2200 VW VWC VWCLP MANUAL
Contents
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3. within 1m 40 from the main breaker isolator These requirements are mandatory to meet USCG ABYC and NMMA rules After connecting the power lines spray all ports and fittings with anti corrosive waterproof coating CRC 3013 Soft Seal or equivalent 2 8 NOTE TO BOAT BUILDER Experience has shown that on long ocean deliveries sulphur from the ship s exhaust can settle on polished surfaces which can affect the quality of the finish Please ensure that upon completion of installation the windlass is treated with suitable corrosion protective coating CRC 3097 Long Life and wrapped in plastic film This ensures that your customer receives the windlass from you in the same top quality condition as you received it from Maxwell 10 Picture 2 9 Pendant controller for operating two windlasses 3 0 3 1 USING THE WINDLASS PERSONAL SAFETY WARNINGS As with all load carrying equipment the consequences of heavy overload neglect or misuse may be unexpected failure and exposure of crew and or vessel to risk Operate the windlass with extreme care at all times Before testing the windlass for the first time check that all the wiring has been done correctly When using the windlass at all times practice good seamanship and adhere to the following rules in order to avoid any likelihood of injury or accident At all times keep hands feet loose clothing cordage and your hair WELL CLEAR Never operate the windlass
4. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Address 1 1 1 1 1 Telephone Facsimile 1 1 1 1 1 1 Windlass Model Serial Number 1 1 1 1 1 1 1 1 1 1 1 1 Date of Purchase Boat Type Windlasses Supplied 1 1 1 With boat 1 1 L O A Fitted by boat yard dealer 1 1 1 i E Purchased from dealer chandler Built by 1 1 1 1 y 32 33
5. U U U ojojo 02 NN Y gt J NIN IN VWC VW standard VWC VW 100mm extra deck clearance VWCLP standard VWCLP 100mm extra deck clearance 41 opacer tube standard 100mm extra deck clearance ocket head cap screw 3 8 x 1 1 4 opring washer 3 8 earbox Key Electric DC motor 12V P11165 Electric DC motor 24V P11166 Hydraulic motor P14369 Washer Flat 5 16 Electric DC motor 12V Hydraulic motor Electric M8 x 25 Hydraulic M8 x 30 Hex Hd Nut M8 Clutch nut handle 23 P9508022 Gearbox Apply Cyberbond Anaerobic adhesive 7518 to this surface Note Items 2 and 23 must be tightened to a torque setting between 40 to 60 in Ib Once assembled fill with 800mls of VG320 oil 24 _ Description Qty 55 x 70 x 8 oil seal M6 x 20 cap screw gearcase upper 20 x 2 O ring Sight glass Lay shaft M6 x 80 SS cap screw Bush Final drive gear 2200 3500 series 21 tooth pinion 75 to 1 gearbox Intermediate gear assembly 20T 21T Consists of 4182 Intermediate gear 20t 211 2200 SP0650 Bush 625in x 75in x 1 5in Key Bush 1 8 x 3 8 lg tension pin Gearcase lower 2200 3500 series 40 x 47 x 20 needle roller bearing O ring ID 90mm section dia 2mm Thrust washer Wormwheel 29T 2000 3500 series Pinion stop Bush Plug M6 x 40 cap screw Worm box 2200 3500 series 12 x
6. damage Grease the components using lithium complex base water proof grease especially grease the conical surface on both clutch cones as shown on Picture 2 6 Some deckplates may have a grease nipple lf so grease bearing in the deckplate through the grease nipple Clean chromed surfaces with a cloth damp with Before doing any maintenance work on electric kerosene After cleaning spray them with CRC 3037 motor starter units and wiring make sure the Long Life or alternatively with CRC 6 66 or WD power supply is switched off 40 Regular use of CRC3097 Long Life will assist in maintaining the bright chrome finish Re assemble in the reversed order Inspect the components below deck for corrosion chipped paint etc clean them and touch up the paint if necessary Spray them for protection with CRC 3013 Soft Seal 4 3 EVERY YEAR Carry out the three monthly maintenance as described above Remove gearbox spacer tube Ensure drainage slots are free from debris by flushing with fresh cold water Remove DC motor and service Replacement brush sets are available Part No P100807 12V Part No P100808 24V Picture 4 1 Drainage Holes 4 4 EVERY 3 YEARS Carry out the three monthly maintenance as described above Detach the gearbox and spacertube 46 41 off the deckplate by undoing screws 17 Make sure the drive is appropriately supported or suspended before detaching it from the de
