Maxwell HWVC 3500 Horizontal Windlass Owner's Manual (PDF)

OWNER'S MANUAL

Specifications, installation, wiring, operation, maintenance, troubleshooting and the full spare parts lists for the Maxwell HWVC 3500 horizontal windlass with vertical capstan, electric (12V/24V) or hydraulic (manual P103140 Rev.8.00).

DocumentMaxwell HWVC 3500 Horizontal Windlass Owner's Manual

FormatPDF · 43 pages · 4.1 MB

LanguageEnglish

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Specifications Installation Cable Sizes Operation Maintenance Troubleshooting Parts Products

Maxwell HWVC 3500 Horizontal Windlass — Owner's Manual

Specifications

	Electric DC 12V	Electric DC 24V	Hydraulic
Line speed at normal working load	8.7m/min (29ft/min)	11m/min (36ft/min)	12m/min (39ft/min)
Maximum pull capacity	1590kg (3500lb)	1590kg (3500lb)	1590kg (3500lb) continuous
Current at normal working load	110-160A	66-88A	–
Current at stall	450A	240A	–
Motor power	1.2kW (1.6HP)	1.2kW (1.6HP)	–
Hydraulic oil flow	–	–	Recommended 40l/min (11USgal/min); max 48l/min (13USgal/min)
Max hydraulic pressure / ports	–	–	138bar (2000psi); 7/8"-14UNF pressure and return
Weight – double chainwheel	94.5kg (207.9lb)	94.5kg (207.9lb)	79.9kg (175.8lb)

Topworks: port drum / starboard chainwheel / vertical drum; double drum / double chainwheel / vertical drum; or double chainwheel / vertical drum.
Chainwheel numbers have a main part number and a suffix for chain size and type (e.g. 3182-001): your Maxwell dealer selects the right one for your chain.
Hydraulic oil: viscosity ISO 32 - 68 (at 20°C).

Rated capacity and chain speed are based on the chainwheel for 10mm chain; performance may vary by up to ±10% with other chainwheels.

Position & Deck

Straight chain run from bow roller to chainwheel, no more than 2° from horizontal; bow roller with a vertical groove to suit the chain.
Chain stopper aligned with the chain; if the hawse pipe is angled outboard, angle the stopper by half the hawse pipe angle (vertical is fine below 4 (as printed) degrees).
Minimum 600mm (23") between underside of deck and the piled chain; the chain must gravity feed into the locker.
Footswitches at least 700mm (28") from the windlass; motor starter (or hydraulic solenoid valves) dry and close by, never in the chain locker.
Bolt down with four 12mm (½") 316 stainless bolts with large washers or clamp plates under deck; on steel or aluminium decks insulate windlass, fixings, chainpipe, anchor and chain from the hull.
Bed on sealant with the four insulating bushes in place; tighten nuts progressively and evenly by hand – no power tools. Align stripper arms squarely in the chainwheel groove.

Power & Controls

Two-cable, ungrounded, fully insulated negative return system; DC motor terminals F1, "–" and F2 ("–" to battery negative, F1/F2 to the solenoids).
Hold the lower nut while tightening the upper nut on the motor terminals to avoid damaging the motor.
Hydraulic: pressure and return ports to a solenoid controlled valve (not supplied by Maxwell).
Controls: footswitches, single or dual speed pendant, helm switch, chain counter, wired in parallel. Footswitches need an isolator in the wheelhouse.
Control wiring no smaller than 1.5mm² (AWG 16) with a 3A manually re-settable ignition-proof breaker within 1m (40") of the main breaker/isolator.
Spray terminals and fittings with CRC 3013 Soft Seal; builder: CRC 3097 Long Life and plastic wrap for delivery.

Recommended Wire Sizes (Table 2.1)

12v systems (135amp breaker)

Total length battery → winch → battery	Cable size	Engine room correction
Up to 10m (33')	25 mm² / 4 AWG	35 mm² / 2 AWG
10m - 15m (33'-50')	35 mm² / 2 AWG	–
15m – 20m (50' – 65')	50 mm² / 1 AWG	–
20m – 25m (65' – 82')	50 mm² / 0 AWG	–
25m – 35m (82' – 115')	70 mm² / 2/0 AWG	–
35m – 45m (115' – 150')	95 mm² / 3/0 AWG	–

24v systems (80amp breaker)

Total length battery → winch → battery	Cable size	Engine room correction
Up to 10m (33')	10 mm² / 6 AWG	6 mm² / 5 AWG (as printed)
10m - 15m (33'-50')	16 mm² / 4 AWG	42 mm² / 1 AWG (as printed)
15m – 20m (50' – 65')	25 mm² / 4 AWG	–
20m – 25m (65' – 82')	35 mm² / 3 AWG	–

Lengths are the full loop from battery terminal to motor via the solenoid box and back. Sizes allow a maximum 10% voltage drop and assume insulation rated at least 90°C.

