VWC, VWCLP 1200 OWNERS MANUAL
Contents
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4. epos 9215 1eeus VIN Or8L0Ld SIOJON PUNOM 104 Eotd UNM OYN Ave 10 ACL AHALLVS 22 peeoxe Jou 10jeJosi pue ure sjueuoduioo yooid uoniui pe oudde qN Jojejosjjexeelg TI3MXVIA jeuondo TI3MXVIN peeoxe jou 1exee1q pue Jamod 1o0jonpuoo jo ujBue IM 0LO 0Ld 0L LE VL3 Jayeeiq JexXeaiq ejqenesai Ajenueui dwy eAgeBeu 1ubi 1 4 uonejs TISMXVIN uoneis TIHMXVW MOV 9L ON 2215 1ojonpuoo uunuuiu W Jenueui uoponujsul 55 O 19j81 SjueuieJinbei 104 oed plouajog TIHMXVIN 4 TIIMXYN JO uonejo4 ay piou os uo pue uonoeuuoo JO 24 pue 4 JO uoneoydde jo uonejol 9UEUjeln JE9 2 040 10 leas 30S 2102040 0 EOVZONO Aq aunjsiow 1285 s s Auessadau pue ayy Buoys jejueprooe 1o loid 0 p A ls o eie
5. To All Dimensions With X Nett Weight Inclusive Of Clutch Lever Emergency Crank 23 8Kg 52 4Lbs Electric 16 8Kg 37Lbs Hydraulic 80mm Dia 3 5 32 N 4 Holes 9 6mm Dia 3 8 2 Through Deck On A 5 135mm 5 5 16 PCD To Suit Deck Bolts E _ N F Bin i 518 g 3 A A 54 Oj x N iD E 44mm Dia amp N 1 3 4 x VWC 1200 E Hydraulic Motor 4 11 32 250mm Electric Motor Copyright 1991 24 114 mm Dia 4 1 2 Position 1 Dotted Line Indicates gt Extent Of Hydraulic Option Position 3 AS Shipped Extent Of Clutch Y Nut Lever FWD Position 2 Me PA 50mm Ctrs EB NOTE For 150mm 6 1 31 32 Deck Allowance Add 50mm 2 107mm To All Dimensions With X 4 7 32 Nett Weight Inclusive Of Clutch Lever Emergency Crank 21 8Kg 47 96Lbs Electric 14 8Kg 32 56Lbs Hydraulic 4 9 5mm Dia 3 8 Through Deck 135mm 5 5 16 PCD To Suit Deck Bolts 111mm 4 3 87 N e e el 2 E EIS s ef 8 E i DAN a 2 x ng gt 35 44mm Dia N 1 3 4 n VWCLP 1200 2 110mm Hydraulic Motor ae eae re 4 11 32 P i i 250mm Electric Motor Copyright 1891 9 27 32 25 10 jeeus SLN tv
6. Oil oils Shell Rimula X 40 Shell Myrina M 15W 40 SAE 10W 40 Texaco 2109 15W Texaco 1814 SAE 10W 40 10mm 3 8 short link 1200 Ibs 545Kg 430 amps 12volts 210 amps 24volts 56 1 24 Metres min 79 Feet min 17 Metres min 56 Feet min P100110 12Volt DC P100113 24Volt DC P100116 Hydraulic P100128 12Volt DC P100131 24Volt DC P100134 Hydraulic P100111 12Volt DC P100114 24Volt DC P100117 Hydraulic P100129 12Volt DC P100132 24Volt DC P100135 Hydraulic See Pages 13 14 P14366 20 Litre min 5 3 US Gal min 138 BAR 2000 p s i 12mm 72 diameter 34 U N F Viscosity ISO 32 ISO 68 9 20 50 Minimum of 0 125 zinc anti wear additive Suitable 15W Penzoil SAE Levels of flow pressure below that specified can be accommodated with a motor change see options page 5 Motor Max Flow Min Max Pressure Max Pull Normal Rate Min Option Lt US Gal Bar P S I Kg Lbs Metres Feet P14365 15 4 0 138 2000 273 600 22 72 WEIGHT Nett including Emergency Crank Product Code KGS LBS VWC 1200 100mm 4 Deck Clearance P100110 23 8 52 4 P100113 23 8 52 4 P100116 16 8 37 0 150mm 6 Deck Clearance P100128 24 2 53 2 P100131 24 2 53 2 P100134 17 2 37 82 VWCLP 1200 100mm 4 Deck Clearance P100111 21 8 48 0 P100114 21 8 48 0 P100117 14 8 32 5 150mm 6 Deck Clearance P100129 22 2 48 8 P100132 22 2 48 8 P100135 15 2 33 4 IMPORTANT PERSONAL SAFETY WARNINGS WHEN USING
7. Winch Delivery Power Relief Setting Series Motor Ltrs min US Galis min KW HP psi bar 800 P14366 20 5 3 3 8 45 1480 100 138 1200 P14366 P 14369 36 9 5 6 3 P14368 8 5 6 3 2000 1800 124 Windlass Hyd Motor Case Drain For SP2224 Motor LT Dual Direction Solenoid Control Valve Open Centred In Neutral Pressure Switch Optional Adjust To 60 Max Recommended Pressure For Model Being Installed 4 Electric Clutch US al Hydraulic Relief Valve Pump See Chart y Motor Engine dod boc 2 1 L1 urn Li i Return Line Filter Suction Strainer 4 4 HYDRAULIC SCHEMATIC INSTALLATION UTILISING ENGINE DRIVEN MAIN PUMP J Note 7 2 1 Chart Refers MAXWELL Standard Build Levels Of Flow Pressure Below That Specified 1 Can Be Accommodated Refer Manual Or Consult MAX WELL 27 Ensure Selected Hydraulic Components Copyright 1990 Are Adequate For Recommended Flow Rate ree UNLESS SPECIFIED i f MAXWELL Winches Ltd AUCKLAND NEW ZEALAND MATERIAL HYDRAULIC SCHEMATIC FOR INDLASSES TYPES 52 VW vwc VWCLP 7 51 203103 Z 29 T 40 38895 9215 PAUS Sb 9225 ELLOOtd WWOOL 0021 OMA OLLOOLd OGL AZL 002 OMA ipeup LEL
