1500 HWCCOPYRIGHT 1991 MAXWELL MARINE LTD MAXWELL MARINE RIGHTS RESERVED Ltd reserves the right to makePATENTS PENDING engineering refinements on allPRINTED IN NEW ZEALAND products without notice Illustrations and specifications not binding as to detailManual ProductCode No P103109 Rev400160310 HWC 1500 OWNERS MANUAL Page NumberCONTENTS 1INTRODUCTION 3PERSONAL SAFETY WARNING 4APPLICATION 6INSTALLATION Location Windlass 7 Chainstopper 8 Chainpipe 8 Footswitches 8 Reversing Solenoid 8 Panel 8 Controls 9 Control Circuits 9 Main Electrical System 10 Hydraulic Systems 11 Preparation and Mounting 12IMPORTANT NOTE TO BOAT BUILDERS 14OPERATION OF THE CONTROL SYSTEM 14OPERATING THE WINDLASS 15MAINTENANCE 17 Servicing of Gearbox 18 Servicing of Motor 18ORDERING SPARE PARTS AND TECHNICAL SUPPORT 18INSTALLATION 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 25ASSEMBLY DRAWINGS HWC 1500 Electric Single Chainwheel Single Drum 2627 HWC 1500 Hydraulic Single Chainwheel Single Drum 2829 HWC 1500 Electric Double Chainwheel 3031 HWC 1500 Electric Double Chainwheel Double Drum 3233 Gearbox 34WARRANTY 35 1 INSTALLATION OPERATING INSTRUCTIONS AND SERVICE MANUAL HWC 1500 WINDLASS SINGLE DRUMSINGLE now own a Windlass from MAXWELLS premier range designed for automatic in conjunction with MAXWELLS control equipment you will get system protection andfingertip control of anchor raising or loweringThis Windlass offers exceptional power ease and smoothness of operation The for these Windlasses to be arranged as a handed pair for dual installations on larger craftClutches allow manual control for lowering the anchors under free fall and also allows of the warping drums IMPORTANT FAILURE TO ADHERE TO THE CORRECT APPLICATION INSTALLATION OPERATION ANDTO CARRY OUT THE MAINTENANCE SERVICE AS DESCRIBED HEREIN YOUR SAFETY AND INVALIDATE THE WARRANTYYour MAXWELL Windlass is a precision engineered product Please read these MAXWELL HWC 1500 chain size 10mm 38 short linkMaximum rated load at chainwheel 1500 lbs 680 KgGearbox ratio 561Chain haul speed at no load 30 metresmim 98 FeetminPOWER OPTIONSHWC 1500SUPPLY CABLES See Page 10HYDRAULIC MODELS Maximum Recommended Flow 20 Litremin 53 US GalminMaximum Recommended Pressure 138 BAR 2000 psiHydraulic Supply Lines 12mm Motor Ports UNFOil Viscosity ISO 32 ISO 68 2050C Suitable oils Shell Rimula X 15W40 Shell Myrina M 15W40 Penzoil SAE 10W40 Texaco 2109 SAE 15W Texaco 1814 SAE 10W40 BP HLPHM 3268 Castrol Hysin AWS 3268 BP Autrans T0410 Levels of flowpressure below that specified can be accommodated with a motor change see options below Motor Max FlowMin Max Pressure Max Pull Normal RateMin Option Lt US Gal Bar PSI Kg Lbs Metres Feet P14365 15 40 138 2000 273 600 25 81WEIGHT Product code KGS LBSNett including Emergency Crank P100203 235 517 P100204 235 517 P100205 171 376 3 IMPORTANT PERSONAL SAFETY WARNINGSWHEN USING YOUR WINDLASS AT ALL TIMES PRACTICE GOOD SEAMANSHIP AND AVOIDANY LIKELIHOOD OF INJURY OR ACCIDENT BY ADHERING TO THE FOLLOWING RULESAT ALL TIMES KEEP HANDS FEET LOOSE CLOTHING AND HAIR WELL CLEAR OF USE THE WINDLASS UNDER POWER WITH THE LEVER INSERTED IN THE CLUTCHNUT OR THE EMERGENCY CRANK COLLARWHEN OPERATING THE CHAINWHEEL PAWL KEEP FINGERS AWAY FROM THEINCOMING CHAINWHEN THE WINDLASS IS NOT IN USE OR WHEN USING THE EMERGENCY CRANK MAKESURE THE WINDLASS IS ISOLATED FROM THE POWER SUPPLY BY TURNING THEWINDLASS ISOLATOR SWITCH TO OFFNEVER OPERATE THE WINDLASS FROM A REMOTE STATION WITHOUT A CLEAR VIEWOF THE WINDLASS AND HAVING MADE SURE THAT EVERYONE IS WELL AWAY FROMTHE WINDLASSIF YOUR WINDLASS DOES NOT HAVE A REMOTE CONTROL STATION AND IS OPERATEDFROM THE FOOTSWITCHES ONLY ALWAYS IMMEDIATELY AFTER USE TURN THEWINDLASS ISOLATOR SWITCH TO OFF THIS WILL PREVENT ACCIDENTAL 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 YOURSAND OTHERS SAFETY MAY DEPEND ON IT THE WINDLASS SHOULD BE USED INCONJUNCTION WITH A CHAINSTOPPER OF THE APPROPRIATE SIZE FOR TO BE POSSIBLE THE ANCHOR MUST BE SELF WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF AWINDLASS BY OTHERS INCLUDING DISTRIBUTORS AND AGENTS IF IN DOUBT SENDFULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT FOR APPRAISAL ANDWRITTEN Run the engine whilst raising or lowering the anchor Not only is this a safety precaution it also helps minimise the drain on the batteries2 Always motor up to the anchor while retrieving the chain Do not use the Windlass to pull the boat to the anchor3 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 loose4 Do not use the Windlass as a Bollard Engage the chainstopper after completing the anchoring manoeuvre5 In heavy weather conditions always use a heavy anchor snub from the chain directly to a Bollard or Sampson Post6 DO NOT USE THE CHAINSTOPPER OR WINDLASS AS A MOORING POINT7 ALWAYS TURN THE ISOLATOR SWITCH