Under Power

Engage the friction clutch with the clutch nut lever (clockwise, firmly) – it engages in any position. Remove the lever, release the pawl, stopper and tensioner.
The windlass runs only while the button, toggle or footswitch is held. Turn off the controls isolator when finished.
Motor up to the anchor; never pull the boat to the anchor or break out a fouled anchor with the windlass – use the engine with the stopper loaded.
Jog in the last metre (3-4') to seat the anchor; never reverse direction before the windlass stops. In deep water with heavy tackle, deploy manually to avoid over-speed.

Manual & Capstans

Manual lowering: tighten clutch, release stopper/tensioner, then ease the clutch nut anticlockwise; tighten to slow, ease to speed up. Never let the chain free fall unrestricted.
Emergency retrieval: stopper (or pawl) engaged, clutch released, pawl end of the lever in the emergency crank collar – ratchet the chainwheel in, a very slow emergency-only process.
Horizontal drum: engage stopper and/or pawl, release the clutch, then work the drum from the footswitch. The vertical drum runs independently.
Use only the turns needed, let the line slip under sudden load, and clear riding turns by paying out.

Maintenance & Lubricants

Interval	Work
Every trip	Check clutch engaged; wash external parts with fresh water.
Every three months	Strip external components (Section 5.1), clean, check, grease with lithium complex waterproof grease – especially both clutch cone tapers and gypsy faces. Clean chrome with a kerosene-damp cloth then CRC 3037 Long Life (as printed), CRC 6-66 or WD-40. Touch up and spray below-deck parts with CRC 3013 Soft Seal.
Every year	Remove gearbox/spacer tube and motor, flush drainage slots, service the DC motor. Brush sets: P100807 (12V), P100808 (24V).
Every 3 years	Clean spacer tube and gearbox top and apply Res-Q-Steel; drain oil, replace seals, refill completely – approximately 800ml (27 fl oz).

Grease: lithium complex, NLGI No.1 to No.3 – no soap based grease; never mix greases.
Gearbox oil: API GL-4 or lower (low sulphur) single weight gear oil SAE 90 to 110w; horizontal 800ml, vertical (capstan) 930ml. Never mix oils.
Anti-corrosion: CRC 3013 Soft Seal, Boeshield T9, Lanocote, International Paints Res-Q-Steel.
Assembly: anti-seize on threads, keys, keyways, main shaft and inside the spacer tube; shaft, bronze clutch cones and capstan coated in marine grease (Shell Nautilus NLG12, Castrol Boating Grease, Valvoline Val Plex EP). Disc springs: smaller diameter towards the lower cone, bigger diameter towards the chainwheel.
Tools: metric hex keys, 13, 17, 19mm and 9/16" spanners, 10mm flat screwdriver, circlip pliers.

Gearbox drawing notes: items 2 and 22 (P100979) or 2 and 25 (P12068) tightened to 40 to 60 in-lb with Loctite 222; fill P100979 with 800mls and P12068 with 950mls (as printed on the drawing; the text gives 930ml for the vertical gearbox) of SP320 oil.

Troubleshooting

Problem	Possible cause	Solution
Windlass does not move	No power to controls / incorrect wiring / no power to windlass	Controls isolator ON, check fuse and wiring, test each control, trace the supply; check main isolator and hydraulic pump.
Cannot pull the specified load	Motor voltage does not match supply; hydraulic relief valve set wrong	Check motor name plate; check valve setting.
DC motor draws high current but struggles	Motor mounting bolts touching the winding	Fit spring washers, adjust bolt length.
Runs but chainwheel stays stationary	Clutch not tight; keys (35) missing	Tighten clutch (Section 3.2); install the key.
Motor stops after prolonged heavy use	Overloaded, critical temperature reached	Let it cool and reset the breaker.
Anchor does not free fall	Cones not greased; clutch not fully off; disc springs (9) missing; pawl (20) engaged	Clean and grease cones, release clutch fully, fit disc springs, disengage pawl.
Chain jumps / slips on chainwheel	Wrong chainwheel; twisted chain; chain angle over 2 degrees	Identify the chain to Maxwell; untwist; check the installation.