8. 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 ITIS IMPERATIVE THAT THE DESIGNER INSTALLER ENSURES THAT THE DECK AND UNDERDECK PAD ARE OF SUFFICIENT THICKNESS AND STRUCTURAL STRENGTH TO SUSTAIN THE LOADS CAPABLE OF BEING IMPOSED ON OR BY THE WINDLASS THE UNDERDECK PAD SHOULD SPREAD THE LOADS AS WIDELY AS POSSIBLE AND IF USE CAN BE MADE OF A BULKHEAD OR CROSS MEMBER TO PROVIDE STIFFENING THIS SHOULD BE DONE 2 ITIS VERY IMPORTANT THAT THE ABOVE DECK PAD TOP SURFACE OR DECK AREA COVERED BY THE GASKET SUPPLIED AND THE UNDERDECK AREA AGAINST WHICH THE LOAD WASHERS SEAT ARE SMOOTH FLAT AND GENERALLY PARALLEL 3 The gasket item 22 supplied with the Windlass can be used for accurately spotting the mounting holes and marking the cut outs After spotting bore the necessary holes These must be drilled parallel to each other and square to the mounting face DON T SPOT THROUGH THE GASKET WITH THE DRILL THIS WILL DAMAGE THE GASKET NOTE For boats of steel or aluminium construction it is very important that the deckplate is insulated from the deck with the non conductive gasket provided that the mounting studs pass through insulators and that the underdeck fixings are insulated from the deck It is also important that the anchor and chain is insulated from the hull includi
9. 3467 4 3470 5 3438 6 3446 7 3173 8 3447 9 SP70 10 4528 11 SP472 12 3441 13 SP663 14 3442 15 SP287 16 SP457 17 3480 18 SP871 19 3372 20 SP463 21 3461 22 3473 23 A 3174 23 B 3471 24 3843 25 4445 26 SP322 27 A 3448 27 B 3453 28 3436 29 3462 30 P20041 31 SP878 32 SP288 33 SP413 34 SP467 35 36 3205 37 38 SP530 39 SP366 40 P14366 100116 100134 DESCRIPTION CAP SCREW RETAINING WASHER LABEL 1200 CLUTCH NUT CLUTCH CONE CHAINWHEEL CLUTCH CONE CAP SCREW CHAIN COVER WAVE SPRING WASHER EMERGENCY CRANK COLLAR BUSH DECKPLATE BOLT WASHER STOP PIN SPIRAL RETAINING WASHER PAWL WAVE SPRING WASHER PAWL PIN GASKET STUD 4 TDC STUD 6 TDC WASHER STRIPPER HEX NUT MAINSHAFT 4 TDC MAINSHAFT 6 TDC DRUM KEY LEVER CIRCLIP BOLT WASHER WASHER PLUG ROL PIN HEX NUT HYDRAULIC MOTOR Fill the gearbox with Castrol Alpha SP 320 Oil 65 mils 33 QTY P AAHRA OAH Bap AH O gt IS Pp T JO 19945 L001d OGL WWOOL APZ 0021 d10MA sies sasu pp 002 8 9 020045 9p 00 8 FPFLLOOLd OGL tutt0S APZ 0021 d10MA wm 5 apew UOISIADY 62100 MT NN 001 OGL WWOSE 0021 d10MA Mel LNG padans ATEUIBHO RENT TI Tor Tem UE SSE LLLOOLd OGLUWOOL AZL 0021 4 LLLOOLd asodind Jayjo Aue Joy pasn jou Humea SHUL PY S9UDUIA
10. change to stall torque and or speed Refer chart page 5 Several levels of supply and control are possible BASIC SYSTEM Refer drawing B203101 and B203103 This covers applications where the Windlass is supplied from an engine driven pump or single function power pack Control of the Windlass is via a hydraulic bi directional solenoid valve which is operated by a self centering UP DOWN toggle switch type remote control or the footswitches Use of MAXWELL S Hydraulic Single Function Controller will enhance the system and allow the interfacing of self centering UP DOWN toggle switch control and footswitches with the hydraulic bi directional solenoid valve controlling the oil flow to the Windlass This unit also provides for remote controlling the oil flow to the Windlass This unit also provides for remote controlling the electric clutch of a main engine pump or the hydraulic power pack motor starter The controller must be located in a dry area IT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAIN LOCKER MAXWELL LINK SYSTEM MULTI FUNCTION ELECTRO HYDRAULIC POWER PACKS See separate manual for these multi function multi purpose systems 13 PREPARATION OF MOUNTING Standard units will accommodate deck thickness up to 100mm 4 Extra clearance models are available to accommodate deck thickness in the range of 100mm to 150mm 6 It should be noted that keeping the thickness to no more than 100mm 4 and 150mm 6
11. 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 5mm 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 dis
12. 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 FREE WHEEL AS THIS WILL ALLOW DANGEROUSLY HIGH CHAIN SPEEDS TO BUILD UP 4 When the required amount of chain is out tighten the clutch nut firmly remove the lever and stow RAISING THE ANCHOR MANUALLY IN AN EMERGENCY An emergency crank facility for raising the anchor is provided To use proceed as follows 1 Check that the chainstopper is engaged If a chainstopper is not fitted ensure that the pawl item 19 is engaged with the chainwheel 2 Insert the lever in the clutch nut and release clutches by backing off the clutch nut in a counter clockwise direction 3 Insert the lever into the emergency crank collar item 12 pin end first with pin uppermost until the pin engages with one of the dogs in the chainwheel in the furthermost counter clockwise position 4 Take the weight by pulling the lever in a clockwise direction as far as possible bring in the chain Ease off and the chainstopper will take the load Pull the lever out until the pin disengages the chainwheel dog Push lever to furthermost counter clockwise position and re engage with the chainwheel Repeat cycle progressively bring in the anchor NOTE If a chainstopper is not fitted or if found more convenient the pawl item 19 may be engaged with the chainwheel after each upward clockwi