OFF BEFORE LEAVING THE BOAT8 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 Warranty9 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 OFF10 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 MAXWELL HWC 1500 SERIES WINDLASSES ARE DESIGNED FOR ALL CHAINSYSTEMS USING UP TO A MAXIMUM CHAIN SIZE OF 10MM 38 SHORT LINK IN ONECONTINUOUS LENGTHTo save weight a smaller size High Tensile Chain may be usedNOTE Care must be taken when Kenter type shackles are used These must be arrangedso that they pass though the chainwheel in the vertical plane In accordance with goodpractice an anchor swivel shackle should be fitted between the anchor and chain The bowchainroller should properly align the chain so that it enters the chainwheel squarelyYour Windlass should have a rating of approximately 3 times total combined weight of the anchorand chainThe ground tackle should have been selected taking into accounta Boat size displacement and windageb Conditions of operation such as maximum depth of water type of bottom and Holding power and size of anchor taking special note of the manufacturers FITCORRECT FIT OF CHAIN TO CHAINWHEEL IS ESSENTIAL FOR THE WINDLASS TOOPERATE PROPERLYA wide range of chainwheels is available to suit your WindlassThe correct fit can only be guaranteed where a standard chain known to us is used Alternativelya 450mm 18 or 12 links whichever is longer sample must be forwarded to us to match fitWhere patterns to suit are not held by us we are able to manufacture to instructions and reservethe right to charge cost WINDLASS SHOULD BE USED IN CONJUNCTION WITH A MAXWELL CHAINSTOPPEROF THE APPROPRIATE SIZE TO LOCATE THE WINDLASSThe MAXWELL HWC 1500 Single DrumSingle Chainwheel Windlass operates in dual directionpower UPDOWNThis Windlass is supplied as standard with the chainwheel fitted to the starboard sideIt should be noted that this arrangement can be changed in the field to the opposite handThis arrangement allows for dual Windlass installations on larger craft or for you to select thearrangement most suited to your applicationThe Windlass must be positioned to allow the chain to have a clear run from the bowchainroller on to the chainwheelThe roller should have a vertical groove to suit the profile of the chain This will align thechain so that it enters the chainwheel without the outlet from the chainpipe should be directly over the chain locker an the chainshould have at least 600mm 2ft clear fall to allow the chain to straighten before pushingthrough the windlassThe chain must gravity feed into the locker If the chainpipe cannot be positioned directly overthe locker heavy wall pipe can be used to direct the chain to the required areaIt is important that the chain slips through easily completely unaidedIt may be necessary to provide the pipe with a bell mouth or to bell mouth the entrance to thechainpipe from the locker to assist the free flow of the chain from the lockerThe chain locker must be of such a size that the chain will heap up and feed out foulingNOTE Make sure you securely fasten the end of the chain to the boat IMPORTANT FOR AUTOMATIC OPERATION TO BE POSSIBLE THE ANCHOR MUST BE SELFLAUNCHING That is once the Windlass is operated to reverse out the chain the anchor mustfree fall or the bowchain roller arrangement be such that the anchor is automatically launchedWhen positioning the Windlass make sure that there is room to swing the clutch lever sothat it will clear the pulpit life lines Bulwark and other access through the deck for conveniently connecting the supply lines 7WHERE TO LOCATE THE chainstopper should be positioned and aligned in a convenient position between the Windlassand the bow or chain roller so that it clears the anchor stock The chain should pass through thestopper without being deflectedWHERE TO LOCATE THE the chainpipe relative to the Windlass as shown on the deck cutout detail refer installation drawingsWHERE TO LOCATE THE SHOULD BE POSITIONED FAR ENOUGH AWAY FROM THE WINDLASS TOENSURE OPERATOR SAFETYTo allow the operator to tail from the warping drum footswitches should be at least 250mm 10from the rear WindlassTHE BELOW DECK PORTION OF THE FOOTSWITCH SHOULD NOT BE EXPOSED TOWATER OR WET ENVIRONMENT AND THE BREATHER HOLES MUST BE KEPT CLEARIdeally they should be external to the chain lockerThe arrows on the footswitches should be arranged to indicate the direction of operationWHERE TO LOCATE THE REVERSING SOLENOID Electric Windlass OnlyThis unit is used ONLY when a Dual Direction Control System is being installed Referwiring diagrams The Reversing Solenoid should be located in a dry area in close proximityto the WindlassIT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAIN LOCKERLocating close by the Windlass considerably shortens the total length of the main power