Spare Parts (Appendix B)

Recommended spares on board

Part No.	Description
SP2790	O-ring for cap	View part →
5953	Disc spring (2)	View part →
2311	Retention clip (2)	View part →
3207	Key – topworks (2)	View part →
3150	Key – gearbox	Ask us to source it →
7068	Washer	Ask us to source it →
2310	Spring	View part →
SP0846	Circlip (2)	View part →
SP2787	O-ring – elect motor	Ask us to source it →

Maxwell HWVC 3500 starboard side exploded view

Maxwell HWVC 3500 port side exploded view

Maxwell HWVC 3500 vertical capstan arrangement exploded view

Part No.	Description	Item
7191 / 4809	Cap SS – with clutch nut / with 8303 capstan	1	Ask us to source it →
SP2790	O-ring – with 7191 cap	2	View part →
SP2769	O-ring – with 4809 cap	2	Ask us to source it →
SP0040	Screw CSK 3/8" × 1"	3	View part →
3267	Retaining washer	4	View part →
5675	Clutch nut – chainwheel only (no capstan)	5	Ask us to source it →
8648	Clutch nut – chainwheel with capstan	5	Ask us to source it →
8303	Capstan – horizontal (no chainwheel)	6	View part →
8646	Capstan – horizontal, with chainwheel	6	Ask us to source it →
8647	Spacer 38.5ID × 60OD × 9 (capstan with chainwheel)	7	Ask us to source it →
6061	Clutch cone 2500–4000	8	View part →
5953	Disc spring – 4000 clutch	9	View part →
3182	Chainwheel 3500 series (suffix to suit chain)	10	Ask us to source it →
2311	Retaining clip	11	View part →
7068	Washer 5 × Ø39 × Ø48.5	12	Ask us to source it →
2310	Spring – 2200/3500	13	View part →
3158	Emergency crank collar 3500	14	View part →
SP0657	Bearing composite 1.5" × 1.75" × 44.5	15	Ask us to source it →
SP0544	Pin tension 8 × 24	16	Ask us to source it →
SP0875	Plug – head 15.8 dia finned	17	View part →
7661	Pawl pin 2200 3500	18	Ask us to source it →
3504	Spacer	19	Ask us to source it →
2446	Pawl – chainwheel – 2200/3500	20	Ask us to source it →
SP0871	Spiral retaining washer	21	View part →
3295	Case – HWVC 3500	22	Ask us to source it →
SP3216	Bolt hex hd M8	23	Ask us to source it →
3373	Stripper arm HWC3500	24	Ask us to source it →
2414C	Chain pipe	25	Ask us to source it →
SP0366	Nut hex hd M8	26	Ask us to source it →
SP0622	Bush	27	Ask us to source it →
SP0529	Pop rivet truss head	28	Ask us to source it →
3041	Label MAXWELL 125 × 38 serial number	29	Ask us to source it →
SP0223	Bolt hex hd	30	Ask us to source it →
SP0457	3/8" spring washer	31	Ask us to source it →
SP0414	Washer flat 3/8 SS316	32	Ask us to source it →
3300	Main shaft – single chainwheel/single drum or double chainwheel	33	Ask us to source it →
5398	Main shaft – double chainwheel/double drum	33	Ask us to source it →
3150	Key 3/8 sq × 67mm	34	Ask us to source it →
3207	Key (topworks)	35	View part →
SP0846	Circlip ext 1.5"	36	View part →
P100979	Gearbox 3500 DC Hyd 90 degrees (horizontal)	37	Ask us to source it →
P12487	Motor bolt kit – DC motor	38	View part →
P12488	Motor bolt kit – hydraulic	38	View part →
P12072	Motor – 12V (horizontal and vertical drives)	39	Ask us to source it →
P12073	Motor – 24V (horizontal and vertical drives)	39	Ask us to source it →
P14368	Motor – hydraulic (horizontal and vertical drives)	39	View part →
SP3520	Plug for pawl hole when no chainwheel	40	Ask us to source it →
4809	Cap SS (vertical capstan)	41	Ask us to source it →
SP2769	O-ring	42	Ask us to source it →
8303	Capstan – vertical	43	View part →
8606	Shaft HWVC 3500 vertical capstan	44	Ask us to source it →
5198	Retaining washer	45	Ask us to source it →
SP0466	Washer spring M10 SS304	46	Ask us to source it →
SP0166	Cap screw M10 × 25 SS	47	Ask us to source it →
P20043	Ratchet lever HWC 3500	48	View part →
P12068	Gearbox 3500 HWVC DC Hyd (vertical)	49	Ask us to source it →