7. e Hand held pendant controller single or dual speed e Helm switch e Chain counter These control accessories are available from Maxwell customised to suit your windlass It is the choice of the designer builder to use one two or all three of these controls They are wired in parallel to the directional valve for hydraulic windlasses or to the starter unit for electric windlasses The controls can work on 12 or 24V power supply If footswitches are used then an isolator switch for them must be installed in the wheelhouse to prevent operating the windlass by someone accidentally stepping on the footswitch Hand held pendant controller is often the most convenient way of operating the windlass Maxwell offers several variations of pendants including single speed dual speed single pendant for running a pair of windlasses pendants with auxiliary buttons which can be used for starting chain wash system hydraulic pump etc They are supplied with a plug on the other end of cable and a matching waterproof socket which should be installed on a convenient location on the deck All units are supplied with detailed wiring instructions to assist installation Refer to wiring schematics in Appendix C for control circuits All control wiring should be done using no smaller than 1 5mm wire AWG 16 A manually re settable ignition proof 3A breaker or fuse should be installed on the power supply line for controls
8. from a remote station without maintaining a clear view of it and having made sure that everyone 15 well clear of the windlass anchor and chain Never use the windlass under power with the clutch handle inserted into clutch nut emergency crank collar When engaging the pawl while chain is running keep fingers away from the chain Use clutch nut lever underneath and guarded by the chainpipe Always motor up to the anchor position before retrieving it from the bottom 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 chain stopper taking the load use the boat s engine to break the anchor loose When lowering the anchor under manual control use the band brake or friction clutch if fitted to control the speed of the chain Never lower the anchor without maintaining safe chain speed When the windlass is not in use make sure the power supply is isolated making an accidental operation thereby impossible Do not use the windlass as an anchoring point for the chain Engage the chain stopper when the windlass is not in operation Never proceed at speed without first ensuring that the chain stopper is engaged Also engage the tensioner to keep the anchor snug in the pocket When using the windlass do not switch immediately from one direction of rotation to the other without waiting for windlass to stop Abuse is not covered by warranty 11 3 2
9. operations be controlled by the footswitch This makes it a one person operation and offers better control of the capstan in case of emergency Take several turns of the warping line around the drum and pull on the rope tail with sufficient manual force to provide good grip of the line to the drum whilst operating the footswitch Make sure the drum is operated in the same direction as the line is wrapped around it Do not engage more turns on the drum than are necessary to accomplish the task Whilst docking wind and tide can impose sudden and excessive line tension lt is recommended to allow slipping to occur at the drum This will protect the capstan docking lines and vessel from damage 13 While handling docking lines with the capstan everybody has to stay well clear of the lines and the capstan Take care not to allow riding turns This is caused by the loaded line climbing on top of lower loaded coils A riding turn can only be removed by paying out to the point where the riding turn is removed 4 0 MAINTENANCE 4 1 EVERY TRIP Ensure clutch is correctly engaged Failure to carry out the maintenance and The parts external of the case should be washed service as described herein will invalidate down with fresh water at the end of every trip warranty 4 2 EVERY THREE MONTHS Disassemble the above deck components of the windlass up to the deckplate as described in Section 2 3 Clean all components and check for
