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Maxwell Marine 1500 Hwc Windlass Manual



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1500 HWC

COPYRIGHT 1991 MAXWELL MARINE LTD   MAXWELL MARINE INTERNATIONAL
ALL RIGHTS RESERVED.                Ltd reserves the right to make
PATENTS PENDING.                    engineering refinements on all
PRINTED IN NEW ZEALAND.             products without notice.
                                    Illustrations and specifications not
                                    binding as to detail.



Manual Product
Code No: P103109 Rev.4.00
16/03/10
                                  HWC 1500
                                OWNERS MANUAL
                                                        Page
                                                       Number

CONTENTS                                                1
INTRODUCTION                                            2
SPECIFICATIONS                                          3
PERSONAL SAFETY WARNING                                 4
APPLICATION                                             6
INSTALLATION
    Location       - Windlass                           7
                   - Chainstopper                       8
                   - Chainpipe                          8
                   - Footswitches                       8
                   - Reversing Solenoid                 8
                   - Breaker/Isolator Panel             8
                   - Controls                           9
    Control Circuits                                    9
    Main Electrical System                              10
    Hydraulic Systems                                   11
    Preparation and Mounting                            12
IMPORTANT NOTE TO BOAT BUILDERS                         14
OPERATION OF THE CONTROL SYSTEM                         14
OPERATING THE WINDLASS                                  15
MAINTENANCE                                             17
    Servicing of Gearbox                                18
    Servicing of Motor                                  18
ORDERING SPARE PARTS AND TECHNICAL SUPPORT              18
INSTALLATION DRAWINGS
    HWC 1500                                            19
    Chainpipe Location                                  20
    Deck Cutout Details                                 21
    Wiring Diagram (Dual Direction)                     22
    Wiring Diagram (Single Direction)                   23
    Hydraulic Control Diagram                           24
    Hydraulic Schematic                                 25
ASSEMBLY DRAWINGS
    HWC 1500 Electric Single Chainwheel Single Drum     26-27
    HWC 1500 Hydraulic Single Chainwheel Single Drum    28-29
    HWC 1500 Electric Double Chainwheel                 30-31
    HWC 1500 Electric Double Chainwheel Double Drum     32-33
    Gearbox                                             34
WARRANTY                                                35




                                        1
            INSTALLATION, OPERATING INSTRUCTIONS AND SERVICE MANUAL
               HWC 1500 WINDLASS - SINGLE DRUM/SINGLE CHAINWHEEL

INTRODUCTION

You now own a Windlass from MAXWELL'S premier range, designed for automatic anchor
handling.

Used in conjunction with MAXWELL'S control equipment, you will get system protection and
finger-tip control of anchor raising or lowering.

This Windlass offers exceptional power, ease and smoothness of operation. The construction
allows for these Windlasses to be arranged as a handed pair for dual installations on larger craft.

Clutches allow manual control for lowering the anchors under free fall and also allows independent
operation of the warping drums.

                                        ** IMPORTANT **

FAILURE TO ADHERE TO THE CORRECT APPLICATION, INSTALLATION, OPERATION AND
TO CARRY OUT THE MAINTENANCE SERVICE AS DESCRIBED HEREIN, COULD
JEOPARDISE YOUR SAFETY AND INVALIDATE THE WARRANTY.

Your MAXWELL Windlass is a precision engineered product. Please read these instructions
carefully.




                                                 2
SPECIFICATIONS: MAXWELL HWC 1500 WINDLASS

Maximum chain size                           10mm (3/8") short link
Maximum rated load at chainwheel             1500 lbs (680 Kg)
Gearbox ratio                                56:1
Chain haul speed at no load                  30 metres/mim (98 Feet/min)

POWER OPTIONS
HWC 1500

SUPPLY CABLES                                See Page 10


HYDRAULIC MODELS *
Maximum Recommended Flow                      20 Litre/min (5.3 US Gal/min)
Maximum Recommended Pressure                  138 BAR (2000 p.s.i.)
Hydraulic Supply Lines                        12mm (") diameter
Hydraulic Motor Ports                         " U.N.F.
Oil                                           Viscosity ISO 32 - ISO 68 @ 20-50C
                                              Suitable oils: Shell Rimula X 15W-40; Shell Myrina
                                              M 15W-40; Penzoil SAE 10W-40; Texaco 2109
                                              SAE 15W; Texaco 1814 SAE 10W40. BP
                                              HLPHM 32-68; Castrol Hysin AWS 32-68; BP
                                              Autrans T0410.

* Levels of flow/pressure below that specified can be accommodated with a motor change -
see options below.