13. the Isolator Switch is turned OFF Never proceed at speed with a bow mounted self launching anchor in position without first ensuring that your winch clutches are fully engaged and having made fast the anchor and engaged your chainstopper DO NOT DEPEND ON THE WINDLASS TO HOLD THE ANCHOR IN ITS BOW ROLLER A NYLON LINE SHOULD BE USED TO SECURE THE ANCHOR INTO 6 ITS STOWED POSITION WHEN UNDERWAY WILL NEED 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 1200 WINDLASSES ARE DESIGNED FOR ALL CHAIN SYSTEMS USING UP TO A MAXIMUM CHAIN SIZE OF 10MM 3 8 SHORT LINK CHAIN To save weight a smaller size High Tensile Chain may be used WARNING BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED BEFORE INSTALLATION YOURS AND OTHERS SAFETY MAY DEPEND 1 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 an
14. 14 Lift clutch cones and chainwheel items 6 7 and 8 from the shaft Remove two keys item 29 VWC models one key VWCLP models item 29 from shaft item 27 Remove Wave spring washer item 11 and Emergency Crank Collar item 12 from the shaft item 27 6 Remove four bolts item 15 with spring washers item 16 and lift deckplate 14 from gearbox assembly With gearbox held horizontally check that oil is showing half way up the sight glass If necessary top up with SAE 90 Shell Omala 320 Castrol Alpha SP320 or equivalent DON T OVER FILL 7 Remove washers items16 and 24 by undoing four nuts item 26 MOUNTING THE WINDLASS 8 Clean the underside of the deckplate item 14 Make sure the mounting area on the deck is properly prepared as per step 3 above and is clean Using the gasket item 22 between the deckplate and the deck lower the deckplate to the deck guiding the mounting studs 23 through the pre drilled mounting holes and bed the deckplate down 9 From the underside of the deck offer up the four load washers item 24 and replace four washers and nuts items 16 and 26 15 IMPORTANT Tighten the nuts progressively and evenly DO NOT USE POWER Lightly grease shaft item 27 using Shell Alvania R2 Castrol AP2 or equivalent grease Holding the gearbox assembly feed the shaft through the deckplate from below and locate the spacer tube item 15 refer to drawings P12427 on the spigot of the deckplate item 14 Rotate the gear
15. ART NO 1 3223 2 3400 3 SP643 4 3133 5 3584 6 SP720 7 SP838 8 SP642 9 SP844 10 SP726 11 3145 12 SP721 13 SP724 14 SP159 15 A 3183 15 B 3418 P12427 DESCRIPTION SIGHT GLASS WORM BALL BEARING 12x28x8 WORM BOX WORMWHEEL 56T 20x2 O RING 1in EXT CIRCLIP BALL BEARING 25x12x47 47 x 1 85 INT CIRCLIP O RING ID 90MM X2MM BUSH 25x47x7 OIL SEAL 40x55x8 OIL SEAL M6x40 CAP SCREW SPACER TUBE 4 IN SPACER TUBE 6 IN Fill the gearbox with Castrol Alpha SP 320 Oil 65 mils 3 9 QTY P N N
16. ETAINING WASHER 1 19 3372 PAWL 1 20 SP463 WAVE SPRING WASHER 1 21 3461 PAWL PIN 1 22 3473 GASKET 1 23 A 3174 STUD 4 TDC 4 23 B 3471 STUD 6 TDC 4 24 3843 WASHER 4 25 4445 STRIPPER 1 26 SP322 HEX NUT 4 27 A 3448 MAINSHAFT 4 TDC 1 27 B 3453 MAINSHAFT 6 TDC 1 28 3436 DRUM 1 29 3462 KEY 3 30 20041 LEVER 1 31 SP878 CIRCLIP 2 32 SP288 BOLT 2 33 SP413 WASHER 4 34 SP467 WASHER 4 35 A P10156 ELECTRIC MOTOR 12V 1 35 B P10157 ELECTRIC MOTOR 24V 1 36 3205 PLUG 1 37 38 SP530 ROL PIN 1 Fill the gearbox with Castrol Alpha SP 320 Oil 65 mils 31 9LLOOLd bELOOld 33H CadWVLS ON TVTU3S uondii5s q T JO I 32995 2539905 2002 8 9 EET OGL WWOOL 0021 waj _ OGL 1 0021 OMA 8210014 EBETITTNMM 020045 9 eoeidog SILL PIF Dun 1 5 SiopejUOIGgNs suosiad 13430 Aue sJu luo5 51 40 poueo paidoo 1sntu pue uodn pauinjas eq znw SIUE SSHONIM 1 jo y sprejep pue ubisap y pue Aq si siu L _ 00 32 VWC 1200 HYDRAULIC ITEM PART NO 1 3465 2 SP40 3
17. LO2NDH SIONS OMNVYGAH TISAXVW ONISPn TOHLNOOD dung euius JO uongAnoV uini AO 100W 49404 OQln p H JO 5 48416001 sst puj 940 JO uojeJago 0128 503 euunegd fagonuo voyouns DEG SYNBIPAH 1 CTISAAXVW JO asn 20 dung JO yo 919912 01 Ave 01161 APOD tonpoJg Jejogjuoz tronoun j aug TIIMXYN QABY DOSN siu uoauioo 10024 MEB SEHUN SYL 01 1205 ON TTISAXVW SBA EA 010 1 prouajog yeuayseng NMOG i Ajdang 5445 30 21 YNNN OAGY Ob 01 jOojejosj jexEaig 9 Jamog ussmjag Joponpuoj JO bus SIuauiannbeg 555 DMY 91 ON 0 45 10jonpuo aapebay 1457 o 51041007 o1 ON yanposg 107005 ajowsy TI1HAX VIN 90061 10081 SON tonpojg Sau 2S 1004 113A X VV 28 See Note 1 Below HYDRAULIC SUPPLY REQUIREMENTS