10. 2200 VW VWC VWCLP MANUAL Copyright Maxwell Marine International Ltd All rights reserved Patents pending Printed in New Zealand P19070 Rev 7 00 27 07 10 Maxwell Marine International Ltd reserves the right to make engineering changes to all products without notice Illustrations and specifications not binding as to detail 1 0 1 1 1 2 1 3 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 0 3 1 3 2 3 3 3 4 3 5 3 6 4 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 0 Contents INTRODUCTION PRE INSTALLATION NOTES PRODUCT VARIATIONS SPECIFICATIONS INSTALLATION SELECTION OF POSITION FOR THE WINDLASS PREPARATION OF MOUNTING AREA PREPARATION OF THE WINDLASS INSTALLING THE WINDLASS POWER CONNECTIONS TO DC MOTOR POWER CONNECTIONS TO HYDRAULIC MOTOR INSTALLATION OF CONTROLS NOTE TO BOAT BUILDER USING THE WINDLASS PERSONAL SAFETY WARNINGS LOWERING THE ANCHOR UNDER POWER RETRIEVING THE ANCHOR UNDER POWER LOWERING THE ANCHOR UNDER MANUAL CONTROL RETRIEVING THE ANCHOR UNDER MANUAL CONTROL OPERATING THE WARPING DRUM INDEPENDENTLY MAINTENANCE EVERY TRIP EVERY THREE MONTHS EVERY YEAR EVERY THREE YEARS RECOMMENDED LUBRICANTS SPARE PARTS TOOLS FOR MAINTENANCE TROUBLESHOOTING APPENDIX A Dimensional drawings APPENDIX B Spare Parts APPENDIX C Electric Wiring schematics APPENDIX D Warranty Form O JJ JO OcYC1i 4 WN I l3 NO RP F
11. 28 x 8 ball bearing Worm 25 x 12 x 47 ball bearing 1in Ext circlip 47 x 1 85 Int circlip 25 x 47 x 7 oil seal N alol N gt gt 5 25 JO 19945 VIN LAG vvglOLd uonoauig ejBuis 104 jes dA wesBeiq V N uonduoseq JoloN jueueuuegd TIIMXVAN N ON Assy fe w J i 9SJ9A9J ol 24 ol Y9JIMSIOOY jenuew uononujsul SSEIPUIM 0 Jaja Sjueuieumnboi seHes TISMXVW Joyonpuoo JO Y gm c AlddNS LJ Ax Ave 10 21 E 22 Wg peeoxe JOU SG UE JO uonejo1 y 10 pue Alsyeq uee geq 10jonpuoo Jamod oda an Ms Nem uo sjeuiuue Buiddems jo uonejoJ BULAN jeep 10 5 YOS ELOEDYO 18092 15814 5 Aq ainjsiow jsureBe sjeuiuuej 29 5158 uessooou pue uonejeijsur Buruous jejuepiooe jsureBe 1 91014 MOV 9L ON 921
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13. LOWERING THE ANCHOR UNDER POWER e Ensure the clutch is fully engaged by inserting the clutch nut lever in one of the slots on the clutch nut and turning clockwise firmly The windlass is equipped with a friction clutch so it can be engaged in any position there is no need to match the position of the opposite sides of the clutch before engaging it e Remove clutch handle e Release the pawl Disengage chain stopper and chain tensioner if fitted To disengage the chain stopper pawl the windlass may require momentary jogging in the up direction e windlass may now be lowered under power by operating either the hand held pendant control helm switch or footswitch e When finished turn off the isolator switch for the controls 3 3 RETRIEVING THE ANCHOR UNDER POWER Ensure clutch is engaged and pawl is released Remove clutch handle Release chain stopper and or tensioner The windlass may now be operated to raise the anchor e After retrieving the anchor engage chain stopper and or tensioner e Turn off the isolator switch for the controls As a safety feature the windlass will continue to operate up or down only while the operating button toggle switch or foot switch is held in the engaged position Picture 3 1 Engaging the clutch It is regarded as sound practice to motor over the anchor position and so reduce chain tension This will also help the anchor to break out reduce the power consumptio
14. P PRP CO 18 20 26 31 1 0 1 1 INTRODUCTION PRE INSTALLATION NOTES Read this manual thoroughly before installation and using the windlass Failure to adhere to the correct procedures recommendations and guidelines described in this Owner s Manual may invalidate the warranty Be mindful that the correct selection of windlass for each application together with correct installation normal care in use and maintenance are essential for long life and reliable performance Inspect your windlass carefully when unpacked Any damage or lack of components should be reported immediately to your Maxwell distributor The windlass is supplied with chainwheel as specified on purchase order Make sure it is the appropriate one for the chain being used on board Correct fit of the chain to chainwheel is essential for reliable and safe operation of the windlass This can be guaranteed only when calibrated chain to a recognised international standard is used and the chain is correctly identified to Maxwell or if a chain sample is provided to Maxwell to develop a custom chainwheel The windlass is designed for use in conjunction with chain stopper of the appropriate size Their use is an important safety feature For side pocket anchors a chain roller should be installed above the hawse pipe to ensure smooth and quiet travel of the chain from deck to hawse pipe The roller requires a central groove to align chain a