  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        25          81


WEIGHT                                        Product code      KGS          LBS
(Nett including Emergency Crank)              P100203           23.5         51.7
                                              P100204           23.5         51.7
                                              P100205           17.1         37.6




                                              3
                             IMPORTANT
                   PERSONAL SAFETY WARNINGS


WHEN USING YOUR WINDLASS AT ALL TIMES PRACTICE GOOD SEAMANSHIP AND AVOID

ANY LIKELIHOOD OF INJURY OR ACCIDENT BY ADHERING TO THE FOLLOWING RULES.



AT ALL TIMES KEEP HANDS, FEET, LOOSE CLOTHING AND HAIR WELL CLEAR OF THE

WINDLASS.



NEVER USE THE WINDLASS UNDER POWER WITH THE LEVER INSERTED IN THE CLUTCH

NUT OR THE EMERGENCY CRANK COLLAR.



WHEN OPERATING THE CHAINWHEEL PAWL, KEEP FINGERS AWAY FROM THE

INCOMING CHAIN.



WHEN THE WINDLASS IS NOT IN USE, OR WHEN USING THE EMERGENCY CRANK, MAKE

SURE THE WINDLASS IS ISOLATED FROM THE POWER SUPPLY BY TURNING THE

WINDLASS ISOLATOR SWITCH TO "OFF".


NEVER OPERATE THE WINDLASS FROM A REMOTE STATION WITHOUT A CLEAR VIEW

OF THE WINDLASS AND HAVING MADE SURE THAT EVERYONE IS WELL AWAY FROM

THE WINDLASS.



IF YOUR WINDLASS DOES NOT HAVE A REMOTE CONTROL STATION AND IS OPERATED

FROM THE FOOTSWITCHES ONLY, ALWAYS IMMEDIATELY AFTER USE, TURN THE

WINDLASS ISOLATOR SWITCH TO "OFF". THIS WILL PREVENT ACCIDENTAL WINDLASS

OPERATION IF YOU OR PASSENGERS ACCIDENTALLY STAND ON FOOTSWITCHES.




                                     4
                **   IMPORTANT HINTS FOR SAFE USE OF WINDLASS **

BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED AND INSTALLED, YOURS
AND OTHERS SAFETY MAY DEPEND ON IT. THE WINDLASS SHOULD BE USED IN
CONJUNCTION WITH A CHAINSTOPPER OF THE APPROPRIATE SIZE. FOR AUTOMATIC
OPERATION TO BE POSSIBLE, THE ANCHOR MUST BE SELF LAUNCHING.
MAXWELL WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF A
WINDLASS BY OTHERS, INCLUDING DISTRIBUTORS AND AGENTS. IF IN DOUBT, SEND
FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT FOR APPRAISAL AND
WRITTEN RECOMMENDATION.

1. Run the engine whilst raising or lowering the anchor. Not only is this a safety
   precaution, it also helps minimise the drain on the batteries.

2. Always motor up to the anchor while retrieving the chain.
   Do not use the Windlass to pull the boat to the anchor.

3. If the anchor is fouled, do not use the Windlass to break it out.
   With the chainstopper taking the load, use the boat's engine to break the anchor loose.

4. Do not use the Windlass as a Bollard.
   Engage the chainstopper after completing the anchoring manoeuvre.

5. In heavy weather conditions, always use a heavy anchor snub from the chain directly to
   a Bollard or Sampson Post.

6. DO NOT USE THE CHAINSTOPPER OR WINDLASS AS A MOORING POINT.

7. ALWAYS TURN THE ISOLATOR SWITCH "OFF" BEFORE LEAVING THE BOAT.

8. When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE DIRECTION TO
   THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THIS COULD
   DAMAGE THE WINDLASS. Abuse is not covered by Warranty.

9. The Circuit Breaker and Isolator Switch Panel provides high current protection for the
   main supply cables and also the means to isolate the circuit. When the Isolator Switch
   is "ON" (red indicator light shows) the system can be activated at either the foot
   switches or the remote control station. When the system is not being used, ensure that
   the Isolator Switch is turned "OFF".

10. Never proceed at speed with a bow mounted self launching anchor in position, without
    first ensuring that your winch clutches are fully engaged, and having made fast the
    anchor and engaged your chainstopper.

   DO NOT DEPEND ON THE WINDLASS TO HOLD THE ANCHOR IN ITS BOW ROLLER. A
   NYLON LINE SHOULD BE USED TO SECURE THE ANCHOR INTO 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.
                                             5
APPLICATION

THE MAXWELL HWC 1500 SERIES WINDLASSES ARE DESIGNED FOR ALL CHAIN
SYSTEMS USING UP TO A MAXIMUM CHAIN SIZE OF 10MM (3/8") SHORT LINK IN ONE
CONTINUOUS LENGTH.
To save weight, a smaller size High Tensile Chain may be used.
NOTE: Care must be taken when Kenter type shackles are used. These must be arranged
so that they pass though the chainwheel in the vertical plane. In accordance with good
practice an anchor swivel shackle should be fitted between the anchor and chain. The bow/chain
roller should properly align the chain so that it enters the chainwheel squarely.