requiredWHERE TO LOCATE THE PANEL Electric Windlasses OnlyThe Maxwell Panel is used when either the Dual Direction system or the system is used Refer wiring diagramsThe Panel is selected to provide limited protection only for the motor andfull protection for the supply cablesThis unit also provides the means for isolating the electrical system from the batteryIt should be mounted in a dry place within 18 metres 72 of cable length from batteryThis equipment or equivalent is mandatory to meet USCG requirements 8WHERE TO LOCATE THE CONTROLSThe remote control stations can be positioned as required ie Bridge Helm Cockpit or Foredeckto suit your the panels where the terminals project into a dry area and if mounted in an area wherethe face is exposed to the weather ie Fly Bridge the mounting must be bedded down may be wired directly to or linked together in series to the Reversing Solenoid refer Windlasses may be installed for single direction or dual direction operationThe control circuits are detailed in Drawings at the rear of the manualThese systems should be wired throughout using 15mm 16AWG cable A ignition proof 3 amp fuse or breaker should be fitted within one metre 40 ofthe Panel as shown in wiring diagramsThe above requirements are mandatory for this system to meet USCG ABYC and NMMAAfter all connections have been made and system tested seal terminals against moistureby spraying with CRC2043 PlastiCoat CRC3013 Soft Seal or CRC2049 Clear Urethane 9MAIN ELECTRICAL SYSTEMCable lengths given are from the battery terminal to the terminal on the windlass motor via thesolenoid box and back to the batteryWhere a portion of cable runs through the engine room a size increase should be made all connections have been made and system tested seal terminals against moisture byspraying with CRC2043 PlastiCoat CRC3013 Soft Seal or CRC2049 Clear UrethaneAll installations must be carried out in accordance with USCG ABYC NMMA or other conductor sizes allow for a maximum 10 voltage drop over the total length 12v systemsTotal Cable Length From Battery Engine room Sizeto Winch Back to Battery Cable Length Correction mm AWG mm AWGUp to 13 m 43 26 3 34 213m 17m 43 56 34 2 17m 22m 56 72 42 1 22m 27m 72 88 54 0 27m 35m 88 115 67 00 24v systemsTotal Cable Length From Battery Engine room Sizeto Winch Back to Battery Cable Length Correction mm AWG mm AWGUp to 17 m 56 14 6 14 617m 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 10HYDRAULIC quoted in specification on page 4 assumes operation at rated capacity withstandard motor fitted Levels below that specified can be accommodated by a motor changewith a corresponding change to stall torque andor speed Refer to Specifications sectionSeveral levels of supply and control are possibleBASIC SYSTEM Refer to Hydraulic covers applications where the Windlass is supplied from an engine driven pump or singlefunction power pack Control of the Windlass is via a hydraulic bidirectional solenoid valve whichis operated by a self centering UPDOWN toggle switch type remote control or the of MAXWELLS Hydraulic Single Function Controller will enhance the system and allowthe interfacing of self centering UPDOWN toggle switch control and footswitches with thehydraulic bidirectional solenoid valve controlling the oil flow to the Windlass This unit alsoprovides for remote controlling the electric clutch of a main engine pump or the hydraulic powerpack motor starterThe controller must be located in a dry areaIT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE LINKSYSTEM MULTIFUNCTION POWER PACKSSee separate manual for these multifunction multipurpose systems 11PREPARATION AND MOUNTINGThe Windlass should be bolted to the deck using four 12mm 316 stainless steel bolts ofsuitable length to accommodate the deck thicknessThe nuts under the deck should be backed up with larger diameter thick stainless steel washers ora stainless steel clamp plate bridging between each of the forward bolts and rear bolts to spreadthe loadFor decks of steel or aluminium constructionIt is very important that the Windlass is insulated from the deck with a timber pad or nonconductive gasket That the fixings pass through the insulators provided and that the are insulated from the deck It is also important that the anchor and chain are insulatedfrom the hull including rubber lining the chain locker and insulating the fixing for the end of thechain to the hullWithout these precautions severe electrolysis can occur IMPORTANT 1 IT IS IMPERATIVE THAT THE 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 DONE2 IT IS VERY IMPORTANT THAT THE ABOVE DECK PAD TOP SURFACE OR DECK AREA COVERED BY THE TEMPLATE SUPPLIED IS SMOOTH AND FLAT3 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 faceRefer to the appropriate assembly drawing provided for the Windlass