Maxwell 1200 Windlass (VW, VWC, VWCLP & HWC) — Owner's Manual

VWC / VWCLP 1200

Option motor P14365 for lower flow/pressure: max flow 15 Lt/min (4.0 US Gal), max pressure 138 Bar (2000 P.S.I.), max pull 273 Kg (600 Lbs), normal rate 22 Metres (72 Feet)/min.

Power Options & Weights

• Designed for chain up to 10MM (3/8") short link; a smaller high tensile chain may be used to save weight. Rating approximately 3 times the combined weight of anchor and chain.
• Fit of chain to chainwheel is essential: standard chain known to Maxwell, or a 450mm (18") / 12 link sample. Use with a Maxwell chainstopper of the appropriate size.
• VWC has a vertical drum for mooring and docking lines; 180º chain wrap; removable chain cover.

Location & Controls

• Dual direction UP/DOWN; “UP” is clockwise looking down. Point the deckplate at the incoming chain with its left hand side parallel to it (drawings B201219 VWC, B201220 VWCLP).
• Clear run from fairlead or bow roller (vertical groove for the chain profile). Chainpipe outlet ideally over the locker with at least 500mm (2ft) clear fall; if possible put the locker bulkhead between chainpipe outlet and gearbox to keep gearbox, motor and wiring dry.
• Room to swing the emergency crank clear of pulpit, lifelines or bulwark. The gearbox can be indexed through 4 positions relative to the deckplate – pick the one that keeps the chain clear of the motor.
• Footswitches at least 500mm (20") from the windlass, below-deck part dry, breather holes clear. Reversing solenoid (dual direction, drawing B3424) dry and close to the windlass – never in the chain locker.
• Breaker/isolator panel (dual direction B3424 or single direction B3555) in a dry place within 1.8 metres (72") of cable length from the battery – mandatory for U.S.C.G.
• Control circuits in 1.5mm² (16 AWG) cable with a manually resettable ignition proof fuse or breaker within 1 metre (40") of the power source on line 2. Seal terminals with CRC2043 “Plasti-Coat”, CRC3013 “Soft Seal” or CRC2049 “Clear Urethane”.
• Hydraulic: basic system (B203101, B203103) from an engine driven pump or power pack via a bi-directional solenoid valve; Maxwell's Hydraulic Single Function Controller must be in a dry area.

Mounting

1. Standard units suit decks up to 100mm (4"); extra clearance models 100mm to 150mm (6"). Staying within these lets the gearbox come out as a sealed unit without stripping the topworks.
2. Deck and underdeck pad must carry the loads; the gasket area on deck and the underdeck seat for the load washers must be smooth, flat and parallel. Use the gasket to spot the holes and cut-outs – do not drill through it; drill holes parallel and square to the mounting face.
3. Steel or aluminium boats: insulate the deckplate with the non conductive gasket, studs through insulators, underdeck fixings insulated, anchor and chain insulated from the hull. No separate earth needed (isolated earth motor).
4. If the motor is separate: offer it up aligning the drive pin with the slot in the worm; electric motors with two bolts and washers, hydraulic motors with bolts, washers and nuts.
5. Strip the topworks: cap, screw, retaining washer, clutch nut, drum (VWC), chain cover and stripper, clutch cones and chainwheel, keys, wave spring washer and emergency crank collar. Remove the four bolts and lift the deckplate off the gearbox.
6. Gearbox horizontal: oil half way up the sight glass; top up with SAE 90 (Shell Omala 320, Castrol Alpha SP320 or equivalent). Do not over fill.
7. Bed the deckplate on the gasket with the studs through the deck; fit load washers, washers and nuts underneath and tighten progressively and evenly – no power tools.
8. Lightly grease the shaft (Shell Alvania R2, Castrol AP2 or equivalent), feed it up through the deckplate, locate the spacer tube on the deckplate spigot in the chosen position and refit the four bolts evenly.
9. Grease the shaft thread and the bores and clutch faces of the topworks parts and reassemble in reverse order, with the keys properly seated.
10. Boat builders: spray the topworks with CRC3097 “Long Life” and wrap in plastic film and tape for delivery.

Anchor

• Never run under power with the lever in the clutch nut or emergency crank collar. Isolator “OFF” when not in use or when cranking; with footswitch-only control switch it off immediately after use. Do not switch direction before the windlass stops; give the motor time to cool.
• Run the engine; motor up to the anchor; never break out a fouled anchor with the windlass – let the chainstopper take the load and use the engine. Do not use windlass or chainstopper as a mooring point; snub to a bollard in heavy weather; secure the anchor with a nylon line or pin under way.
• Under power: tighten the clutch nut firmly clockwise with the lever and REMOVE THE LEVER. For “DOWN” open the chainstopper and disengage the pawl (jog “UP” if needed); “UP” works with pawl and stopper engaged. Jog in the last metre carefully.
• Manual lowering: clutches tight, stopper open, pawl off; standing clear, slowly back off the clutch nut and regulate the speed with it. Never let the chainwheel free wheel. Tighten firmly when done.
• Emergency crank: chainstopper (or pawl) engaged; release the clutch counter clockwise; insert the lever pin end first, pin uppermost, into the emergency crank collar so the pin engages a chainwheel dog in the furthermost counter clockwise position; pull clockwise to bring in chain, let the stopper or pawl take the load, re-engage and repeat.
• Chain jam: loosen the cap screw and swing the chainpipe cover clockwise out of the way, clear the jam, refit.

Warping Drum (VWC)

1. Engage the pawl with the chainwheel.
2. Back off the clutch nut counter clockwise until it stops: the capstan turns while the chainwheel stays stationary.
3. Several turns clockwise on the drum; pull on the tail and press “UP”. More or less tail load increases or decreases the hauling rate; extra turns give more grip.
4. Never put on so many turns that easing the tail will not let the rope slip.

Schedule & Lubricants

• Gearbox oil: SAE 90, e.g. Shell Omala 320, Castrol Alpha SP 320; the assembly drawings specify filling the gearbox with Castrol Alpha SP 320 Oil 65 mils.
• Mainshaft and bearing: marine grease, lithium or lithium complex based (e.g. Duckhams ‘Keenol’, ‘Castrol LMX’) – no soap based grease. Above-deck components: CRC 3097 spray.
• Prior to season, six-monthly and end of season: remove and grease the topworks, check gearbox oil, spray underdeck components (CRC3097 “Long Life”, CRC6-66 or WD40), especially motor, footswitch, solenoid, battery and isolator terminals.
• Clean the topworks with a kerosene-damp cloth, spray CRC3097 and polish; mild abrasive polish for bronze only, never chrome.
• Failure to carry out the maintenance invalidates the warranty.

Gearbox & Motor

• Every three years remove the gearbox, drain, clean and refill with SAE 90. It is sealed: the motor comes off without draining it.
• Electric motor: remove two bolts and washers; the replaceable drive pin is a press fit in the drive shaft and engages the slot in the worm. Brush sets: SP 1383 – 12 Volt, SP1384 – 24 Volt.
• Hydraulic motor: remove two bolts, washers and nuts.
• When ordering spares quote model, serial number, power supply, drawing reference, item no., part no., description and quantity.