P100979 Gearbox (horizontal)

Maxwell P100979 gearbox exploded view

Part No.	Description	Item
P90005	Seal kit (items 1×2, 4×2, 5, 21, 28): 55 × 70 × 8 oil seal, 20 × 2 O-ring, sight glass, O-ring ID 90mm section 2mm, 25 × 47 × 7 oil seal	1, 4, 5, 21, 28	View part →
SP0172	M6 × 20 cap screw	2	Ask us to source it →
3135	Gearcase upper	3	Ask us to source it →
3168	Bush	6	Ask us to source it →
P14071	Gear pinion (3225 gear/pinion + SP0650 bush)	7	Ask us to source it →
3226	Final drive gear 2200 3500 series	8	Ask us to source it →
3141	Lay shaft	9	Ask us to source it →
SP0542	1-8 × 3-8 lg tension pin	10	Ask us to source it →
3146	Bush	11	Ask us to source it →
3134	Gearcase lower 2200 3500 series	12	Ask us to source it →
SP0644	40 × 47 × 20 needle roller bearing	13	Ask us to source it →
3170	Thrust washer	14	Ask us to source it →
3288	Pinion	15	Ask us to source it →
3287	Key	16	View part →
3137	Wormwheel 29T 2000 3500 series	17	Ask us to source it →
P90007	Bearing kit (items 18×2, 24, 26): 1in ext circlip, 12 × 28 × 8 and 25 × 12 × 47 ball bearings	18, 24, 26	View part →
3145	Bush	19	Ask us to source it →
3263	Plug	20	View part →
SP0159	M6 × 40 cap screw	22	Ask us to source it →
3136	Worm box 2200 3500 series	23	Ask us to source it →
3140	Worm	25	Ask us to source it →
SP0844	47 × 1.85 int circlip	27	Ask us to source it →

P12068 Gearbox (vertical capstan)

Maxwell P12068 gearbox exploded view

Part No.	Description	Item
SP0722	55 × 70 × 8 oil seal	1	View part →
SP0172	M6 × 20 cap screw	2	Ask us to source it →
3135	Gearcase upper	3	Ask us to source it →
SP0720	20 × 2 O-ring	4	View part →
3223	Sight glass	5	View part →
3168	Bush	6	Ask us to source it →
P14071	Gear pinion (3225 gear/pinion + SP0650 bush)	7	Ask us to source it →
3226	Final drive gear 2200 3500 series	8	Ask us to source it →
3141	Lay shaft	9	Ask us to source it →
SP0542	1-8 × 3-8 lg tension pin	10	Ask us to source it →
3146	Bush	11	Ask us to source it →
3134	Gearcase lower 2200 3500 series	12	Ask us to source it →
SP0726	O-ring ID 90mm section dia 2mm	13	Ask us to source it →
3327	Pinion	14	Ask us to source it →
SP0644	Bearing	15	Ask us to source it →
3170	Thrust washer	16	Ask us to source it →
3287	Key	17	View part →
3326	Spacer tube	18	Ask us to source it →
SP0474	Spring washer – M6	19	Ask us to source it →
SP0175	Cap screw – M6 × 25	20	Ask us to source it →
3137	Wormwheel 29T 2000 3500 series	21	Ask us to source it →
SP0838	1in ext circlip	22	View part →
3145	Bush	23	Ask us to source it →
3263	Plug	24	View part →
SP0159	M6 × 40 cap screw	25	Ask us to source it →
3136	Worm box 2200 3500 series	26	Ask us to source it →
SP0643	12 × 28 × 8 ball bearing	27	Ask us to source it →
3140	Worm	28	Ask us to source it →
SP0642	25 × 12 × 47 ball bearing	29	Ask us to source it →
SP0844	47 × 1.85 int circlip	30	Ask us to source it →
SP0721	25 × 47 × 7 oil seal	31	View part →