texaco 1814 SAE 10W40. BP HLPHM
32-68; Castrol Hysin AWS 32-68; BP
Autrans T0410.
* Levels of flow/pressure below that specified can be accommodated with a motor
change - see options page 4.
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
25
4.0
2000
81.0
WEIGHT (Nett including Emergency Crank)
VWC 800
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
VWCLP 800
100mm (4”) Deck Clearance
150mm (6”) Deck Clearance
4
Product code
KGS
LBS
P12335
P12336
P14383
P12375
P12376
P14399
20.25
20.25
13.98
20.65
20.65
14.38
44.55
44.55
30.75
45.43
45.43
31.63
P12345
P12346
P14387
P12385
P12386
P14403
18.75
18.75
12.48
19.15
19.15
12.88
41.25
41.24
27.45
42.13
42.13
28.33
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.
WHEN THE WINDLASS IS NOT IN USE, 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 not 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 boat’s 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 “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”
6
10. Never proceed as 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 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 800 WINDLASSES ARE DESIGNED FOR ALL
CHAIN SYSTEMS USING UP TO A MAXIMUM CHAIN SIZE OF 8MM (5/16”) SHORT
LINK CHAIN.
** 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 800 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
D200828 VWC types and D200829 VWCLP types). This arrangement allows the chain
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 for the chain should be directly over the chainlocker and the
chain should have at least 300mm (1 ft) 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 chain
outlet in the deckplate and the Windlass gearbox. This will keep the gearbox, motor
and wiring 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 chain outlet 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 chain outlet 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 D200828 VWC types and D200829 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 D200828 VWC types and D200829 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 33) on bolts (item 15). 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 table below.
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 3-4 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 4).
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 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 CHAINLOCKER.
MARINE 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
MOUNTING IS OF SUFFICIENT THICKNESS AND STRUCTURAL STRENGTH
TO SUSTAIN THE LOADS CAPABLE OF BEING IMPOSED ON OR BY THE
WINDLASS. A BACKING 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 MOUNTING SURFACE OR DECK AREA
COVERED BY THE GASKET SUPPLIED, AND THE UNDERSIDE AREA
AGAINST WHICH THE LOAD WASHERS SEAT, ARE SMOOTH, FLAT AND
GENERALLY PARALLEL.
3. The gasket 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 boat with a 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 42.
Insert and tighten two bolts item 47 and washers items 48, 49 provided (refer to
Assembly Drawings B200834 and B200836).
For Hydraulic Motors
Offer motor up to gearbox aligning drive pin with slot in the worm item 42.
Insert and tighten two bolts item 47, washers items 48, 49 and nuts item 52
provided (refer to Assembly Drawing B200835 and B200837).
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 54 from shaft (VWC models only)
Undo bolts, item 9, with washers item 28 and remove stripper/chain cover item 10,
from deckplate item 14.
Lift clutch cones and chainwheel, item 6 and 7 from the shaft.
Remove two keys, item 29 (VWC models), one key (VWCLP models), item 29 from
shaft item 27.
Lift ring seal, item 18 from 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 in the gearbox upper half.
If necessary, top up with SAE90 (Shell Omala 320, Castrol Alpha SP320 or
equivalent. DON’T OVER FILL.
7. Remove washers items 16 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 is properly prepared, as per step 3 above and is
clean.
Using the gasket item 22 between the deckplate and the mounting surface lower
the deckplate, guiding the mounting studs 23 through the pre drilled mounting
holes and bed the deckplate down.
15
9. From the underside of the deck offer up the washers items 24 and 16 and replace
nuts, item 26.
IMPORTANT
Tighten the nuts progressively and evenly.
DO NOT USE POWER TOOLS.
Do not overtighten. Ensure installation is firm.
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 33 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, items 29/30 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 55 into the clutch nut item 5 and check that the clutches are
tightened down firmly by turning the nut clockwise.
REMOVE THE LEVER.
2. The Windlass may be operated under power by using the switch on the Remote
Control Station. Hold the switch “DOWN” until the required amount of chain is out.
RAISING THE ANCHOR UNDER POWER
Proceed as follows:
1. Carry out step 1 above.
2. The Windlass may be operated under power by using the switch on the Remote
Control Station. Hold the switch “UP” 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.