Your Windlass should have a rating of approximately 3 times total combined weight of the anchor
and chain.

The ground tackle should have been selected taking into account:
a)     Boat size, displacement and windage.
b)     Conditions of operation such as maximum depth of water, type of bottom and      weather
conditions.
c)     Holding power and size of anchor, taking special note of the manufacturers'
       recommendations.

CHAIN FIT
CORRECT FIT OF CHAIN TO CHAINWHEEL IS ESSENTIAL FOR THE WINDLASS TO
OPERATE PROPERLY.
A wide 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.




                                                6
INSTALLATION

WHERE TO LOCATE THE WINDLASS
The MAXWELL HWC 1500 Single Drum/Single Chainwheel Windlass operates in dual direction
power UP/DOWN.
This Windlass is supplied as standard with the chainwheel fitted to the starboard side.
It should be noted that this arrangement can be changed in the field to the opposite hand.
This arrangement allows for dual Windlass installations on larger craft or for you to select the
arrangement most suited to your application.
The Windlass must be positioned to allow the chain to have a clear run from the bow/chain
roller on to the chainwheel.
The 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 an the chain
should have at least 600mm (2ft) clear fall to allow the chain to straighten before pushing
through the windlass.
The chain must gravity feed into the locker. If the chainpipe cannot be positioned directly over
the locker, heavy wall pipe can be used to direct the chain to the required area.
It is important that the chain slips through easily, completely unaided.
It may be necessary to provide the pipe with a bell mouth or to bell mouth the entrance to the
chainpipe from the locker to assist the free flow of the chain from the locker.
The chain locker must be of such a size that the chain will heap up and feed out naturally
without fouling.
NOTE: Make sure you securely fasten the end of the chain to the boat.

                                       ** 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/chain roller arrangement be such that the anchor is automatically launched.
When positioning the Windlass, make sure that there is room to swing the clutch lever so
that it will clear the pulpit, life lines, Bulwark and other obstructions.
Allow access through the deck, for conveniently connecting the supply lines.




                                                 7
WHERE TO LOCATE THE CHAINSTOPPER

The chainstopper should be positioned and aligned in a convenient position between the Windlass
and the bow or chain roller, so that it clears the anchor stock. The chain should pass through the
stopper without being deflected.

WHERE TO LOCATE THE CHAINPIPE

Position the chainpipe relative to the Windlass as shown on the deck cutout detail drawing
provided (refer installation drawings).

WHERE TO LOCATE THE FOOTSWITCHES

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 250mm (10")
from the rear 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.

WHERE TO LOCATE THE REVERSING SOLENOID (Electric Windlass Only)

This unit is used ONLY when a Dual Direction Control System is being installed. (Refer
wiring diagrams). 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 CHAIN LOCKER.
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 or the Single
Direction system is used. (Refer wiring diagrams).

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.
It 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.




                                                8
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 wiring
diagrams).



CONTROL CIRCUITS

MAXWELL Windlasses may be installed for single direction or dual direction operation.
The control circuits are detailed in Drawings at the rear of the manual

These systems should be wired throughout using 1.5mm (16AWG) cable. A manually
resettable ignition proof 3 amp fuse or breaker should be fitted within one metre (40") of
the Breaker/Isolator Panel as shown in wiring diagrams.
The above requirements are mandatory for this system 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".




                                                 9
MAIN ELECTRICAL SYSTEM

Cable lengths given are from the battery terminal to the terminal on the windlass motor via the
solenoid box and back to the battery.

Where a portion of cable runs through the engine room, a size increase should be made as
indicated.

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".
All installations must be carried out in accordance with USCG, ABYC, NMMA or other local
electrical requirements.

Recommended conductor sizes allow for a maximum 10% voltage drop over the total length




                                           12v systems
Total Cable Length From Battery                                           Engine room Size
to Winch Back to Battery                     Cable Length                     Correction
                                          mm          AWG                mm           AWG
Up to 13 m (43')                           26             3                34            2
13m  17m (43'  56')                      34             2                 -            -
17m  22m (56'  72')                      42             1                 -            -
22m  27m (72'  88')                      54             0                 -            -
27m  35m (88'  115')                     67            00                 -            -


                                           24v systems
Total Cable Length From Battery                                           Engine room Size
to Winch Back to Battery                     Cable Length                     Correction
                                          mm          AWG                mm           AWG
Up to 17 m (56')                           14             6                14            6
17m  21m (56'  69')                      14             6                 -            -
21m  33m (69'  108')                     22             4                 -            -

      * Engine Room size correction is based on the ambient temperature of the engine room to
   be 60 C.