15. box and then back to the battery Where a portion of cable runs through the engine room a size increase should be made as indicated After connecting the cables spray all terminals with anti corrosive waterproof coating 3013 Soft Seal or equivalent 12v Uu Total Cable Length from battery to winch then back to battery Up to 14m 46 From 14m 16m 46 52 From 16m 21m 52 69 From 21m 26m 69 85 Total Cable Length from battery to winch then back to battery Up to 24m 79 From 24m 38m 79 124 Table 2 1 When tightening the cables to the motor ensure the lower nut is secure against turning when tightening the upper nut This will prevent damage occurring within the motor Nut Lower Nut Picture 2 7 Motor Connections Engine Room Wire Size EA 34 42 54 67 24v Systems Engine Room Wire Size Correction Recommended wire sizes 2 6 POWER CONNECTION TO HYDRAULIC MOTORS A basic hydraulic schematic is shown in Appendix C Port sizes on the hydraulic motor and minimum hose sizes are specified in Section 1 3 The pressure and return ports should be connected to a solenoid controlled valve not supplied by Maxwell After connecting the power lines spray all ports and fittings with anti corrosive waterproof coating CRC 3013 Soft Seal or equivalent 2 1 INSTALLATION OF CONTROLS The windlass can be operated using e Deck mounted footswitches
16. ckplate Remove spacer tube from the gearbox clean it as well as top of the gearbox and apply Res Q Steel on mating faces Drain oil form the gearbox using the two lowest plugs on the body Replace seals 14 Replace plugs lay the gearbox horizontally so that one of the plugs on the upper part of the body faces upwards Remove it and fill the gearbox with new oil We recommend flushing inside the gear case with flushing liquid recommended by oil manufacturer before filling new oil The gearbox should be filled with oil completely which is approximately 800ml 27 fl oz Never mix different types of oil even if they are from the same manufacturer 4 5 RECOMMENDED LUBRICANTS Greases Lithium complex base NL G1 consistency No 2 CASTROL LMX e DUCKHAMS Keenol e FINA CERAN WR 2 e SHELL Retinex LX e MOBIL Mobilgrease HP Gearbox Oils ISO 3448 VG 320 e CASTROL Alpha MAX 320 e SHELL Tivela oil SC320 e MOBIL Mobilgear 632 e BP MACH GR XP 320 Anti Corrosive Coatings e 3013 Soft Seal e Boeshield T9 e Lanocote Anti Seize Coating e International Paints Res Q Steel Never mix greases use only one type If in doubt remove the previous lubricant and clean the parts thoroughly before applying the new one 15 4 6 SPARE PARTS Maxwell recommends a modest quantity of spare parts to be ordered as familiarity with the windlass 15 developed during installation Frequently smaller parts are lost during main
17. e after being in contact for a prolonged period of time Also ensure anti corrosive coating is liberally applied to the inside wall of the spacer tube 2 4 INSTALLING THE WINDLASS Refer to the drawing in Appendix B for help with identifying components and installing them correctly Extra care should be exercised when handling polished parts to avoid any damage to polished surfaces When assembling the parts apply an anti seize compound generously over all screw threads keys and keyways main shaft and inside the spacer tube Proceed with installation in the following order e After cutting holes for the windlass in the deck apply an appropriate bedding sealing compound and bolt the deckplate 20 to the deck using mounting studs 22 washers 23 24 and nuts 25 Tighten them evenly to 35 40 Nm 25 30 ft Ib The chainpipe 32 and the pawl 27 if applicable should already be assembled to the deckplate e Offer up from below deck the drive assembly sliding the main shaft through the deckplate taking care not to damage the deck bearing e After aligning them correctly bolt the deckplate When installing the Capstan the shaft MUST be coated in Shell Nautilus NLG12 Marine Grease Castrol Boating Grease Vavoline Val Plex EP or equivalent grease and spacer tube together from above deck using the 3 8 hex head screws 17 and spring washers 18 Tighten them evenly to 35 40 Nm 25 30 ft Ib e Re check that th
18. e position of the drive assembly is satisfactory and convenient for connecting power supply lines to the motor Also make sure that the drive is not in the way of chain coming into the locker e chain counter is used its sensor should be fitted into the 215mm hole in the deckplate currently covered with a plastic plug 16 Make sure the deck is drilled below for the sensor cable See brochure supplied with chain counter for detailed assembly instructions e Slide the emergency crank collar 13 over the main shaft and then the spring 12 and washer 11 on top of it e Insert the two retention clips 10 into the groove in the main shaft Apply some grease to help keep them in position e Apply anti seize compound generously over the main shaft and keyway Insert key 15 into the lower keyway on the main shaft e Assemble the lower clutch cone 9 making sure it sits nicely on the retention clips picture 2 5 Apply Lithium based marine grease generously to the conical surface of the clutch cone to assist with free falling the anchor e Put the disc spring 8 on top of the lower clutch cone 9 turning its smaller diameter towards the clutch cone picture 2 6 e Install Chainwheel 9 and the remaining disc spring 8 on top of it turning its bigger diameter towards the Chainwheel e Install Upper Clutch Cone 7 after applying marine grease to its conical surface see picture e Assemble drum 6 on top of the clu