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 55 into the clutch nut item 5.
Standing well clear, 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.
2. When the required amount of chain is out, tighten the clutch nut firmly, remove the
lever and stow.
18
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.
2. 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 54.
3. Place the lever on chainwheel inserting drive pin into hole as shown below and
ensure lever is engaged against shaft.
Replace drum item 54 and clutch nut, tighten LIGHTLY.
4. Take the weight by pulling the lever in a clockwise direction, preferably the lever
should be rotated slowly and continuously but it may be necessary to reposition if
deck obstructions should prevent full rotation of the emergency crank.
When ‘eased off’ the chainstopper will take the load.
CHAINPIPE
Chainpipe Cover can be swung out of position to relieve chain jam if necessary.
1. Loosen the captive knurled pin (item 57) & rotate cover (item 10) clockwise,
2. Relieve chain jam,
3. Replace cover in reverse order to pint 1.
19
USING THE WARPING DRUM
The vertical Capstan can be used independently of the chainwheel.
This is ideal for handling the mooring lines, docking lines or a second anchor.
To use proceed as follows:
1. Insert the lever item 55 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.
2. Take several turns of line around the drum in a clockwise direction.
Whilst pulling on the tail have someone operate the Remote Control Station by
holding the switch “UP”. The Capstan will rotate in a clockwise direction.
Increasing or decreasing the load on the tail, whilst the remote switch is held, will
increase/decrease the rate at which the line will be hauled in.
20
MAINTENANCE
** IMPORTANT **
Failure to carry out the maintenance and service as described herein will
invalidate the 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 Solenoids 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 sealed 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, e.g. 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 47 and washers items 48 and 49 (refer
to assembly drawing B200834 for VWC types and B200835 for VWCLP types).
A replaceable drive pin item 50 is a press fit in the output end of the drive shaft. This
pin engages the slot in the worm item 42.
Providing the Windlass is properly installed with the Maxwell Breaker/Isolator 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. SP
1384 - 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 47, washers items 48 and 49,
and nuts item 52. (Refer to drawing B200835 for VWC type and B200837 for
VWCLP type).
22
ORDERING SPARE PARTS AND TECHNICAL SUPPORT
Please refer back cover for your nearest MAXWELL distributor
or visit our website www.maxwellmarine.com.
When ordering spare parts and for technical support, please quote the following:
Windlass Model…………………………….
Serial Number………………………………
Power Supply 12V, 24V or Hydraulic
Drawing Reference Number……………..
Item No………………………………………
Part No………………………………………
Description…………………………………
Quantity Required…………………………
23
24
25
26
27
28
29
30
31
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
27/C
27/D
28
29
30
31
32
33/A
33/B
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51/A
51/B
52
53
54/A
54/B
55
56
57
PART NO.
D3465
SP40
E3467
E3468
D3438
E3497
C3172
3205
SP0070
D4528
SP663
C3443
SP287
SP457
SP708
D3476
E3174
E3471
E3843
E4445
SP322
C3450
C3455
D3561
D3562
E3462
SP878
SP724
C3183
C3418
E3145
SP726
D3403
C3133
SP720
D3223
SP159
SP643
D3404
SP642
SP844
SP838
SP721
SP288
SP413
SP467
SP530
P11112
P11114
D3436
D3563
P20044
-
VWC 800 ELECTRIC
B200834
DESCRIPTION
CAP
SCREW
RETAINING WASHER
LABEL
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
PLUG
CHEESE HEAD SCREW
CHAIN COVER
QTY
1
1
1
1
1
2
1
1
1
1
BUSH
DECKPLATE
BOLT
WASHER
1
1
4
8
V.28A RING SEAL
1
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC UP TO SERIAL NO. 65849
MAINSHAFT 6” TDC UP TO SERIAL NO. 65849
MAINSHAFT 4” TDC FROM SERIAL NO. 65850 ON
MAINSHAFT 6” TDC FROM SERIAL NO. 65850 ON
1
4
4
4
1
4
1
1
1
1
KEY
3
CIRCLIP
SEAL
SPACER TUBE 4” TDC
SPACER TUBE 6” TDC
BUSH
‘O’ RING
WORMWHEEL
WORM BOX
‘O’ RING
SIGHT GLASS
SCREW
BEARING
WORM
BEARING
CIRCLIP
CIRCLIP
SEAL
BOLT
WASHER
WASHER
ROLL PIN
ELECTRIC MOTOR 12 V
ELECTRIC MOTOR 24V
2
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
2
4
4
1
1
1
DRUM UP TO SERIAL NO. 65849
DRUM FROM SERIAL NO. 65850
LEVER
-
1
1
1
32
33
ITEM
PART NO.