                                                10
HYDRAULIC SYSTEMS

Pressure/flow quoted in specification on page 4 assumes operation at rated capacity with
standard motor fitted. Levels below that specified can be accommodated, by a motor change,
with a corresponding change to stall torque and/or speed. (Refer to Specifications section).

Several levels of supply and control are possible.

BASIC SYSTEM (Refer to Hydraulic diagrams/skhematics).

This covers applications where the Windlass is supplied from an engine driven pump or single
function power pack. Control of the Windlass is via a hydraulic bi-directional solenoid valve which
is operated by a self centering UP/DOWN toggle switch type remote control or the footswitches.
Use of MAXWELL'S Hydraulic Single Function Controller will enhance the system and allow
the interfacing of self centering UP/DOWN toggle switch control and footswitches, with the
hydraulic bi-directional solenoid valve controlling the oil flow to the Windlass. This unit also
provides for remote controlling the electric clutch of a main engine pump or the hydraulic power
pack motor starter.
The controller must be located in a dry area.
IT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAINLOCKER.

MAXWELL LINK-SYSTEM MULTI-FUNCTION ELECTRO-HYDRAULIC POWER PACKS
See separate manual for these multi-function, multi-purpose systems.




                                                11
PREPARATION AND MOUNTING

The Windlass should be bolted to the deck using four 12mm (") 316 stainless steel bolts of
suitable length to accommodate the deck thickness.

The nuts under the deck should be backed up with larger diameter thick stainless steel washers or
a stainless steel clamp plate bridging between each of the forward bolts and rear bolts to spread
the load.

For decks of steel or aluminium construction:
It is very important that the Windlass is insulated from the deck with a timber pad or non-
conductive gasket. That the fixings pass through the insulators provided and that the underdeck
fixings are insulated from the deck. It is also important that the anchor and chain are 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.

                                         ** IMPORTANT **

1. IT IS IMPERATIVE THAT THE DESIGNER/INSTALLER ENSURES THAT THE DECK AND
   UNDERDECK PAD ARE OF SUFFICIENT THICKNESS AND STRUCTURAL STRENGTH
   TO SUSTAIN THE LOADS CAPABLE OF BEING IMPOSED ON OR BY THE WINDLASS.
   THE UNDERDECK PAD SHOULD SPREAD THE LOADS AS WIDELY AS POSSIBLE AND
   IF USE CAN BE MADE OF A BULKHEAD OR CROSS MEMBER TO PROVIDE
   STIFFENING, THIS SHOULD BE DONE.

2. IT IS VERY IMPORTANT THAT THE ABOVE DECK PAD TOP SURFACE OR DECK AREA
   COVERED BY THE TEMPLATE SUPPLIED, IS SMOOTH, AND FLAT.

3. Refer to deck cutout detail drawing and accurately mark out the mounting holes and access
   hole as convenient for passing supply lines through deck. The mounting holes must be drilled
   parallel to each other and square to the mounting face.

Refer to the appropriate assembly drawing provided for the Windlass being installed and
proceed as follows:

4.   Remove the Windlass from the packing crate and with the Windlass on its side and the shaft
     vertical check that oil is showing half way up the sight glass in the side of the gearbox. If
     necessary, top up with SAE 90 (Shell Omala 320, Castrol Alpha SP320 or equivalent).
     DON'T OVER FILL.

5.   Make sure the mounting area on the deck is properly prepared, as per step 3 above and is
     clean.
     Make sure the underside of the Windlass case is clean.
     Use sealant/bedding compound between deck, pad/gasket and the Windlass case and lower
     the Windlass, aligning the mounting holes in the case with the pre drilled mounting holes in
     the deck and bed the Windlass down.
     Make sure that the four insulating bushes are in place in the mounting holes in the case.
     Stainless steel washers should be used under the head of the mounting bolts to spread the
     load on the insulating bushes.




                                                  12
6.   Apply a little sealing compound to the four mounting bolts and feed the bolts down through
     the bushes in the case and deck.
     From the underside of the deck offer up the clamp plates or large washers and fix in place
     with the nuts.
     IMPORTANT
     Tighten the nuts progressively and evenly.
     DO NOT USE POWER TOOLS.
     Do not overtighten. Ensure installation is firm.

