Maxwell 2500 VW, VWC & VWCLP Windlass — Manual

Position & Deck Cutout

• Often installed in pairs (one clockwise, one anticlockwise) as a backup. Choose the position with hawse pipe and spurling pipe; the deckplate's narrower end points at the incoming chain.
• Straight run from the bow roller with no more than 2° deviation from horizontal; roller groove to suit the chain, centre line tangential to the chainwheel. Side pocket anchors: chain roller above the hawse pipe.
• Chain stopper essential, aligned and at the right height, clear of the anchor shank; tensioner recommended. Hawse pipe angled outboard: angle the stopper by half that angle (vertical if under 4).
• Minimum 800mm (32") between the end of the spurling pipe and the piled chain; gravity feed unaided. If possible run the locker bulkhead between chainpipe outlet and gearbox; the gearbox indexes through several angles.
• Footswitches at least 700mm (28") from the windlass; motor starter (solenoid valves for hydraulic) dry and close by, never in the chain locker.
• Deck cutout drawings: 3340 “Deck Cutout Template” for use with 2200 / 2500 VW (Ø132 cutout, 4 – Ø12 holes equispaced on a Ø164 PCD, R8 notch) – print the PDF at 100% and check the accuracy of all dimensions before cutting; 3328 (2200 2500 VWC-VWCLP) is marked “do not use as a template, for reference only”.

Installing

1. Strip the topworks: stainless cap 7191, retaining screw SP0040 and washer 3267, clutch nut 3228C, drum 3230C (VW and VWC), upper cone 6061 and disc spring 5953, stripper (screws SP0254), chainwheel 3231, disc spring, lower cone, key 3207, retention clips 2311, washer 7068, spring and collar 4233; then deckplate screws SP3221 and deckplate 3233C.
2. Anti-seize on all threads, keys, keyways, main shaft and inside the spacer tube; coat the shaft with Shell Nautilus NLG12, Castrol Boating Grease, Valvoline Val Plex EP or equivalent.
3. Bed the deckplate (chainpipe and pawl fitted) with sealing compound; studs, washers and nuts tightened evenly to 35-40 Nm (25-30 ft lb).
4. Offer up the drive from below without damaging the deck bearing; bolt deckplate and spacer tube with the M10 hex head screws SP3221 and spring washers to 35-40 Nm (25-30 ft lb).
5. Chain counter: sensor in the Ø15mm hole in the deckplate (plug SP0875); drill below for the cable.
6. Collar 4233, spring (printed 3210 here; 2310 in the parts list) and washer 7068; two retention clips 2311; key 3207 in the lower keyway.
7. Lower cone 6061 on the clips, cone face greased; disc spring 5953 smaller diameter towards the cone; chainwheel 3231; second disc spring bigger diameter towards the chainwheel; greased upper cone; drum 3230C (VW, VWC); clutch nut 3228C; washer 3267 and screw; cap 7191.

Anchor

• Keep clear of the windlass; never operate from a remote station without a clear view; never run under power with the clutch handle in the clutch nut or emergency crank collar. Do not reverse before the windlass stops. Isolate the power when not in use. Never proceed at speed without the chain stopper and tensioner engaged.
• Lowering under power: engage the friction clutch firmly clockwise (it engages in any position), remove the handle, release the pawl, chain stopper and tensioner (jog up to free the stopper pawl), then use pendant, helm switch or footswitch. The windlass runs only while the control is held; turn off the controls isolator when finished.
• Retrieving: clutch engaged, pawl released, stopper/tensioner off; motor over the anchor position to reduce chain tension; jog in the last meter (3-4') carefully; re-engage stopper and tensioner.
• Manual lowering (quick drop, “quiet ship”, power loss): tighten the clutch, release stopper/tensioner (pull the chain in slightly if the stopper pawl is loaded), then slowly ease the clutch nut anticlockwise; tighten to slow. Never let the chain free fall unrestricted.
• Emergency crank: stopper or pawl engaged, release the clutch anticlockwise, engage the lever in the emergency crank collar with a chainwheel dog at the furthest forward position, pull back, engage the pawl, repeat. Very slow – emergencies only.

Warping Drum

1. VW and VWC only. Engage the chain stopper and/or the pawl and fully disengage the clutch; the drum now turns independently of the chainwheel.
2. Control warping with the footswitch for one-person operation.
3. Several turns on the drum in the direction of rotation; pull the tail for grip while operating the footswitch. No more turns than needed; allow the line to slip under sudden wind or tide loads.
4. Stay clear of lines and capstan; avoid riding turns (they can only be cleared by paying out).

Schedule

Lubricants & Spares

• Grease: lithium complex, NLGI No.1 to No.3 – no soap based grease. Never mix greases or oils.
• Gearbox oil: API GL-4 or lower (low sulphur) single weight gear oil between SAE 90 and 110w; quantity for DC and hydraulic drives printed as 0.35 litres (the 3-year service text says approximately 300ml).
• Anti-corrosive: CRC 3013 Soft Seal, Boeshield T9, Lanocote; anti-seize: International Paints Res-Q-Steel.
• Carry on board: SP2790 O-ring for cap, two 5953 disc springs, two 2311 retention clips, two 3207 topworks keys, 3150 gearbox key, 7068 washer, 2310 spring, two SP0846 circlips, SP2787 motor O-ring.
• Tools: metric hexagon keys, 13, 17, and 19mm spanners, flat screwdriver 10mm blade, circlip pliers.