18. OOLd OQLWWOSL APZOOZL OMA enne _ 8210014 OGL AZL 0021 OMA 8610014 ON 020095 9 00S 002 8 9 Spey parjddns Sem 3i tDiuM 10 180 ue Jed asodind jayjo Aue 10 aq jou 3snui SIUL PYT SOUOUIAA DURUM Ut 1 5 5 suos iad Aue s uaqu02 51 40 pardoo aq jou 3snui pue uodn pauinjas aq siu L QL SAHONIM TIHAXVIW T jo Ayadoud y B b x 2 5 10 pue ubisap in 2 pue si sI 15 AP ON TVPH3S P meee 30 1200 ELECTRIC 100110 100113 100128 100131 DESCRIPTION QTY 1 3465 CAP 1 2 SP40 SCREW 1 3 3467 RETAINING WASHER 1 4 3470 LABEL 1200 1 5 3438 CLUTCH NUT 1 6 3446 CLUTCH CONE 1 7 3173 CHAINWHEEL 1 8 3447 CLUTCH CONE 1 9 SP70 CAP SCREW 2 10 4528 CHAIN COVER 1 11 SP472 WAVE SPRING WASHER 1 12 3441 EMERGENCY CRANK COLLAR 1 13 SP663 BUSH 1 14 3442 DECKPLATE 1 15 SP287 BOLT 4 16 SP457 WASHER 8 17 3480 STOP PIN 1 18 SP871 SPIRAL R
19. OP PIN 18 SP871 SPIRAL RETAINING WASHER 19 3372 PAWL 20 SP463 WAVE SPRING WASHER 21 3461 PAWL PIN 22 3473 GASKET 23 A 3174 STUD 4 TDC 23 B 3471 STUD 6 TDC 24 3843 WASHER 25 4445 STRIPPER 26 SP322 HEX NUT 27 A 3449 MAINSHAFT 4 TDC 27 B 3454 MAINSHAFT 6 28 29 3462 30 20041 LEVER 31 SP878 CIRCLIP 32 SP288 BOLT 33 SP413 WASHER 34 SP467 WASHER 35 36 3205 PLUG 1 37 i 38 SP530 ROLL PIN 39 SP366 HEX NUT 40 P14366 HYDRAULIC MOTOR Fillthe gearbox with Castrol Alpha SP 320 Oil 65 mils 37 lt cux ches hore T O IS NS Copyright Maxwell Winches Limited 1998 This drawing is protected by copyright and the design and or details contained therein are the confidential property of MAXWELL MARINE LTD This drawing must be returned upon demand and must not be copied loaned or have its contents communicated to any other persons including subcontractors witnout the consent in writing from Maxwell Marine Ltd This drawing must not used for other purpose other than that for which it was originally supplied 00 Initial issue 29 06 2004 Made Des Drawn D uu 5 DH BVT Dwg No Description P12427 1200 VWC GEARBOX 56 1 SPACER TUBE P12427 BVT View Sheet Size Scale Sheet 1 of 1 38 GEARBOX ASSEMBLY ITEM P
20. P10156 ELECTRIC MOTOR 12V 1 35 B P10157 ELECTRIC MOTOR 24V 1 36 3205 PLUG 1 37 38 5 530 ROL PIN 1 Fill the gearbox with Castrol Alpha SP 320 Oil 65 mils 35 SELOOld 1110014 d43H 15 ON epu dm d ARR e Sy E chi p _ uMmeigiseag uo OGL PAH 0021 d IOMA monina _ OGL WWOOL PAH 0021 LLLOOld T JO I 19945 020095 9 902 494 008 UOISIADY Seer 2002 8 5 payddns SEM Tt tDIUA 10 196 asodind 13430 Aue 10 pasn jou 3snul SIUL pY1 S UDuI A BURUM quasuo aui 1 siope uosqns suosiad Jayjo Aue s1u luo2 5 10 paidod aq 40u pue uodn pauinjes aq stu L SAHONIM TISMXVMW Jo Auiedoud jeruepyuoo aui 10 pue ubisap pue juBuAdoo Aq papajoid 51 stu L 36 VWCLP 1200 HYDRAULIC 100117 100135 ITEM PART NO DESCRIPTION 1 3465 CAP 2 SP40 SCREW 3 3467 RETAINING WASHER 4 3470 LABEL 1200 5 3438 CLUTCH NUT 6 3446 CLUTCH CONE 7 3173 CHAINWHEEL 8 3447 CLUTCH CONE 9 SP70 CAP SCREW 10 4528 CHAIN COVER 11 SP472 WAVE SPRING WASHER 12 D3441 EMERGENCY CRANK COLLAR 13 SP663 BUSH 14 3442 DECKPLATE 15 SP287 BOLT 16 SP457 WASHER 17 3480 ST
21. SMA S3SSVIONIM HOJ 8 SNIHIM 1 OldiOd13 Gnv1v32 MIN ONY DOO TT3AXXVIN ansas 53 Way Te Ye ae ae T T DERART aes S Jd Sign a TRUE oed ALIADOS NOILLVOLISSV19 HO VWINN 99SN 3ONVOHOO2OV NI iNO 38 GINOHS SNOLLYTIVLSNI TIY 066 11954999 W31SAS OISV8 HO 1OB1NOO 21919319 jeuonoezq 8 10 HOD 0 JO 1841 OF 15837 98 BAIBA 48 10 spiouajog of eujDua sajdnog 2 12813 0ABV 9961 BMV 91 ON uut 825 88S 4ojonpuoz 14817 woda NMOG panpa 2 90061 12910 OL werd 10061 SOW 5 1004 TISA XVW 0226 ON jonpoJd UORETS 713A X VW YWAN DOSN sjuauoautot 10014 paAoJ100V UNA si uun siut auy ot 12061 ON 8p02 12npoig JoJejOs J0322J0 TAM HZTIOHINOO NOL