being installed andproceed as follows4 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 DONT OVER FILL5 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 sealantbedding compound between deck padgasket 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 126 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 firm7 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 firm8 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 NutProceed as follows on the starboard running gear note when installing winch and in particular the chain wheel The shaft and bronzeclutch cones MUST be coated in Shell Nautilus NLG12 Marine Grease Castrol BoatingGrease Valvoline Val Plex EP or equivalent grease See Typical Greasing Instructions9 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 side10 Ensure parts removed in step 8 above and the shaft are clean 1311 Use Shell Alvania R2 Castrol AP2 or equivalent grease and with the aid of a clean brush or nonfluffy 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 NOTE TO BOAT BUILDERSAfter completing installation we suggest that you spray the top works of the winch with CRC3097Long LifeAlso protect the winch by wrapping with plastic film and tapeExperience has shown that on long ocean deliveries as deck cargo sulphur from the shipsexhausts settles and severely damages the chrome plating and stainless steel by breaking downthe chrome oxide protective filmPLEASE LET YOUR CUSTOMER RECEIVE THE WINDLASS FROM YOU IN THE SAME TOPQUALITY CONDITION THAT YOU RECEIVED IT FROM USOPERATION OF THE CONTROL SYSTEMDUAL DIRECTION SYSTEM Refer electrical diagramsThis system provides means of controlling the Windlass via a Reversing Solenoid which isactuated by a self centering UPDOWN toggle switch type remote control or the footswitchesAn indicator light on the remote control glows when the power is ON and the system can When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONEDIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THISCOULD DAMAGE THE WINDLASS Abuse is not covered by WarrantyThe Panel provides protection for the main supply cables and means toisolate the circuitWARNING When the Isolator Switch is ON the system can be activated at either or the remoteWhen the system is not being used ensure that the Isolator Switch is turned OFFWARNING This system provides protection for the motor from excessive current andshort circuit It does not provide protection against excessive heat build up due toprolonged operation or repeated operation under overload conditions Make sure you givethe motor time to cool Abuse is not covered by warranty 14OPERATING THE THE ANCHOR UNDER POWERProceed as follows1 Insert the lever into the clutch nut and check that the clutches are tightened down firmly by turning the nut clockwise REMOVE THE LEVER2 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 footswitch3 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 outRAISING THE ANCHOR UNDER POWERProceed as follows1 Carry out step 1 above2 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 THE ANCHOR UNDER MANUAL CONTROLThis method is generally used in tight anchorage or an emergency situation where a fast dump as follows1 Insert the lever into the clutch nut and check that the clutches are tightened down firmly by turning the nut clockwise REMOVE THE LEVER2 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 153 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 OCCUR4 When the required amount of chain is out tighten the clutch nut firmly remove the lever and stowRAISING THE ANCHOR MANUALLY IN AN EMERGENCY1 Tie off the chain so that it does not pay out when the clutch is released2 Insert the crank handle into the clutch nut and turn anticlockwise to loosen the clutch3 Engage the pawl on the chainwheel andor chain stopper onto the chain4 Disassemble winch until the top of the chain wheel is showing5 Insert the Clutch Lever spigot into the chain wheel hole and by levering on the shaft turn the chainwheel6 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 winching7 Repeat cycle progressively bring in the anchor 16USING THE WARPING DRUMThe Capstan can be used independently of the chainwheelThis facilitates handling mooring lines docking lines or handling additional winching requirementsTo use proceed as follows1 Check that the pawl are engaged with the chainwheel2 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 stationary3 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 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 DONT PUT SO MANY TURNS ON THE DRUM THAT EASING THE LOAD ON THE TAIL WILL NOT ALLOW THE ROPE TO SLIP ON THE out the following simple maintenance procedures will provide years of from the windlass and will ensure that the warranty remains validService Intervals Every trip 3 