7. The chainpipe should now be fitted. If the deck is steel or aluminium the chainpipe and
   fastenings must be insulated from the deck. The chainpipe must be through bolted using
   316 stainless steel countersunk screws with the nuts underdeck backed up with large stainless
   steel washers. When fixing ensure that the stripper arm is aligned squarely in the groove of
   the chainwheel with the bevelled end in close proximity to but clear of the root of the groove.
   The chain must pass over the wheel and cleanly through the pipe without fouling on the
   stripper.
   IMPORTANT
   Tighten the nuts progressively and evenly.
   DO NOT USE POWER TOOLS.
   Do not overtighten. Ensure installation is firm.

8. When tightening the cables to the motor, ensure the lower nut is secure     Upper Nut
    against turning when tightening the upper nut. This will prevent damage
    occurring within the motor.




                                                                                  Lower Nut


Proceed as follows on the starboard running gear.


                                      ** ATTENTION**
Please note, when installing winch and in particular the chain wheel. The shaft and bronze
clutch cones MUST be coated in Shell Nautilus NLG12 Marine Grease, Castrol Boating
Grease, Valvoline Val Plex EP or equivalent grease. See "Typical Greasing Instructions".

9. Remove stripper arm from chainpipe by undoing the two bolts, nuts and washers.
   With a pen knife, or similar, carefully remove cap.
   Remove the screw and retaining washer .
   Unscrew clutch nut.
   Slide outer clutch cone, chainwheel and inner clutch cone from shaft.
   NOTE: The port running gear can be disassembled in a similar fashion and the Windlass can
   be reassembled with the chainwheel either port or starboard to suit requirements. When the
   chainwheel is assembled to port the pawl and pawl pin must be removed and reassembled on
   the port side.

10. Ensure parts removed in step 8 above and the shaft are clean.


                                               13
11. Use Shell Alvania R2, Castrol AP2 or equivalent grease and with the aid of a clean brush or
    non-fluffy rag, lightly grease the thread on the shaft and the bores and clutch faces of the
    parts removed in step 9 above, reassemble them as you go in reverse order.
    IMPORTANT: Care must be taken to ensure that the keys are properly seated in the
    shaft keyways.



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 electrical diagrams)
This system provides means of controlling the Windlass via a Reversing Solenoid which is
actuated by a self centering UP/DOWN toggle switch type remote control or the footswitches.
An indicator light on the remote control glows when the power is "ON" and the system can be
operated.

WARNING: When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE
DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THIS
COULD DAMAGE THE WINDLASS. Abuse is not covered by Warranty.
The Breaker/Isolator Panel provides protection for the main supply cables and means to
isolate the circuit.




WARNING: When the Isolator Switch is "ON" the system can be activated at either the
footswitches or the remote.
When the system is not being used, ensure that the Isolator Switch is turned "OFF".

WARNING: This system provides protection for the motor from excessive current and
short circuit. It does not provide protection against excessive heat build up due to
prolonged operation or repeated operation under overload conditions. Make sure you give
the motor time to cool. Abuse is not covered by warranty.




                                               14
OPERATING THE WINDLASS

LOWERING THE ANCHOR UNDER POWER

Proceed as follows:

1. Insert the lever into the clutch nut and check that the clutches are tightened down firmly by
   turning the nut clockwise.
   REMOVE THE LEVER.

2. Check that the chainstopper is open and the pawl is disengaged from the chainwheel.
   NOTE: This may require jogging the Windlass "UP" by momentarily operating the footswitch.

3. If clutches are tightened down and the chainstopper and pawl are disengaged, the Windlass
   may be operated under power by either using the "DOWN" footswitch or the "DOWN" button
   on the Remote Control Station. Hold until the required amount of chain is out.

RAISING THE ANCHOR UNDER POWER

Proceed as follows:

1. Carry out step 1 above.

2. If the clutches are tightened down, the Windlass may be operated under power by either using
   the "UP" footswitch or the "UP" button on the Remote Control Station. Hold until the required
   amount of chain has been brought in.

    Care should be taken when docking the anchor. Jog in the last metre (few feet) carefully
    seating the anchor home.

    NOTE: It is not necessary to disengage the pawl or open the chainstopper to operate the
    Windlass in the "UP" direction.

LOWERING THE ANCHOR UNDER MANUAL CONTROL

This method is generally used in tight anchorage or an emergency situation, where a fast dump is
required.

Proceed as follows:

1. Insert the lever into the clutch nut and check that the clutches are tightened down firmly by
   turning the nut clockwise.
   REMOVE THE LEVER.

2. Check that the chainstopper is open and the pawl is disengaged from the chainwheel.
   NOTE: This may require jogging the Windlass "UP" under power or easing the load on the
   chain.
   IF JOGGING UNDER POWER MAKE SURE THAT THE LEVER IS REMOVED FIRST.