22. TION You now own a Windlass from MAXWELL S premier range designed for automatic anchor handling Used in conjunction with MAXWELL S Link System Electronic Controls you will get system protection and finger tip control of anchor raising or lowering The compact deck saving vertical design allows 180 wrap of the chain ensuring maximum engagement with the chainwheel On VWC types a vertical drum allows working of mooring or docking lines from any direction A clutch allows manual control for lowering the anchor under free fall and manual override when using the emergency crank The clutch also allows independent operation of the drum on VWC types IMPORTANT FAILURE TO ADHERE TO THE CORRECT APPLICATION INSTALLATION OPERATION AND TO CARRY OUT THE MAINTENANCE SERVICE AS DESCRIBED HEREIN COULD JEOPARDISE YOUR SAFETY AND INVALIDATE THE WARRANTY Your MAXWELL Windlass is a precision engineered product Please read these instructions carefully SPECIFICATIONS MAXWELL VWC VWCLP 1200 WINDLASS Maximum chain size Maximum rated load at chainwheel Current stall load Gearbox ratio Chain haul speed at no load Line speed normal working POWER OPTIONS VWC 1200 10mm 4 Deck clearance 150mm 6 Deck clearance VWCLP 1200 100mm 4 Deck clearance 150mm 6 Deck clearance SUPPLY CABLES HYDRAULIC MODELS Max recommended Flow Max recommended Pressure Hydraulic Supply Lines Hydraulic Motor Ports
23. TIONED 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 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
24. TS When ordering spare parts please quote the following Windlass Serial Number Power Supply 12V 24V or Hydraulic Drawing Reference Number Description Quantity Required TECHNICAL ASSISTANCE We are always at your service If you require information or assistance contact Head Office MAXWELL MARINE LTD Street Address 16 18 William Pickering Drive Albany Auckland NEW ZEALAND PHONE 64 9 477 0900 FAX 64 9 476 0555 Australia MAXWELL MARINE AUSTRALIA Street Address Unit 1 10 Neumann Street Capalaba 4157 Queensland AUSTRALIA PHONE 61 7 3245 4755 FAX 61 7 3245 5906 America MAXWELL MARINE INC Street Address 2907 South Croddy Way Santa Ana CA 92627 6302 USA PHONE 1 714 689 2900 FAX 1 714 689 2910 Postal address P O Box 100 703 North Shore Mail Centre Auckland NEW ZEALAND EMAIL info maxwellmarine com WEBSITE www maxwellmarine com Postal Address P O Box 1292 Capalaba 4157 Queensland AUSTRALIA 114 mm Dia 4 1 2 Position 1 Dotted Line Indicates L Extent Of Hydraulic Option 10 29 32 Position 3 As Shipped Nut Lever FWD Position 2 For 150mm 6 Deck Allowance Add 50mm 2
25. TS IF IN DOUBT SEND FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT FOR APPRAISAL AND WRITTEN RECOMMENDATION 1 10 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 Always motor up to the anchor while retrieving the chain Do no 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 boats 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 TO 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 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
26. VWC VWCLP 1200 OWNERS MANUAL Manual Product Code No P19156 Removable Chain Cover and A Gearbox Ratio Of 56 1 COPYRIGHT 1991 MAXWELL WINCHES LTD ALL RIGHTS RESERVED PATENTS PENDING PRINTED IN NEW ZEALAND MAXWELL WINCHES reserve the right to make engineering refinements on all products without notice Illustrations and specifications not binding as to detail VWC VWCLP 1200 OWNERS MANUAL CONTENTS INTRODUCTION SPECIFICATIONS PERSONAL SAFETY WARNING APPLICATION INSTALLATION Location Windlass Chainstopper Footswitches Reversing Solenoid Breaker Isolator Panel Controls Control Circuits Main Electrical System Hydraulic Systems Preparation of Mounting Preparation of Windlass Mounting the Windlass OPERATION OF THE CONTROL SYSTEM OPERATING THE WINDLASS MAINTENANCE Servicing of Gearbox Servicing of Motor ORDERING SPARE PARTS ASSISTANCE INSTALLATION DRAWINGS VWC 1200 B201219 VWCLP 1200 B201220 Wiring Diagram Dual Direction B3424 Wiring Diagram Single Direction D3555 Hydraulic Control Diagram B203101 Hydraulic Schematic B203103 ASSEMBLY DRAWINGS VWC 1200 Electric P100128 VWC 1200 Hydraulic P100116 VWCLP 1200 Electric P100111 VWCLP 1200 Hydraulic P100117 Gearbox P12427 WARRANTY CUSTOMER WARRANTY REGISTRATION Page Number 30 31 32 33 34 35 36 37 38 39 INSTALLATION OPERATING INSTRUCTIONS AND SERVICE MANUAL VWC 1200 AND VWCLP 1200 WINDLASSES INTRODUC
27. YOUR WINDLASS AT ALL TIMES PRACTICE GOOD SEAMANSHIP AND AVOID ANY LIKELIHOOD OF INJURY OR ACCIDENT BY ADHERING TO THE FOLLOWING RULES AT ALL TIMES KEEP HANDS FEET LOOSE CLOTHING AND HAIR WELL CLEAR OF THE WINDLASS NEVER USE THE WINDLASS UNDER POWER WITH THE LEVER INSERTED IN THE CLUTCH NUT OR EMERGENCY CRANK COLLAR WHEN OPERATING THE CHAINWHEEL PAWL KEEP FINGERS AWAY FROM THE INCOMING CHAIN WHEN THE WINDLASS IS NOT IN USE OR WHEN USING THE EMERGENCY CRANK MAKE SURE THE WINDLASS IS ISOLATED FROM THE POWER SUPPLY BY TURNING THE WINDLASS ISOLATOR SWITCH TO OFF NEVER OPERATE THE WINDLASS FROM A REMOTE STATION WITHOUT A CLEAR VIEW OF THE WINDLASS AND HAVING MADE SURE THAT EVERYONE 15 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 IMPORTANT HINTS FOR SAFE USE OF WINDLASS BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED AND INSTALLED YOURS AND OTHERS SAFETY MAY DEPEND 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 AGEN
