Maxwell HWVC 3500 Horizontal Windlass — Owner's Manual
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
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 → |
| 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)
| 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)
| 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 → |
Quantities depend on the topworks arrangement (port, starboard or both sides). Quote the windlass serial number when ordering.
Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.
Products in this Manual
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Maxwell Windlass Replacement Disc Spring - 2200-4000 Series Clutch
MAX-5953
$81.95 USDUnit price /Unavailable -