monthly 12 monthly 3 yearlyEnsure clutch is adjusted correctlyStrip and grease clutchRemove windlass components greasewith suitable motorRemove gearbox replace oil and Oil Capacity 70ml 24 fl oz Type SAE viscosity grade 90 110 eg Shell Omala 320 Castrol Alpha SP 320 or other approved Bearing Marine Grease Lithium based or Lithium complex based eg Duckhams Keenol Castrol LMX Do not use soap based grease 17Above deck components CRC 3097 parts external of the case should be washed down with fresh water regularlyEvery three months remove the chainwheel set and lubricate the clutch faces and shaft boreinside the deckplate with marine gearbox is a selfcontained sealed unitWe recommend that the gearbox be removed and serviced by an authorised Maxwell every three years Visit our website for a list of servicecentres and agentsCheck the gearbox oil level every six months using the sight glassTo remove the gearbox proceed as follows1 Remove both sets of running gear as per step 9 of installation instructions above2 Remove the two circlips from shaft either side of the gearbox and slide shaft from case3 On port side proceed as follows Remove four bolts and washers Gently tap gearbox assembly releasing it from the case4 For disassembly of gearbox refer to gearbox assembly drawing and accompanying parts listMotorFor maximum protection we recommend that the motor be sprayed periodically with CRC SoftSealFor Electric motors spray also around electrical connectionsThe electric motors should be serviced by a qualified electrician annually or more frequently incommercial brush sets are available order Part No P100807 12 Volt Part No P100808 24 VoltORDERING SPARE PARTS AND TECHNICAL SUPPORTPlease refer back cover for your nearest MAXWELL distributoror visit our website ordering spare parts and for technical support please quote the ModelSerial NumberPower Supply 12V 24V or Reference NumberItem NoPart Required 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 ss 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 ss SP0288 2 36 ORing 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 38 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 ss SP0259 2 53 Nut Hex Hd UNC x 1 ss SP0319 2 54 Clutch Lever P20044 1 2829Item 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 ss 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 ss 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 38 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 ss SP0259 2 50 Nut Hex Hd UNC x 1 ss SP0319 2 51 Clutch Lever P20044 1 3031Item 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 ss 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 ss SP0288 2 35 ORing 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 38 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 ss SP0259 4 51 Nut Hex Hd UNC x 1 ss SP0319 4 52 Clutch Lever P20044 1 3233Item 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 ss 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 ss SP0288 2 35 ORing 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 38 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 ss SP0259 4 52 Nut Hex Hd UNC x 1 ss SP0319 4 53 Clutch Lever P20044 1 34Serial number location 35 LIMITED Maxwell Marine International Ltd provides a three year limited warranty on all windlasses for pleasure boat usage and a one year for those systems used on commercial or charter vessels Warranty service and parts are available around the world Contact yournearest Maxwell office for a complete list of service centres and warranty is subject to the following conditions and limitations1 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 purchaser2 Maxwells liability shall be limited to repair or replacement as determined by Maxwell of the goods or parts defective in materials or workmanship3 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 suitability4 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 product5 This Warranty applies to the original purchaser of the products only The benefits of the Warranty are not transferable to subsequent purchasers6 Maxwell shall not be responsible for shipping charges or installation labour associated with any warranty claims7 There are no warranties of 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 user8 Maxwell shall not be liable for consequential damages to any vessel equipment or other property or persons due to use or installation of Maxwell equipment9 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 country10 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 Name Address Telephone Facsimile Supplier Dealer Name Address Telephone Facsimile Windlass Model Serial Number Date of Purchase Boat Type Windlasses Supplied With boat Name LOA Fitted by boat yarddealer Purchased from dealerchandler Built by 363738