28. aged the Windlass may be operated under power by either using the DOWN footswitch or the DOWN button on the remote control station Hold until the required amount of chain is out RAISING THE ANCHOR UNDER POWER Proceed as follows 1 2 Carry out step 1 above If the clutches are tightened down the Windlass may be operated under power by either using the UP footswitch or the UP button on the remote control station Hold until the required amount of chain has been brought in Care should be taken when docking the anchor Jog in the last metre few feet carefully seating the anchor home NOTE It is not necessary to disengage the pawl or open the chainstopper to operate the Windlass in the UP direction LOWERING THE ANCHOR UNDER MANUAL CONTROL This method is generally used in tight anchorages or an emergency situation where a fast dump is required Proceed as follows 1 Insert the lever item 30 into the clutch nut item 5 and check that the clutches are tightened down firmly by turning the nut clockwise REMOVE THE LEVER 18 2 Check that chainstopper is open and the pawl item 19 is disengaged from the chainwheel NOTE This may require jogging the Windlass UP under power or in an emergency by using the emergency crank lever IF JOGGING UNDER POWER MAKE SURE THAT THE LEVER IS REMOVED FIRST 3 Standing well clear insert the lever into the clutch nut Slowly back off the clutch
29. box 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 in reverse order IMPORTANT care must be taken to ensure that the key keys item 29 are properly seated in shaft IMPORTANT NOTE TO BOAT BUILDERS After completing installation we suggest that you spray the top works of the winch with CRC3097 Long Life Also protect the winch by wrapping with plastic film and tape Experience has shown that on long ocean deliveries as deck cargo sulphur from the ship s exhausts settles and severely damages the chrome plating and stainless steel by breaking down the chrome oxide protective film PLEASE LET YOUR CUSTOMER RECEIVE THE WINDLASS FROM YOU IN THE SAME TOP QUALITY CONDITION THAT YOU RECEIVED IT FROM US 16 OPERATION OF THE CONTROL SYSTEM DUAL DIRECTION SYSTEM Refer drawing B3424 This system provides means of controlling the Windlass via a Reversing Solenoid which is actuated by a self centering UP DOWN toggle switch type remote control or the
30. cussed After all connections have been made and system tested seal terminals against moisture by spraying with CRC2043 Plasti Coat CRC3013 Soft Seal or CRC2049 Clear Urethane The main supply cables should be selected from the following table RECOMMENDED MAIN CABLE CONDUCTOR SIZE 12 VOLT D C SYSTEMS Conductor Length Conductor Size Engine Room Battery to Winch Size Correction Metres 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 MM 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 12 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 90 C The above recommendations are in accordance with the requirements of USCG ABYC AND NMMA HYDRAULIC SYSTEMS Pressure flow quoted in specification on page 4 assumes operation at rated capacity with standard motor fitted Levels below that specified can be accommodated by a motor change with a corresponding
31. d 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 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 INSTALLATION WHERE TO LOCATE THE WINDLASS The MAXWELL VWC and VWCLP 1200 Windlasses operate in dual direction power UP DOWN UP is clockwise rotation when looking down on the Windlass The deckplate should be mounted pointing in the direction of the incoming chain and with the left hand side parallel to the line of the incoming chain refer drawing B201219 VWC types and B201220 VWCLP types This arrangement allows the chian to have maximum engagement with the chainwheel The Windlass must be positioned to allow the chain to have a clear run
