Maxwell-Windless Manual-800VWC
Contents
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7. 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 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 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 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 2 Carry out step 1 above 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 2 Insert the lever item 55 into the clutch nut item 5 Standing well clear slowly back off
8. 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 KEY 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 HEX NUT HYDRAULIC MOTOR DRUM UP TO SERIAL NO 65849 DRUM FROM SERIAL NO 65850 ON LEVER 34 B200835 QTY co A CO 35 VWCLP 800 ELECTRIC SERIAL STAMPED x wm rane Winches Liu AUCRLAND NUN ZEALAID B200836 Rev 2 00 G Copyright 1990 QQ N 03465 5 40 E3467 E3468 D3438 E3497 C3172 3205 5 0070 04528 SP663 C3443 SP287 SP457 SP708 D3476 E3174 E3471 E3843 E4445 5 322 C3451 C3456 E3462 SP878 SP724 C3183 C3418 E3145 SP726 D3403 C3133 SP720 D3223 SP159 SP643 D3404 5 642 5 844 5 838 5 721 5 288 5 413 5 467 SP530 P11112 P11114 P20044 VWCLP 800 ELECTRIC B200836 PART NO DESCRIPTION CAP SCREW RETAINING WASHER LABEL CLUTCH NUT CLUTCH CONE CHAINWHEEL PLUG CHEESE HEAD SCREW CHAIN COVER BUSH DECKPLATE BOLT WASHER V 28A RING SEAL GASKET STUD 4 TDC STUD 6 TDC WASHER STRIPPER HEX NUT MAINSHAFT 4 TDC MAINSHA
9. C P12336 24 Volt D C P14383 Hydraulic P12375 12 Volt D C P12376 24 Volt D C P12399 Hydraulic P12345 12 Volt D C P12346 24 Volt D C P14387 Hydraulic P12385 12 Volt D C P12386 24 Volt D C P14403 Hydraulic 12 Volt 80 120 Amps 24 Volt 40 60 Amps 12 Volt 305 Amps 24 Volt 150 Amps See Pages 12 13 20 Litre min 5 3 US Gal min 100 BAR 1450 p s i 12mm 2 diameter 34 U N F Viscosity ISO 32 ISO 68 20 50 Suitable oils Shell Rimula X 15W 40 Shell Myrina M 15W 40 Penzoil SAE 10W 40 2109 SAE 15 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 Motor Max Flow Min P14365 15 4 0 138 2000 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 Max Pressure Option Lt US Gal Bar P S I Max Kg Lbs 273 600 Product code P12335 P12336 P14383 P12375 P12376 P14399 P12345 P12346 P14387 P12385 P12386 P14403 Normal Rate Min Metres 25 20 25 20 25 13 98 20 65 20 65 14 38 18 75 18 75 12 48 19 15 19 15 12 88 Feet 81 0 44 55 44 55 30 75 45 43 45 43 31 63 41 25 41 24 27 45 42 13 42 13 28 33 IMPORTANT PERSONAL SAFETY WARNINGS WHEN USING YOUR WINDLASS AT ALL TIMES PRACT
10. Clutch Hydraulic 1 Note amp 1 Chart Refers To MAXWELL Standard Build Levels Of Flow Pressure Below That 1 Accommodated Refer Manual Or Consult MAXWELL 1 2 Ensure Selected Hydraulic Components Copyright 1990 Are Adequate For Recommended Rate MAXWELL Winches Ltd AUCKLAND ZEALAND HYDRAULIC SCHEMATIC rinse WINDLASSES TYPES VW VWC VWCLP HWC 30 MATERIAL VWC 800 ELECTRIC SEs STAMPED HERE 32 MAXWELL Winches Ltd AUCKLAND NEW ZEALAND 8200834 Rev 2 00 950 31 QQ N PART 03465 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 DESCRIPTION CAP SCREW RETAINING WASHER LABEL CLUTCH NUT CLUTCH CONE CHAINWHEEL PLUG CHEESE HEAD SCREW CHAIN COVER BUSH DECKPLATE BOLT WASHER V 28A RING SEAL 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
11. LL TL o 32 E S lt e Oj x a a m ae 38mm Dia 1 1 2 gt j gt lt 1 10mm T e aud Hydraulic Motor 4 11 32 VWCLP 800 SUM mmm Electric Motor Copyright 1991 nece 0200828 9 23 32 25 I ES 2 id 3 40 UE 12430 sodund a AF Aue snw BUIMeIp SIL aunen je xej4 A 50 557 80 60 V N ul au buipnput 19245 9215 881 auou 2 1 TEFEN suosJed Aue o sy JO psugo paidoo ag JOU 5 pue uodn peuunjal eq ysni BUMP 941 007 T9FC SA00SL 2A00cL MA 2 008 9 294 jo furadaid januapjuos ale uaiu Jo ubisep u1 si butMgup siu p ION 2580 ejp dx29p Gere PUD LUMP 01 YUM QOGLOA 491 OSIE esp x 31ON 339 A INO 35 34353534 Od SI SIH L V SV ASM LON Od 1991435 Jo 43495 vi lt 7 x gt SET uo pededsinbe OT D
12. 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 6 the products are serviced repaired or maintained improperly 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 shall not liable for any loss damages harm claim attributed to a use 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 subsequen