19. e5 1914 02 40 soueJealD 89 mom 09 x MOM ZEIG a 1075 13043 ds jo TST 19 APPENDIX B Topworks Spare Parts E O 2 O Z VWCLP VW Deckplate UY 2 EN NE gt J U E A AA VWC VWCLP Deckplate 20 10 17 19 NIN 2 1 N 3 24 25 26 27 28 29 30 3 CD 2 3 I 2 Qty Label Countersunk screw 3 8 etaining washer utch nut R C D U c pper and lower clutch cone Disc Spring Chainwheel Retention clip Washer ey CD ITI CO c O ex head screw 3 8 x 1 1 4 pring washer 3 8 Deck bearing Deckplate OJI VWC VWCLP VW Mounting stud standard 100mm extra deck clearance lat washer 38 x O10mm pring washer 3 8 ut 3 8 opiral retaining ring otripper Fasteners VWC VWCLP Hex head bolt M8 x 20 VW Cheese head screw M8 x 16 Chainpipe clockwise configuration anticlockwise configuration 2 1 Stripper VWC VWCLP VW gt 21 Part no 3227 3860 SP0040 3267 3228C 3230C 6061 5953 2311 7068 2310 4233 3207 3233C 3324C SP0167 3174 3217 3843 3904 1238 SP0463 3435 SP0254 SP0037 SP0413 3245C 3466C 3246 3325C CD
20. f the Warranty are not transferable to subsequent purchasers Maxwell shall not be responsible for shipping charges or installation labour associated with any warranty claims 7 There 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 e 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 Due TRU TED RN Ar HR PT PENIS NEM ENCOUNTER To be eligible for warranty protection please either complete the form below at the time of purchase and return it to the appropriate retailer or supplier of the goods Purchaser or fill out the electronic warranty form on our website www maxwellmarine com Name Address Telephone Facsimile Supplier Dealer 1 1 1
21. mechanism to retrieve the anchor in case of emergency It involves operating the windlass manually under heavy load and extra care must be exercised when using it to avoid injury To use proceed as follows e Check that the chain stopper is engaged If chain stopper is not fitted ensure that the pawl is engaged with the chainwheel e Insert the clutch nut lever the clutch nut and release clutch by turning the clutch nut in anticlockwise direction e Insert the clutch nut lever the end with spigot into the emergency crank collar and engage the spigot with one of the dogs in the chainwheel in the furthermost forward position Picture 3 2 e Pull the lever back as far as possible bringing the chain in Engage the pawl and ease off the lever e Push lever to furthermost forward position and re engage with the chainwheel Repeat the cycle until the anchor is retrieved It is a very slow process and should be used only in emergencies Picture 3 2 Using emergency crank mechanism 3 6 OPERATING THE WARPING DRUM INDEPENDENTLY This is applicable to VW and VWC models only The drum can be operated independently of the chainwheel and can be used to manage docking lines or a second anchor To use in this way proceed as follows e Engage the chain stopper and or the pawl e Fully disengage the clutch as described in oection 3 4 The drum may now be operated independently of the chainwheel Maxwell recommends all warping
22. n and reduce load on the windlass and deck gear Care should be exercised when docking the anchor to avoid damage to the anchor pocket Jog in the last meter 3 4 of the chain carefully seating the anchor home 3 4 LOWERING THE ANCHOR UNDER MANUAL CONTROL This method will normally be employed to lower the anchor quickly to lower it in quiet ship and in emergencies power loss or control failure Proceed as follows e Tighten the clutch Release the chain stopper and or chain tensioner If the anchor has to be lowered in case of power loss and pawl on the chain stopper is engaged and under tension by chain to release it pull the chain in slightly either by power or manually If there is too much slack in the chain it might be necessary to jog the windlass up under power or use the emergency crank lever If doing that make sure the clutch is still engaged for safety reasons e Slowly disengage the clutch by turning the clutch nut anticlockwise Regulate the speed by tightening to slow clockwise or easing anticlockwise to increase speed e When the required amount of chain is out tighten the clutch nut firmly 12 It is considered potentially dangerous to allow the chain to free fall in an unrestricted manner always control the chain speed If jogging under power ensure the lever is removed first 3 0 RETRIEVING THE ANCHOR UNDER MANUAL CONTROL The windlass is equipped with a cranking