                                                15
3. Standing well clear, insert the lever into the clutch nut.
   Slowly back off the clutch nut.
   This will release the chain.
   Regulate the speed at which the chain goes out by tightening to slow, or easing to increase.

                                         ** CAUTION **

     DO NOT ALLOW THE CHAINWHEEL TO FREE WHEEL AS THIS WILL ALLOW
     DANGEROUSLY HIGH CHAIN SPEEDS TO BUILD UP AND DAMAGE COULD OCCUR.

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

1.    Tie off the chain so that it does not pay out when the clutch is released.

2.    Insert the crank handle into the clutch nut and turn anticlockwise to loosen the clutch.

3.    Engage the pawl on the chainwheel and/or chain stopper onto the chain.

4.    Disassemble winch until the top of the chain wheel is showing.

5.    Insert the Clutch Lever spigot into the chain wheel hole and by levering on the shaft, turn
      the chainwheel.

6.    Before releasing pressure, always make sure the pawl is engaged into the chainwheel or
      the chain stopper is engaged. This is to prevent the anchor from releasing while manually
      winching.

7.    Repeat cycle, progressively bring in the anchor.




                                                16
USING THE WARPING DRUM

The Capstan can be used independently of the chainwheel.
This facilitates handling mooring lines, docking lines or handling additional winching requirements.

To use proceed as follows:

1. Check that the pawl are engaged with the chainwheel.

2. Insert the lever in to the clutch nut and back off in a counter clockwise direction until it stops.
   The Capstan will now operate whilst the chainwheel remains stationary.

3. Take several turns of line around the drum in a clockwise direction.

    Whilst pulling on the tail press the "UP" footswitch. The Capstan will rotate in a clockwise
    direction.
    Increasing or decreasing the load on the tail, whilst holding the footswitch down will
    increase/decrease the rate at which the line will be hauled in.
    Extra turns around the drum will increase the grip and require less load on the tail.

    CAUTION: ENSURE THAT FOOTSWITCH IS NOT OPERATED ACCIDENTALLY WHILST
    EXTRA TURNS ARE BEING TAKEN. KEEP FINGERS CLEAR.
    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.


MAINTENANCE

Carrying out the following simple maintenance procedures will provide years of trouble-free
service from the windlass and will ensure that the warranty remains valid.

Service Intervals

                                             Every trip    3 monthly    12 monthly     3 yearly
Ensure clutch is adjusted correctly
Strip and grease clutch
Remove windlass components, grease
with suitable lubricant
Service motor
Remove gearbox, replace oil and seals



Recommended Lubricants

Gearbox Oil:                Capacity: 70ml (2.4 fl oz)
                            Type: SAE viscosity grade 90 -110,
                                  ( e.g. Shell Omala 320, Castrol Alpha SP 320 or other
                                    approved equivalents)

Mainshaft & Bearing:        Marine Grease, Lithium based or Lithium complex based, e.g.
                            Duckhams `Keenol'; `Castrol LMX'. Do not use soap based grease.
                                                   17
Above deck components: CRC 3097 Spray.

Topworks
The parts external of the case should be washed down with fresh water regularly.
Every three months, remove the chainwheel set and lubricate the clutch faces and shaft bore
inside the deckplate with marine grease.

Gearbox
The gearbox is a self-contained sealed unit.
We recommend that the gearbox be removed and serviced by an authorised Maxwell service
technician every three years. Visit our website (www.maxwellmarine.com) for a list of service
centres and agents.
Check the gearbox oil level every six months using the sight glass.

To remove the gearbox, proceed as follows:

1. Remove both sets of running gear as per step 9 of installation instructions above.

2. Remove the two circlips from shaft either side of the gearbox and slide shaft from case.

3. On port side proceed as follows:
   Remove four bolts and washers .
   Gently tap gearbox assembly releasing it from the case.

4. For disassembly of gearbox refer to gearbox assembly drawing and accompanying parts list.

Motor
For maximum protection, we recommend that the motor be sprayed periodically with CRC Soft
Seal.
For Electric motors spray also around electrical connections
The electric motors should be serviced by a qualified electrician annually (or more frequently in
commercial applications).

Replacement brush sets are available - order Part No. P100807 - 12 Volt, Part No. P100808 -
24 Volt.


ORDERING SPARE PARTS AND TECHNICAL SUPPORT

Please refer back cover for your nearest MAXWELL distributor
or visit our website www.maxwellmarine.com.

When ordering spare parts and for technical support, please quote the following:

Windlass Model..................................
Serial Number....................................
Power Supply 12V, 24V or Hydraulic
Drawing Reference Number.................
Item No.............................................
Part No.............................................
Description.......................................
Quantity Required..............................