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
27/C
27/D
28
29
30
31
32
33/A
33/B
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54/A
54/B
55
56
57
D3465
SP40
E3467
E3468
D3438
E3497
C3172
3205
SP0070
D4528
SP663
C3443
SP287
SP457
SP708
D3476
E3174
E3471
E3843
E4445
SP322
C3450
C3455
D3561
D3562
E3462
SP878
SP724
C3183
C3418
E3145
SP726
D3403
C3133
SP720
D3223
SP159
SP643
D3404
SP642
SP844
SP838
SP721
SP279
SP413
SP467
SP530
SP366
P14366
D3436
D3563
P20044
-
VWC 800 HYDRAULIC
DESCRIPTION
B200835
QTY
CAP
SCREW
RETAINING WASHER
LABEL
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
PLUG
CHEESE HEAD SCREW
CHAIN COVER
1
1
1
1
1
2
1
1
1
1
BUSH
DECKPLATE
BOLT
WASHER
1
1
4
8
V.28A RING SEAL
1
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC UP TO SERIAL NO. 65849
MAINSHAFT 6” TDC UP TO SERIAL NO. 65849
MAINSHAFT 4” TDC FROM SERIAL NO. 65850 ON
MAINSHAFT 6” TDC FROM SERIAL NO. 65850 ON
1
4
4
4
1
4
1
1
1
1
KEY
3
CIRCLIP
SEAL
SPACER TUBE 4” TDC
SPACER TUBE 6” TDC
BUSH
‘O’ RING
WORMWHEEL
WORM BOX
‘O’ RING
SIGHT GLASS
SCREW
BEARING
WORM
BEARING
CIRCLIP
CIRCLIP
SEAL
BOLT
WASHER
WASHER
ROLL PIN
2
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
2
4
4
1
HEX NUT
HYDRAULIC MOTOR
DRUM UP TO SERIAL NO. 65849
DRUM FROM SERIAL NO. 65850 ON
LEVER
-
2
1
1
1
1
34
35
VWCLP 800 ELECTRIC
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/A
33/B
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51/A
51/B
52
53
54
55
56
57
PART NO.
D3465
SP40
E3467
E3468
D3438
E3497
C3172
3205
SP0070
D4528
SP663
C3443
SP287
SP457
SP708
D3476
E3174
E3471
E3843
E4445
SP322
C3451
C3456
E3462
SP878
SP724
C3183
C3418
E3145
SP726
D3403
C3133
SP720
D3223
SP159
SP643
D3404
SP642
SP844
SP838
SP721
SP288
SP413
SP467
SP530
P11112
P11114
P20044
-
B200836
DESCRIPTION
CAP
SCREW
RETAINING WASHER
LABEL
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
PLUG
CHEESE HEAD SCREW
CHAIN COVER
QTY
1
1
1
1
1
2
1
1
1
1
BUSH
DECKPLATE
BOLT
WASHER
1
1
4
8
V.28A RING SEAL
1
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
1
4
4
4
1
4
1
1
KEY
2
CIRCLIP
SEAL
SPACER TUBE 4” TDC
SPACER TUBE 6” TDC
BUSH
‘O’ RING
WORMWHEEL
WORM BOX
‘O’ RING
SIGHT GLASS
SCREW
BEARING
WORM
BEARING
CIRCLIP
CIRCLIP
SEAL
BOLT
WASHER
WASHER
ROLL PIN
ELECTRIC MOTOR 12V
ELECTRIC MOTOR 24V
2
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
2
4
4
1
1
1
LEVER
-
1
36
37
ITEM
VWCLP 800 HYDRAULIC
PART NO.