13. 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 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 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 Holding power and size of anchor t
14. 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 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 the system can be activated at either the footswitches or the remote
15. 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 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 amp 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 s
16. FT 6 TDC KEY 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 LEVER 36 mr lt a3 ROD A RA VWCLP 800 HYDRAULIC 40 SENIAL 47 4849 STAMPED HERE LARUE Winches Lid AUCRLAHD HEW ZEALAND _ B200837 Rev 2 00 Copyright 1900 37 03476 E3174 E3471 E3843 E4445 SP322 C3451 C3456 E3462 SP878 5 724 C3183 C3418 E3145 SP726 D3403 C3133 SP720 D3223 SP159 SP643 D3404 SP642 SP844 SP838 SP721 SP279 SP413 SP467 SP530 SP366 P14366 P20044 VWCLP 800 HYDRAULIC PART NO DESCRIPTION CAP SCREW RETAINING WASHER LABEL CLUTCHNUT CLUTCH CONE CHAINWHEEL PLUG CHEESE HEAD SCREW CHAIN COVER BUSH DECKPLATE BOLT WASHER V 28A RING SEAL GASKET STUD 4 STUD 6 TDC WASHER STRIPPER HEX NUT MAINSHAFT 4 TDC MAINSHAFT 6 TDC KEY CIRCLIP SEAL SPACER TUBE 4 TDC SPACER TUBE 6 TDC BUSH O RING WORMWHEEL WORM BOX O RING SIGHT GLASS SCREW ROLL PIN HEX NUT HYDRAULIC MOTOR LEVER 38 B200837 TY Ros PE L F a A Pp A N N N N LIMITED WARRANTY Warranty Maxwell Marine Ltd provides a three year limited warranty on
17. ICE 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 1 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 IMPORTANT HINTS FOR SAFE USE OF WINDLASS BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED AND INSTALLED YOURS AND OTHERS SAFETY MAY DEPEND 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 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 an
18. Name L O A Fitted by boat yard dealer I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Built by Purchased from dealer chandler 1 1 1 X 39 40 41
19. 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 ITIS 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 15 not necessary to separately earth the Windlass as the electric motor is of the isolated earth type 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 ge
20. TDC FROM SERIAL NO 65850 ON MAINSHAFT 6 TDC FROM SERIAL NO 65850 ON KEY 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 DRUM UP TO SERIAL NO 65849 DRUM FROM SERIAL NO 65850 LEVER 32 B200834 QTY CO VWC 800 HYDRAULIC 2 46 10 3 33 MOTOR N SS 9 XO BRS 47 4849 STAMPED HERE 32 AWIE p giles Winches AUCH M CT ZEALAND g1 n B200835 Rev 2 00 5 Copyright 1990 SERIAL No c O O Q N 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 SP279 SP413 SP467 SP530 SP366 P14366 D3436 D3563 P20044 VWC 800 HYDRAULIC DESCRIPTION CAP SCREW RETAINING WASHER LABEL CLUTCH NUT CLUTCH CONE CHAINWHEEL PLUG CHEESE HEAD SCREW CHAIN COVER BUSH DECKPLATE BOLT WASHER V 28A RING SEAL GASKET STUD 4 TDC STUD 6 TDC WASHER STRIPPER HEX NUT MAINSHAFT 4 TDC UP TO SERIAL NO
21. 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 lllustrations 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 Page Number 2 3 4 5 7 7 8 31 32 33 34 35 36 37 38 INSTALLATION OPERATING INSTRUCTIONS AND SERVICE MANUAL VWC 800 AND VWCLP 800 WINDLASSES INTRODUCTION You n
22. aking 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 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 di
23. arbox 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 200836 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 With a pen knife or similar carefully remove cap item 1 Hemove 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 Hemove 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 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 Remov