                                                       18
19
20
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24
25
26
27
Item No.                                  Description        Part No.   Qty
    1      Case                                               6199       1
    2      Bush                                              SP0622      4
    3      Plug                                               3573       1
    4      Plug                                              SP0875      2
    5      Label                                              3041       1
    6      Bolt  Hex Hd M8 x 25 s/s                         SP0288      4
    7      Washer  M8 spring                                SP0467      6
    8      Washer - Flat                                     SP0413      6
    9      Bearing                                           SP0663      1
   10      Pawl Pin                                           6148       1
   11      Pawl                                               3514       1
   12      Rivet                                             SP0529      2
   13      Gearbox                                           P12436      1
   31      Motor          - 12V                              P11164      1
                          - 24V                              P11166      1
  33       Bolt  Hex Hd M8 x 25 s/s                         SP0288      2
  36       O-Ring                                            SP2787      1
  37       Mainshaft                                          6197       1
  38       Circlip - external                                SP0878      2
  39       Key                                                3462       3
  40       Circlip - external                                SP0848      1
  41       Drum                                               3436       1
  42       Retaining Washer                                   3467       2
  43       Screw  CSK 3/8" x 1"                             SP0040      2
  44       Cap                                                3465       2
  45       Label                                              6425       2
  46       V28 A ring seal                                   SP0708      2
  47       Clutch Nut                                         6195       1
  48       Clutch cone                                        3497       2
  49       Chainpipe                                          2259       1
  50       Stripper                                           2260       1
  51       Washer  Flat                                     SP0412      2
  52       Bolt  Hex Hd " UNC x 1 s/s                      SP0259      2
  53       Nut  Hex Hd " UNC x 1 s/s                       SP0319      2
  54       Clutch Lever                                      P20044      1




                                                        28
29
Item No.                                  Description        Part No.   Qty
    1      Case                                               6199       1
    2      Bush                                              SP0622      4
    3      Plug                                               3573       1
    4      Plug                                              SP0875      2
    5      Label                                              3041       1
    6      Bolt  Hex Hd M8 x 25 s/s                         SP0288      4
    7      Washer  M8 spring                                SP0467      6
    8      Washer - Flat                                     SP0413      6
    9      Bearing                                           SP0663      1
   10      Pawl Pin                                           6148       1
   11      Pawl                                               3514       1
   12      Rivet                                             SP0529      2
   13      Gearbox                                           P12436      1
   29      Hydraulic Motor                                   SP0995      1
   31      Nut  Hex Hd M8 s/s                               SP0366      2
   34      Mainshaft                                          6197       1
   35      Circlip - external                                SP0878      2
   36      Key                                                3462       3
   37      Circlip - external                                SP0848      1
   38      Drum                                               3436       1
   39      Retaining Washer                                   3467       2
   40      Screw  CSK 3/8" x 1"                             SP0040      2
   41      Cap                                                3465       2
   42      Label                                              6425       2
   43      V28 A ring seal                                   SP0708      2
   44      Clutch Nut                                         6195       1
   45      Clutch cone                                        3497       2
   46      Chainpipe                                          2259       1
   47      Stripper                                           2260       1
   48      Washer  Flat                                     SP0412      2
   49      Bolt  Hex Hd " UNC x 1 s/s                      SP0259      2
   50      Nut  Hex Hd " UNC x 1 s/s                       SP0319      2
   51      Clutch Lever                                      P20044      1




                                                        30
31
Item No.                                  Description        Part No.   Qty
    1      Case                                               6199       1
    2      Bush                                              SP0622      4
    3      Plug                                              SP0875      2
    4      Label                                              3041       1
    5      Bolt  Hex Hd M8 x 25 s/s                         SP0288      4
    6      Washer  M8 spring                                SP0467      6
    7      Washer - Flat                                     SP0413      6
    8      Bearing                                           SP0663      1
    9      Pawl Pin                                           6148       2
   10      Pawl                                               3514       2
   11      Rivet                                             SP0529      2
   12      Gearbox                                           P12436      1
   30      Motor          - 12V                              P11164      1
                          - 24V                              P11166      1
  32       Bolt  Hex Hd M8 x 25 s/s                         SP0288      2
  35       O-Ring                                            SP2787      1
  36       Circlip - external                                SP0878      2
  37       Key                                                3462       3
  38       Mainshaft                                          6196       1
  39       Circlip - external                                SP0848      2
  40       Clutch Nut                                         6195       2
  41       Retaining Washer                                   3467       2
  42       Screw  CSK 3/8" x 1"                             SP0040      2
  43       Cap                                                3465       2
  44       Clutch cone                                        3497       4
  45       Label                                              6425       2
  46       V28 A ring seal                                   SP0708      2
  47       Chainpipe                                          2259       2
  48       Stripper                                           2260       2
  49       Washer  Flat                                     SP0412      4
  50       Bolt  Hex Hd " UNC x 1 s/s                      SP0259      4
  51       Nut  Hex Hd " UNC x 1 s/s                       SP0319      4
  52       Clutch Lever                                      P20044      1