32. earbox 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 3097 Spray 1 Prior to Season the above deck components should be removed and greased following the instructions under steps 5 11 and 12 of the installation instructions Check level of oil in gearbox If necessary top up as per step 6 of preparing the windlass instructions The underdeck components should be sprayed preferably with CRC3097 Long Life or alternatively CRC6 66 or WD40 Particular attention should be paid to the motor on electric units including the motor terminals footswitch terminals terminals on the Reversing Solenoid Pack or the Overload Control Box plus the battery and isolator terminals Six monthly repeat procedure under item 1 above End of Season before storage carry out procedure under item 1 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 gearb
33. footswitches An indicator light on the remote control glows when the power is ON and the system can be operated WARNING When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THIS COULD DAMAGE THE WINDLASS Abuse is not covered by Warranty The Breaker Isolator Panel provides protection for the main supply cables and means to isolate the circuit WARNING When the Isolator Switch is ON the system can be activated at either the footswitches or the remote When the system is not being used ensure that the Isolator Switch is turned OFF WARNING This system provides protection for the motor from excessive current and short circuit It does not provide protection against excessive heat build up due to prolonged operation or repeated operation under overload conditions Make sure you give the motor time to cool Abuse is not covered by Warranty 17 OPERATING THE WINDLASS LOWERING THE ANCHOR UNDER POWER Proceed as follows 1 Insert the lever item 30 into the clutch nut item 5 and check that the clutches are tightened down firmly by turning the nut clockwise REMOVE THE LEVER Check that the chainstopper is open and the pawl item 19 is disengaged from the chainwheel NOTE This may require jogging the Windlass UP by momentarily operating the footswitch If clutches are tightened down and the chainstopper and pawl are diseng
34. from the fairlead or bow roller on to the chainwheel The bow roller should have a vertical groove to suit the profile of the chain This will align the chain so that it enters the chainwheel without twisting Ideally the outlet from the chainpipe should be directly over the chain locker and the chain should have at least 500mm 2ft clear fall to allow the chain to straighten before passing through the Windlass If it can be arranged the chain locker bulkhead should pass between the chainpipe outlet in the deckplate and the Windlass gearbox This will keep the gearbox motor and wiring or hydraulic hoses dry and away from flaying chain Access for servicing from inside the cabin area can usually be arranged through a locker The chain must gravity feed into the locker If the chainpipe cannot be positioned directly over the locker heavy wall flexible plastic pipe can be used to direct the chain to the required area It is important that the chain slips through easily completely unaided may be necessary to provide the pipe with a bell mouth or to bell mouth the entrance to the chainpipe from the locker to assist the free flow of the chain from the locker The chain locker must be of such a size that the chain will heap up and feed out naturally without fouling NOTE Make sure you securely fasten the end of the chain to the boat IMPORTANT FOR AUTOMATIC OPERATION TO BE POSSIBLE THE ANCHOR MUST BE SELF LAUNCHING That is once t
35. he Windlass is operated to reverse out the chain the anchor must free fall or the bow roller arrangement be such that the anchor is automatically launched When positioning the Windlass make sure that there is room to swing the emergency crank so that it will clear the pulpit and life lines or Bulwark refer drawing B201219 VWC types and B201220 VWCLP types Allow access for conveniently connecting the supply lines under deck after the Windlass is bolted in position It should be noted that the gearbox can be indexed through 4 different positions in relation to the deckplate refer drawing B201219 VWC types and B201220 VWCLP types This can be achieved on installation by referring to the appropriate assembly drawing and indexing at the top end of the spacer tube item 15 on gearbox assembly P12427 on bolts item 15 on windlass assembly Be sure to select the most convenient position and allow for the best run for the chain to clear the motor WHERE TO LOCATE THE CHAINSTOPPER The chainstopper should be positioned and aligned in a convenient position between the Windlass and the bow roller so that it clears the anchor stock The chain should pass through the stopper without being deflected WHERE TO LOCATE THE FOOTSWITCHES Footswitches are not normally fitted on open sports boats as the Windlass can be seen and operated from the helm however if footswitches are required the following should be adhered to FOOTSWITCHES SHOULD BE POSI