23. n be transmitted to the mounting area of the windlass and chain stopper This should be equal to the loading of the equipment to beyond breaking strength of the chain The mounting area for the windlass must be perfectly flat and rigid Structural grade fillers can be used to level this area if initial flatness is inadequate Mounting area for the chain stopper should be prepared at the same time The chain stopper has to be installed at an appropriate height to ensure that chain lays horizontally when it comes out of the chain stopper and into windlass Maximum allowed angle deviation in vertical plane is 2 If hawse pipe is angled outboard from deck to anchor pocket the chain stopper should also be angled by half of the angle of the hawse pipe Picture 2 4 That will help to reduce twisting of the chain between the chain stopper and the windlass and ensure good fit of the chain into the chainwheel The chain stopper can be installed vertically if the hawse pipe angle is less than 4 A deck cutout detail drawing is enclosed with these instructions to assist in marking out all the drilling and cutting required for installing the windlass Before drilling and cutting check the marked out area is dimensionally correct and make any necessary corrections Picture 2 4 Positions of drive relative to topworks less i gt A Inclinati
24. nd flat faces for longer chains to support and avoid bending the chain links The connection of the power lines and control circuitry to the windlass must be done by skilled technicians to ensure reliable and safe operation of the windlass 1 2 PRODUCT VARIATIONS There are several options of above deck arrangements or topworks combined with three types of drives The types of topworks are VWC vertical windlass with chainpipe VWCLP vertical windlass with chainpipe low profile VW vertical windlass Each of the above topworks is available as clockwise or anticlockwise configuration see description of Definition of rotation in Section 2 1 The types of drives are Electric DC drive 24V or 12V Hydraulic drive For applications where deck is unusually thick or is more convenient for drive to be positioned lower Maxwell offers an extra deck clearance version which extends the drive by 100mm Chainwheels The chainwheel numbers consist of two parts main part number and suffix for example 3231 001 The main part number refers to the type of chainwheel and the suffix refers to size and type of chain Please refer to your closest Maxwell Marine agent or distributor Appendix D who will select the correct replacement chainwheel for your chain Picture 1 1 Picture 1 2 VWC Topworks VW Topworks Picture 1 3 VWCLP Topworks E Y Picture 1 4 Pic
25. nes dry and away from flaying chain Access for servicing from inside the cabin area can usually be arranged through a locker Note that the gearbox can be indexed through a number of different angles in relation to the windlass deckplate Picture 2 4 Be sure to select the most convenient arrangement at installation and Anticlockwise topworks Clockwise topworks Picture 2 1 B i A P AL 2 DIN CES ES e TEX city TEN e FT Do Deck Level Picture 2 2 Correct angle of chain and height of chain stopper Picture 2 3 Recommended free space in chain locker ensure incoming chain well clears the gearbox motor and power supply lines To ensure safe position of the operator while tailing from the warping drum footswitches should be positioned at least 00mm 28 away 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 The arrows on the footswitches should be arranged to indicate the direction of operation The motor starter solenoid valves for hydraulic windlasses should be located in a dry area in close proximity to the windlass It must not be located in the wet environment of the chain locker 2 2 PREPARATION OF MOUNTING AREA It is of paramount importance that the vessel has sufficient deck reinforcing and total structural strength to sustain the loads that ca