24. chor Not only is this a safety precaution it also helps minimise the drain on the batteries Always motor up to the anchor while retrieving the chain Do not use the Windlass to pull the boat to the anchor 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 Do not use the Windlass as a Bollard In all but the lightest conditions engage the chainstopper after completing the anchoring manoeuvre In heavy weather conditions always use a heavy anchor snub from the chain directly to a Bollard or Sampson Post DO NOT USE THE CHAINSTOPPER OR WINDLASS AS A MOORING POINT ALWAYS TURN THE ISOLATOR SWITCH OFF BEFORE LEAVING BOAT 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 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 as speed with bow mounted self launching anchor position without first ensuring that your winch clutches are fully
25. e 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 10 11 12 From the underside the offer 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 Lightly grease shaft 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 Ensure parts removed in step 5 above are clean along with the top area of the deckplate Use grease specified in step 10 above and with the aid of a clean brush or non fluffy 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
26. ed 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 1 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 ect Quantity Required 23 114 mm Dia 4 1 2 Position 1 Dotted Line Indicates Extent Of Hydraulic Option Position 3 As Shipped P Extent Of Clutch Nut Lever
27. 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 3424 CONTROL CIRCUITS Footswitches if required and remote control circuits are to be wired using 1 5 16 AWG cable A manually resettable ignition proof fuse or breaker 1 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 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 Le
28. fe lines or Bulwark refer Drawing 0200828 VWC types and 0200829 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 t
29. hey should be external to the chain locker The arrows on the footswitches should be arranged to indicate the direction of operation WHERE 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 is
30. hould 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 The gearbox is totally 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 Aloha 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 remov
31. nal 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 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
32. ngth Conductor Size Engine Room Battery to Winch Size Correction Metres Feet MM A W G MM A W G 3 1 10 26 3 34 2 4 6 15 26 3 34 2 6 2 20 26 3 34 2 7 7 25 34 2 9 2 30 42 1 10 8 35 54 0 12 3 40 54 0 15 4 50 67 00 Metres Feet MM2 A W G MM A W G 3 1 10 14 0 6 14 6 4 6 15 14 0 6 14 6 6 2 20 14 0 6 14 6 7 7 25 14 0 6 9 2 30 14 0 6 10 8 35 14 0 6 12 3 40 22 0 4 15 4 50 22 0 4 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 90 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 203103 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 directio
33. ow 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 SPECIFICATIONS PULL AT CHAINWHEEL STATIC LOAD CAPACITY CHAIN SIZE RATE AT NORMAL WORKING LOAD POWER OPTIONS 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 364 kg Max 800 165 682 kg 1500 Ibs Short Link Max 8mm 5 16 20 Metres min 65 Feet min Product Code P12335 12 Volt D
34. rectly 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 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 li
35. t 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 Purchaser Form on our website www maxwellmarine com Name Address Telephone Facsimile Supplier Dealer Name Address Telephone Facsimile Windlass Model Serial Number Date of Purchase Boat Type Windlasses Supplied With boat
36. 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 ALLOW THE CHAINWHEEL FREE WHEEL AS THIS WILL ALLOW DANGEROUSLY HIGH CHAIN SPEEDS TO BUILD UP 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 2 Check that the chainstopper is engaged 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 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 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 amp rotate cover item 10 clockwise 2 Relieve chain jam 3 Replace cover in reverse order to pint 1 USING THE WARPING DRUM The
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