Maxwell RC12HD Vertical Windlass Owner's Manual (PDF)

OWNER'S MANUAL

Specifications for every drive (DC 24V/48V, 3-phase AC and four hydraulic options), installation, wiring and cable sizing, operation, maintenance, troubleshooting and the full spare parts lists for the Maxwell RC12HD vertical rope/chain windlass (manual P103151-375 Rev.10.00).

DocumentMaxwell RC12HD Vertical Windlass Owner's Manual

FormatPDF · 34 pages · 4.3 MB

LanguageEnglish

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Specifications Installation Cable Sizes Operation Maintenance Troubleshooting Parts Products

Maxwell RC12HD Vertical Windlass — Owner's Manual

Specifications

Model	Chain size	Rope size
RC12HD-13	13mm DIN766 short link	20 mm (7/8") to 22mm (3/4") (as printed)
RC12HD-12	12mm (1/2") short link	20 mm (7/8") to 22mm (3/4") (as printed)
RC12HD-11	11mm (3/8" G30/G43) short link	16 mm (5/8") to 20mm (7/8")
RC12HD-10	10mm (3/8" BBB) short link	16 mm (5/8") to 20mm (7/8")

Static hold 2200 kg (4840 lbs). Available clockwise or anticlockwise, with or without capstan, 100mm (standard) or 200mm deck clearance, DC electric, AC electric or hydraulic.

	DC 24V / 48V	AC 3 phase	Hyd. type 2 (138 bar)	Hyd. GT type 1 (120 bar)	Hyd. GT type 1 HP (205 bar)	Hyd. GT type 1 high flow (85 bar)
Maximum pull	1820 kg (4000 lbs)	1820 kg (4000 lbs)	1250 kg (2750 lbs)	1820 kg (4000 lbs)	1820 kg (4000 lbs)	1820 kg (4000 lbs)
Continuous pull	300 kg (660 lbs)	620 kg (1360 lbs)	1250 kg (2750 lbs)	1250kg (2640 lbs) (as printed)	1250kg (2640 lbs) (as printed)	1250kg (2640 lbs) (as printed)
Line speed at continuous pull	12 m/min (39 ft/min)	12 m/min (39 ft/min) 50Hz; 14m/min (46 ft/min) 60Hz	15 m/min (49 ft/min)	15 m/min (49 ft/min)	15 m/min (49 ft/min)	14.2 m/min (46.6 ft/min)
Working load limit (10min run time)	610 kg (1335 lbs)	750 kg (1650 lbs)	1250 kg (2750 lbs)	1500 kg (3300 lbs)	1500 kg (3300 lbs)	1500 kg (3300 lbs)
Maximum line speed	22 m/min (72 ft/min)	12 m/min (39 ft/min) 50Hz; 14m/min (46 ft/min) 60Hz	22 m/min (72 ft/min)	15 m/min (49 ft/min)	15 m/min (49 ft/min)	14.2 m/min (46.6 ft/min)
Motor / oil flow	2000W (2.7 HP) 24V; 2300W (3HP) 48V	2200W (3 HP)	Rec. 32 l/min (8.5 US gal/min), max 47 l/min (12.5 US gal/min)	Rec. 47 l/min (12.4 US gal/min), max 49 l/min (12.5 US gal/min)	Rec. 28.5 l/min (7.6 US gal/min), max 29.7 l/min (7.85 US gal/min)	64 l/min (16.9 US gal/min)
Max oil pressure / ports	–	–	138 bar (2000 PSI); 7/8" (SAE 10)	120 bar (1750 PSI); ½" BSPP, drain ¼" BSPP	205 bar (3000 PSI); ½" BSPP, drain ¼" BSPP	85 bar (1250 PSI); 1 1/16" -12 UN (Dash -12), drain 9/16" UN (Dash -6)
Net weight LP / capstan	37 kg (81 lbs) / 40 kg (88 lbs)	51 kg (112 lbs) / 54 kg (118 lbs)	28.5 kg (63lbs) / 31.5 kg (69lbs)	31 kg (68 lbs) / 34 kg (75 lbs)	31 kg (68 lbs) / 34 kg (75 lbs)	31 kg (68 lbs) / 34 kg (75 lbs)

Minimum pull capacity must be three times the combined weight of anchor and rope/chain. Supplied with clutch handle, emergency retrieval handle, reversing solenoid (DC only), deckplate gasket, deck cutout details and nuts, flat and spring washers (x 5).