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28. on angle of chain stopper Inclination angle of hawse pipe B 2xA Deck surface Front view Picture Hawse pipe 2 4 Installation angle of chain stopper 2 3 PREPARATION OF THE WINDLASS Remove windlass from its packing case Disassemble it in the following order refer to drawing in Appendix B e Remove the black Plastic Cap 1 from the top of the windlass taking care not to damage the chromed surface e Undo and remove the Retaining Screw 3 and Retaining Washer 4 under the Cap using a flat screw driver e and remove Clutch Nut 5 e For VW and VWC models only remove Drum 6 e Remove upper Clutch Cone 7 and Disc Spring 8 Undo Screws 30 that retain Chain Stripper 33 and remove it e Remove Chainwheel 9 Disc Spring 8 Lower Clutch Cone 10 Key 33 Retention Clips 11 Emergency Crank Collar 13 and Wave opring 12 Undo Screws 16 and remove the Deckplate 19 e Refer to Appendix B of this Manual and identify all parts If any parts are damaged or missing contact your Maxwell distributor Some smaller parts might not be assembled on the windlass by the factory but supplied in a plastic bag in the packing case Maxwell strongly recommends generous application of a high quality anti corrosive paste or coating to the mating sections of main shaft drive key flanges screw threads dowels and other surfaces that are likely to seiz
29. r than 2 degrees Picture 2 2 Check the installation If the problem persists some height adjustments might have to be made 17 7 1 2 APPENDIX Dimensional Drawings Do 0 dl E ER 8 ANT 8 1 4 208 eg DU Deck Level Zo C 25 O i 3 O P a E S o9 z A VE VL m gt p Note Dimensions are typical throughout the range Each type of topworks can be combined with each type of drive Use the deck level as a reference point to read dimensions for other combinations mW d Deck Level PERSEO Sht Size Pbv Dwg No 1 8 dftisd 1 of 1 2200 VW VWC VWCLP Overall Dimensions File location apollo1 Engineering Product Data assemblies PO10000 P010999 P10102 23 00 pbv 2200 Overall Dimensions 18 L0 XXX 40 IVWIOSG TUI DO xw 60 SITONV TV got 0 V N 3994 9215 9eUS 5 ji SODUBIAJO T TEUSJEW 00S 8225 d I2MA OMMA 0082 0022 1n0ojn 4320 ON UOISIA9M ON uonduo seg 31 yolym 3243 uey 19430 esodund 43430 10 pesn DUIMeIp siu SUMEN
30. tch cone VW and VWC models only e Assemble clutch nut 5 e Put retaining washer 4 on top of the main shaft and secure it with the countersunk screw 3 e Insert plastic cap 1 into the clutch nut 2 5 POWER CONECTIONS TO DC MOTOR The main power system is a two cable ungrounded fully insulated negative return system The motor is of the isolated earth type This system is selected to minimise electrolytic corrosion problems The DC motor has three power terminals marked F1 and F2 Terminal should be connected directly to terminal on the battery see wiring schematic in Appendix C Terminal F1 is for clockwise rotation of the motor and F2 is for Shaft Clutch cone o mL wee Vemm umt no ann A Y m 00060087 amet me ee Retention clip Picture 2 5 Retention Clip Assembly Apply grease Clutch cone Disc springs Picture 2 6 Greasing clutch cones an disc spring orientation anticlockwise rotation Depending on the desired direction of rotation one of these terminals should be connected to solenoid oee Table 2 1 to select the appropriate cable size for power supply The recommendation assumes that the cable insulation has a minimum temperature rating of 90 C and sizes allow for a maximum 10 voltage drop over the total length Cable lengths given are from the battery terminal to the terminal on the motor via the solenoid
31. te the problem Check the power supply to controls from the source step by step and identify the point where it stops Check wiring against diagrams supplied Check power supply lines Check main isolator switch Check hydraulic pump Check name plate on the motor If confirmed contact Maxwell Check valve setting DC motor draws high current The mounting bolts of the motor Make sure the bolts have spring but struggles to pull the load are touching the motor winding washers adjust bolt length Windlass runs but the Windlass runs but the chainwheel chainwheel stays stationary Topworks key 14 not installed Electric motor stops after The motor has been overloaded and has reached its critical temperature Tighten the clutch up as described in Section 3 2 If the problem persists contact Maxwell Install the key Leave it to cool down and reset the circuit breaker Disassemble the clutch cones 7 clean and grease them as described in Section 2 4 lp The clutch is not fully disengaged Disengage the clutch fully Disc springs 8 not fitted Fit disc springs as described in oection 2 4 Pawl 27 engaged Chain jumps slips on the The chainwheel not selected chainwheel correctly Disengage pawl Contact Maxwell with correct identification of the chain used on board Chain twisted between windlass Untwist the chain and bow roller Vertical angle of incoming chain bigge