36. ng rubber lining the chain locker and insulating the fixing for the end of the chain to the hull Without these precautions severe electrolysis can occur It is not necessary to separately earth the Windlass as the electric motor is of the isolated earth type 14 PREPARING THE WINDLASS Remove the Windlass from the packaging Subject to the type of packaging used the Windlass will be either completely assembled or with the motor separated from the gearbox Refer to the appropriate assembly drawing provided for the Windlass being installed and proceed as follows 4 If the motor is not fitted to gearbox assemble it as follows For Electric Motors Offer motor up to gearbox aligning drive pin with slot in the worm item 2 refer to drawings P12427 Insert and tighten two bolts item 32 and washer items 33 34 provided refer to Assembly Drawings P100110 and P100111 For Hydraulic Motors Offer motor up to gearbox aligning drive pin with slot in the worm item 2 refer to drawings P12427 Insert and tighten two bolts item 32 washers items 33 34 and nuts item 39 provided refer to Assembly Drawings P100116 and P100117 5 With a pen knife or similar carefully remove cap item 1 Remove screw item 2 and retaining washer item 3 Unscrew clutch nut item 5 Lift drum item 28 from shaft VWC models only Undo cap screw item 9 with washer item 33 4 34 Remove chain cover item 10 amp stripper item 25 from deckplate item
37. ox is a totally self contained unit Providing the Windlass is not abused this unit should give years of trouble free service Every three years the gearbox should be removed oil drained cleaned and oil replaced with SAE 90 eg Shell Omala 320 Castrol Alpha SP 320 If further maintenance is required refer to the appropriate assembly drawing and accompanying parts list for disassembly SERVICING OF MOTOR Electric Units If necessary the motor can be removed from the gearbox without draining the gearbox oil as the gearbox is a sealed unit The motor is removed by undoing two bolts item 32 and washes items 33 and 34 refer to assembly drawing P100110 for VWC types and P100111 for VWCLP types A replaceable drive pin item 38 is a press fit in the output end of the drive shaft This pin engages the slot in the worm item 2 Providing the Windlass is properly installed with the Maxwell Overload Control Box and Breaker Panel and the Windlass is not abused trouble free operation can be expected Replacement brush sets are available order Part No SP 1383 12 Volt Part No SP1384 24 Volt SERVICING OF MOTOR Hydraulic Units If necessary the motor can be removed from the gearbox without draining the gearbox oil as the gearbox is a sealed unit The motor is removed by undoing two bolts item 32 washers items 33 and 34 and nuts item 39 Refer to drawing P100116 for VWC types and P100117 for VWCLP types 22 ORDERING SPARE PAR
38. se movement to hold the chainwheel from reversing 19 CHAINPIPE Chainpipe Cover can be swung out of position to relieve chain jam if necessary 1 Loosen the cap screw item 9 amp rotate cover item 10 clockwise 2 Relieve chain jam 3 Replace cover in reverse order to point 1 USING THE WARPING DRUM VWC Models only The vertical capstan can be used independently of the chainwheel This is ideal for handling mooring lines docking lines or a second anchor To use proceed as follows 1 2 Check that the pawl item 19 is engaged with the chainwheel Insert the lever item 30 in the clutch nut item 5 and back off in a counter clockwise direction until it stops The capstan will now operate whilst the chainwheel remains stationary Take several turns of line around the drum in a clockwise direction Whilst pulling on the tail press the UP footswitch The Capstan will rotate in a clockwise direction Increasing or decreasing the load on the tail whilst holding the footswitch down will increase decrease the rate at which the line will be hauled in Extra turns around the drum will increase the grip and require less load on the tail DON T PUT SO MANY TURNS ON THE DRUM THAT EASING THE LOAD ON THE TAIL WILL NOT ALLOW THE ROPE TO SLIP ON THE DRUM 20 MAINTENANCE IMPORTANT Failure to carry out the maintenance and service as described herein will invalidate warranty Recommended Lubricants G
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