DESCRIPTION
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/A
33/B
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
D3465
SP40
E3467
E3468
D3438
E3497
C3172
3205
SP0070
D4528
SP663
C3443
SP287
SP457
SP708
D3476
E3174
E3471
E3843
E4445
SP322
C3451
C3456
E3462
SP878
SP724
C3183
C3418
E3145
SP726
D3403
C3133
SP720
D3223
SP159
SP643
D3404
SP642
SP844
SP838
SP721
SP279
SP413
SP467
SP530
SP366
P14366
P20044
-
B200837
QTY
CAP
SCREW
RETAINING WASHER
LABEL
CLUTCH NUT
CLUTCH CONE
CHAINWHEEL
PLUG
CHEESE HEAD SCREW
CHAIN COVER
1
1
1
1
1
2
1
1
1
1
BUSH
DECKPLATE
BOLT
WASHER
1
1
4
8
V.28A RING SEAL
1
GASKET
STUD 4” TDC
STUD 6” TDC
WASHER
STRIPPER
HEX NUT
MAINSHAFT 4” TDC
MAINSHAFT 6” TDC
1
4
4
4
1
4
1
1
KEY
2
CIRCLIP
SEAL
SPACER TUBE 4” TDC
SPACER TUBE 6” TDC
BUSH
‘O’ RING
WORMWHEEL
WORM BOX
‘O’ RING
SIGHT GLASS
SCREW
BEARING
WORM
BEARING
CIRCLIP
CIRCLIP
SEAL
BOLT
WASHER
WASHER
ROLL PIN
2
2
1
1
2
1
1
1
1
1
4
1
1
1
1
1
1
2
4
4
1
HEX NUT
HYDRAULIC MOTOR
2
1
LEVER
-
1
38
LIMITED WARRANTY
Warranty: Maxwell Marine Ltd provides a three year limited warranty on all windlasses for pleasure boat usage, and a one year
limited warranty for those systems used on commercial or charter vessels. Warranty, service and parts are available around the
world. Contact your nearest Maxwell office for a complete list of service centres and distributors.
This warranty is subject to the following conditions and limitations:
1.
This Warranty will be null and void if
(a) there is any neglect or failure to properly maintain and service the products.
(b) the products are serviced, repaired or maintained improperly or by
unauthorised persons.
(c) loss or damage is attributed to any act, matter or omission beyond the
reasonable control of Maxwell or the purchaser.
2.
Maxwell’s liability shall be limited to repair or replacement (as determined by Maxwell) of the goods or parts defective in
materials or workmanship.
3.
Determination of the suitability of the product and the materials for the use contemplated by the buyer is the sole
responsibility of the buyer, and Maxwell shall have no responsibility in connection with such suitability.
4.
Maxwell shall not be liable for any loss, damages, harm or claim attributed to:
(a) use of the products in applications for which the products are not intended.
(b) corrosion, wear and tear or improper installation.
(c) improper use of the product.
5.
This Warranty applies to the original purchaser of the products only. The benefits of the Warranty are not transferable to
subsequent purchasers.
6.
Maxwell shall not be responsible for shipping charges or installation labour associated with any warranty claims.
7.
There are no warranties of merchantability, fitness for purpose, or any other kind, express or implied, and none shall be
implied by law. If any such warranties are nonetheless implied by law for the benefit of the customer they shall be limited to
a period of three years from the original purchase by the user.
8.
Maxwell shall not be liable for consequential damages to any vessel, equipment, or other property or persons due to use or
installation of Maxwell equipment.
9.
This Warranty sets out your specific legal rights allowed by Maxwell; these may be varied by the laws of different countries.
In addition, the purchaser may also have other legal rights which vary from country to country.
10.
To make a claim under this Warranty, contact your nearest Maxwell Marine office or distributor. Proof of purchase and
authorisation from Maxwell will be required prior to any repairs being attempted.
To be eligible for warranty protection, please either complete
the form below at the time of purchase and return it to the
appropriate address above, or fill out the electronic Warranty
Form on our website, www.maxwellmarine.com
Purchaser
Name:
Telephone:
Address:
Facsimile
Supplier / Dealer
Name:
Telephone:
Address:
Facsimile
Windlass Model
Date of Purchase
Serial Number
Boat Type
Windlasses Supplied
With boat
Name
L.O.A.
Fitted by boat yard/dealer
Purchased from dealer/chandler
Built by
39
40
41
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