32. tenance so keeping spares and spare tools is recommended We recommend the following list of spare parts to be carried on board Part no Description Qty 3227 Plastic 1 5953 Disc Spring 2 2311 Retention Clip 2 3207 Key Topworks 2 3150 Key Gearbox 1 7068 Washer 1 2310 Spring 1 SP2764 Circlip 2 SP2787 O Ring Elect Motor 1 If you need any other spare part please refer to the Appendix B for the correct part number and contact one of our distributors worldwide Appendix E When ordering spare parts please also quote the serial number of the windlass 4 7 TOOLS FOR MAITENANCE We recommend the following tools be kept on board for disassembling and assembling the windlass Set of metric hexagon keys e Ring open end spanner 13 17 19mm and 9 16 e Flat screw driver 10mm blade width e Circlip pliers 16 5 0 TROUBLESHOOTING The windlass does not move correctly No electric power to controls Incorrect or incomplete wiring No power supply to the windlass Windlass is not able to pull Motor voltage does not match the the specified load power supply on board Hydraulic relief valve not set Make sure the isolator switch for windlass controls is ON Check the fuse on power supply to controls Make sure the wiring is correct and check it for damage If there is more than one type of control pendant unit footswitch helm switch check them all in an effort to isola
33. ternational 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 15 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 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 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 liable for any loss damages 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 o
34. ture 1 5 Electric DC Drive Hydraulic Drive 1 3 SPECIFICATIONS Current at 500kg load Ban OUR Weight of capstan 41kg 9016 Rated capacity and chain speed is based the chainwheel for 10mm chain The performance may vary by up to 10 when other size chainwheels are used Hydraulic oil characteristics Viscosity ISO 32 68 at 20 C Suitable oils Shell Rimula X 15W 40 Shell Myrina M 15W 40 Penzoil SAE 10W 40 Texaco 2109 SAE 15W Texaco 1814 SAE 10W 40 BP HLPHM 32 68 BP Autrans TO410 2 0 INSTALLATION 2 1 SELECTION OF POSITION FOR THE WINDLASS Windlasses of this size will often be installed in pairs giving an emergency backup in the event of mechanical or electrical failure In this case one of the windlasses will normally be retrieving anchor running clockwise and the other anticlockwise Picture 2 1 Position of the windlass should be selected together with positions of hawse pipe and spurling pipe The deckplate should be installed pointing with its narrower end in the direction of the incoming chain That allows the chain to have maximum engagement with the chainwheel Allow the chain a straight run from the bow roller to the chainwheel with no more than a 2 deviation from horizontal Picture 2 2 The bow roller should have a vertical groove to suit the profile of the chain Its centre line should be tangentional to the chainwheel This will align the chain so that it enters the chainwheel without t
35. wisting The fitting of a chain stopper is essential to take the load off the windlass while the vessel is at anchor It must be correctly aligned with the direction of chain and installed at appropriate height to avoid the chain rubbing over chain stopper body or pawl Make sure the chain stopper clears the anchor shank A tensioner device to tension the anchor into its pocket is recommended If the anchor is not snug in the pocket it could cause damage to the pocket in a heavy seaway Ensure a minimum of 800mm 32 clearance between the end of spurling pipe and the chain piled up in the chain locker Picture 2 3 This will assist kinks which may develop in outgoing chain to shake free The chain must gravity feed into the locker If the chainpipe cannot be positioned directly over the locker a heavy wall pipe can be used to direct the chain to the required area lt is important that the chain slips through the pipe easily completely unaided sharp corners should be avoided 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 and shape that the chain will heap up and feed out naturally without fouling If it can be arranged the chain locker bulkhead should pass between the chainpipe outlet in the deckplate and the gearbox This will keep the gearbox motor and power li
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