                                                        32
33
Item No.                                  Description        Part No.   Qty
    1      Case                                               6199       1
    2      Bush                                              SP0622      4
    3      Plug                                              SP0875      2
    4      Label                                              3041       1
    5      Bolt  Hex Hd M8 x 25 s/s                         SP0288      4
    6      Washer  M8 spring                                SP0467      6
    7      Washer - Flat                                     SP0413      6
    8      Bearing                                           SP0663      1
    9      Pawl Pin                                           6148       2
   10      Pawl                                               3514       2
   11      Rivet                                             SP0529      2
   12      Gearbox                                           P12436      1
   30      Motor          - 12V                              P11164      1
                          - 24V                              P11166      1
  32       Bolt  Hex Hd M8 x 25 s/s                         SP0288      2
  35       O-Ring                                            SP2787      1
  36       Circlip - external                                SP0878      2
  37       Key                                                3462       5
  38       Mainshaft                                          6196       1
  39       Circlip - external                                SP0848      2
  40       Clutch Nut                                         6195       2
  41       Retaining Washer                                   3467       2
  42       Screw  CSK 3/8" x 1"                             SP0040      2
  43       Cap                                                3465       2
  44       Clutch cone                                        3497       4
  45       Drum                                               3436       2
  46       Label                                              6425       2
  47       V28 A ring seal                                   SP0708      2
  48       Chainpipe                                          2259       2
  49       Stripper                                           2260       2
  50       Washer  Flat                                     SP0412      4
  51       Bolt  Hex Hd " UNC x 1 s/s                      SP0259      4
  52       Nut  Hex Hd " UNC x 1 s/s                       SP0319      4
  53       Clutch Lever                                      P20044      1




                                                        34
Serial number
  location




                35
                                                           LIMITED WARRANTY
Warranty: Maxwell Marine International Ltd provides a three year limited warranty on all windlasses for pleasure boat usage, and a one year limited
warranty for those systems used on commercial or charter vessels. Warranty, service and parts are available around the world. Contact your
nearest Maxwell office for a complete list of service centres and distributors.

This warranty is subject to the following conditions and limitations:
1.    This Warranty will be null and void if     (a) there is any neglect or failure to properly maintain and service the products.
                                                 (b) the products are serviced, repaired or maintained improperly or by unauthorised persons.
                                                 (c) loss or damage is attributed to any act, matter or omission beyond the reasonable control of
                                                      Maxwell or the purchaser.
2.    Maxwell's liability shall be limited to repair or replacement (as determined by Maxwell) of the goods or parts defective in materials or
      workmanship.
3.    Determination of the suitability of the product and the materials for the use contemplated by the buyer is the sole responsibility of the buyer,
      and Maxwell shall have no responsibility in connection with such suitability.
4.    Maxwell shall not be liable for any loss, damages, harm or claim attributed to:
                                                 (a) use of the products in applications for which the products are not intended.
                                                 (b) corrosion, wear and tear or improper installation.
                                                 (c) improper use of the product.
5.    This Warranty applies to the original purchaser of the products only. The benefits of the Warranty are not transferable to subsequent
      purchasers.
6.    Maxwell shall not be responsible for shipping charges or installation labour associated with any warranty claims.
7.    There are no warranties of merchantability, fitness for purpose, or any other kind, express or implied, and none shall be implied by law. If
      any such warranties are nonetheless implied by law for the benefit of the customer they shall be limited to a period of three years from the
      original purchase by the user.
8.    Maxwell shall not be liable for consequential damages to any vessel, equipment, or other property or persons due to use or installation of
      Maxwell equipment.
9.    This Warranty sets out your specific legal rights allowed by Maxwell, these may be varied by the laws of different countries. In addition, the
      purchaser may also have other legal rights which vary from country to country.
10.   To make a claim under this Warranty, contact your nearest Maxwell Marine office or distributor. Proof of purchase and authorisation from
      Maxwell will be required prior to any repairs being attempted.


                                                                        To be eligible for warranty protection, please either complete
                                                                        the form below at the time of purchase and return it to the
      Purchaser                                                         appropriate address above, or fill out the electronic Warranty
                                                                        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

      Name                                              L.O.A.                                          Fitted by boat yard/dealer

                                                                                                        Purchased from dealer/chandler

      Built by




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