Position & Mounting

At least 200mm (8") unobstructed fall into the locker from the lowest part of the windlass; rode must not foul the motor. "UP" is clockwise looking down.
Clear run from the bow roller (central groove for the chain size) without deflection; deckplate pointing at the incoming rode, chain leading in parallel to the deckplate base (plinth or angled mounting if needed). Minimum 150mm (6") between bow roller and windlass.
Flat deck and a strong under-deck pad (not supplied). Use the Deck Cutout Details (not to scale – confirm the dimensions before cutting); seal hole edges on GRP or wood with epoxy. Insulate fully on aluminium.
Bolt the deckplate down progressively and evenly by hand – no power tools; offer up the drive from below, bolt deckplate to spacer tube with the M10 screws at 35-40 Nm (25-30 ft lb).
Chain counter sensor goes in the Ø15mm hole in the deckplate.
Topworks: two retaining clips, anti-seize on shaft and keyway, key, lower clutch cone (marine grease on the taper), Belleville washer, chainwheel, Belleville washer, key, upper cone, key and drum (capstan models), clutch nut, retaining washer and screw, cap.

Electrical

Install to USCG, ABYC, NMMA or local rules; seal terminals with CRC2043, CRC3013 or CRC2049.
Solenoid pack dry and close to the windlass, not in the locker.
Circuit breaker/isolator required: RC12-HD 24V 135 Amp, 48V 85 Amp; within 1.8 m (6 ft) of the battery.
Footswitch approximately 500 mm (20") from the windlass; remote panel where the operator can see the windlass.
Hold the lower motor terminal nut while tightening the upper nut.
AC: waterproof gland for armoured cable, earth connection, thermistor leads to the auxiliary terminals; direct-on-line starter or VFD (star-delta and soft starters not recommended); up/down contactors interlocked.
Hydraulic: pressure and return ports to a solenoid valve (not supplied); case drain port.

Maximum Cable Length for 10% Voltage Drop (Table 2.1)

Wire size	24V	48V
10 mm²	*2	41m (136ft) *1
16 mm²	*2	66m (218ft)
25 mm²	25m (85ft) *1	103m (340ft)
35 mm²	36m (119ft)	145m (477ft)
50 mm²	51m (170ft)	207m (681ft)
AWG 8	*2	*2
AWG 6	*2	55m (181ft)
AWG 4	21m (71ft) *1	87m (286ft)
AWG 2	35m (115ft)	141m (463ft)
AWG 0	56m (184ft)	224m (736ft)

Total length battery → windlass → battery, copper with 90°C insulation, based on Maxwell 2300W motors with 135amp (24v) and 80amp (48v) breakers. *1: go one size up through an engine compartment (ABYC ampacity). *2: does not meet ABYC minimum ampacity for the breaker rating.

Under Power

Tighten the clutch with the handle only enough to pull the anchor up easily, then remove the handle. Over-tightening can damage the motor when docking the anchor.
Toggle down (or "Down" footswitch) to pay out; watch for jams; tie off to a chainstopper, snubber or cleat.
Toggle up to retrieve while motoring up to the anchor; bring in the last meter (3') slowly with some clutch slip. Never secure the anchor in the roller with the windlass.
Free fall: loosen the clutch anticlockwise standing clear; tighten clockwise to control descent.

Manual & Capstan

Manual retrieval: tie off the rode, release the clutch, remove cap, washer, screw and clutch nut (and capstan and key), fit the emergency handle and tighten it with the clutch handle, pawl engaged with the upper chainwheel; lever the line in.
Capstan: secure the anchor, turn the clutch nut anticlockwise until it stops so the chainwheel stays put, up to three turns clockwise on the drum, tail and use the UP footswitch.

Maintenance

Interval	Work
Every trip	Check clutch adjustment; wash topworks and rope; flush the gearbox drainage slot with fresh water.
Every 3 months	Remove chainwheel, strip and grease the clutch; split gearbox from spacer tube, clean and re-grease the faces; clean with kerosene, spray CRC3097 Long Life (or CRC6-66 / WD40) above and below deck; check fasteners.
Every year	Motor serviced by a qualified technician; remove rust and repaint the casing.
Every 3 years	Inspect gearbox seals – lubricated for life, no oil change required.

