Maxwell BH8 Windlass — Owner's Manual

Location & Fitting

1. In the box: windlass, solenoid, clutch handle (Allen key), deck cut-out details (rear of manual), motor bolt kit, small parts, circuit breaker/isolator panel, up/down rocker switch.
2. Plan the location: rode must feed correctly, flat mounting surface (fit a plinth if not), avoid bulkheads, wiring and piping, strong enough mounting area. Allow at least 200mm (8") unobstructed fall into the locker from the lowest part of the windlass.
3. The motor position is adjustable in 30° increments, but keep it out of the zone shown in the manual so the input gear stays at least partially submerged in oil. Leave clearance around the winch before drilling.
4. Choose the configuration: standard for a clear run from roller to windlass, or flipped bracket for chain runs through a bulkhead or stern. To flip the bracket remove circlip (item 31), the shaft/chainwheel/clutch assembly, bolts (item 22) and bolt (item 20).
5. Use the deck cut-out template (part no. 9925, at the back of the manual): check the scale before printing and drill only one pattern, standard or flipped bracket. Align the gypsy with the bow roller.
6. Seal hole edges with epoxy (not for steel or aluminium). Fasten with the nuts and washers supplied, progressively and evenly, no power tools. Insulate dissimilar metals and stainless fasteners from the deck.
7. Fit the main case into the mounting bracket, install the gearbox in the chosen motor orientation with the hawse pipe aligned to the locker, and torque the mounting-bracket M10 bolt to 28 N·m.
8. If you use a sealant, avoid permanent adhesive: use a non-acid cure flexible sealant.

Electrical

• Wiring by qualified technicians to USCG, ABYC, NMMA, CE requirements. A circuit breaker/isolator is required; solenoid pack and up/down control switch recommended.
• Breaker/isolator no further than 1.8 m (6 ft) from the battery, accessible and dry. Solenoid pack in a dry area close to the windlass, not in the chain locker.
• Control circuit: 5 Amp manually resettable breaker or 5 Amp slow blow fuse, minimum 1.5mm (No.16 AWG) conductor.
• Footswitch approximately 500 mm (20") from the windlass, arrow showing the direction; up/down switch where the operator can see the windlass.
• Hold the lower motor nut (A1) while tightening the upper nut (B1). Swapping F1 and F2, or connections 1 and 3 on the solenoid box, reverses rotation: check rotation before fitting chain or rope.
• BH8-6 and BH8-7 use a permanent magnet motor; BH8-8 a series wound motor (wiring schematics in section 7.3).

Cable length is the total run battery → windlass → battery; sizes keep voltage drop under 10% (copper, 90° C insulation).

Anchoring

• Lowering: press down on the up/down switch (or the Down footswitch), watch the rode pay out, and tie off on a chain stopper, snubber or cleat to protect the windlass from shock loads.
• Raising: press up; motor up to the anchor rather than pulling the boat with the windlass, and bring in the last meter (3') slowly. Use a tensioner or snubber, not the windlass, to hold the anchor in the roller.
• Manual release: insert the clutch handle in the clutch nut and turn it clockwise to loosen; turning anticlockwise controls the descent. Retighten when the rode is out and remove the handle. Never let the chainwheel free-wheel uncontrolled.
• Never reverse direction before the windlass stops; run the engine to keep the charging system on; never use the windlass as a mooring point or to break out a fouled anchor.

Automatic Free Fall

• With Automatic Free Fall engaged the windlass free-falls when lowering and re-engages the clutch automatically when raising. It can be left in this mode.
• Engage or disengage only with the clutch fully engaged. To engage: slide the lever down, turn it right and lift up. To disengage: slide it down and push left to secure.
• To lower, pulse the Down button until the anchor falls freely. With enough rode out, press and hold Up until the rode starts to retrieve to re-engage the clutch.
• Never hold Up to stop rode running out at high speed: shock loading causes damage. Very high pay-out speeds can tangle the rode in the locker.
• Always use a Maxwell reversing solenoid in free fall mode: other solenoids may damage the windlass through motor overrun.

Schedule

• Gearbox oil: 70 – 80 ml (2.4 – 2.7 fl oz), API GL-4 or lower (low sulphur), 90 to 110 weight.
• Main shaft, bearing and clutch surfaces: lithium complex grease, NLGI No.1 to No.3.
• Seat the keys properly in the shaft on reassembly; never wrap the motor in grease cloth (it stops the motor cooling).

Troubleshooting

• Does not operate: breaker/isolator on; connections at switches, breaker, solenoid and motor; battery condition; solenoid clicks when activated.
• Motor runs, chainwheel does not turn: clutch nut too loose; chainwheel jammed (reverse to free); shaft-gearbox key missing; rough running or noise means gearbox damage; check the motor drive pin.
• Rope does not retrieve or pay out: wrong rope size/type; fouled rope or anchor; twists or knots in the chain pipe; worn or stiff rope (wash with fresh water and fabric softener); too much rope in the locker; worn splice; rough deck hole; twisting chain (fit a swivel).
• Runs slowly: power cable too small, low battery voltage, deckplate bearing, worn motor brushes, loose or dirty connections, low gearbox oil.