Grease: lithium complex base NLG1 consistency No. 2. Gearbox oil ISO 3448 VG 320, approximately 560mls; synthetic only, never mix oils or greases.
Anti-corrosion: CRC 3013 Soft Seal, Boeshield T9, Lanocote, International Paints Res-Q-Steel. Don't wrap the motor in grease cloth (cooling).
Pressure arm: 5mm hex key on the chaincover capscrew (spring may jump out), grease the spring, seat the lower spring pin in the arm groove and align with the capscrew hole.
Tools: hex keys 5, 6 and 8mm; 13mm and 17mm spanners; 10mm flat screwdriver; external circlip pliers.

Troubleshooting

Problem	Possible cause / solution
Windlass does not rotate	Controls isolator ON, fuse, wiring, each control in turn, VFD isolator and fuse (if fitted), main supply. AC: thermistor resistance should be between 50 and 500 ohms (measure without voltage).
Cannot pull the specified load	Motor voltage not matching the supply (check name plate); hydraulic relief valve setting.
High current, struggles to pull	Motor mounting bolts touching the winding – spring washers, adjust bolt length.
Stops after prolonged heavy use	Motor at maximum temperature – let it cool, reset the breaker.
Runs, chainwheel stationary	Clutch not fully engaged; topworks key(s) missing.
Anchor does not free fall	Cones not greased, clutch not fully released, disc springs missing, pawl engaged.
Chain jumps / slips	Wrong chainwheel, twisted chain, or vertical angle of incoming chain more than 2 degrees.

Spare Parts (Appendix B)

Recommended spares on board

Part No.	Description
P104750	Retaining cap & O-ring	View part →
2311	Retaining clip (2)	View part →
7465	Key (2)	Ask us to source it →
3150	Drum key (capstan version only)	Ask us to source it →
4635	Gearbox key	Ask us to source it →
SP2799	Deck seal	Ask us to source it →
SP0879	Mainshaft circlip	View part →

Maxwell RC12HD topworks exploded view

Part No.	Description	Item
7191	Cap	1	Ask us to source it →
SP2790	O-ring	2	View part →
SP0095	Screw CSK M8 × 24	3	Ask us to source it →
3267	Retaining washer	4	View part →
7440	Clutch nut	5	Ask us to source it →
7441	Clutch nut capstan	5	Ask us to source it →
7527	Washer – capstan only	6	View part →
7443	Capstan	7	Ask us to source it →
7439	Clutch cone	8	View part →
5015	Bellville washer	9	View part →
SP0178	Cap screw M5 × 16	10	Ask us to source it →
SP5167	Magnet	11	Ask us to source it →
7444	Stripper	13	Ask us to source it →
7544	Bush	14	Ask us to source it →
SP4509	Cap screw M6 × 70	15	Ask us to source it →
SP0474	Spring washer	16	Ask us to source it →
2311	Retaining clip	17	View part →
SP2799	Seal	18	Ask us to source it →
SP0657	Bearing	19	Ask us to source it →
7037	Spring CW	20	Ask us to source it →
7436	Spring ACW	20	Ask us to source it →
7435	Pressure arm	21	View part →
SP3519	Plug	22	Ask us to source it →
SP3518	Bush	23	Ask us to source it →
SP3221	Screw M10 × 35	24	View part →
SP0466	Spring washer	25	Ask us to source it →
7458	Spring	26	Ask us to source it →
7456	Pawl	27	Ask us to source it →
SP0413	Washer	28	Ask us to source it →
SP0158	Cap screw M8 × 25	29	Ask us to source it →
3150	Key – capstan	30	Ask us to source it →
7465	Key	31	Ask us to source it →
7457	Pawl	32	Ask us to source it →
7480	Bush	33	Ask us to source it →
SP2785	O-ring	34	Ask us to source it →
SP0170	Cap screw M6 × 16	35	Ask us to source it →
5225	Stud – 90TDC (4)	36	Ask us to source it →
7652	Stud – 90TDC (1)	36	Ask us to source it →
7482	Stud – 190TDC (4)	36	View part →
4710	Stud – 190TDC (1)	36	Ask us to source it →
SP0473	Washer flat	37	Ask us to source it →
SP0466	Washer spring	38	Ask us to source it →
SP0371	Nut – M10	39	Ask us to source it →
7430	Deckplate CW	40	Ask us to source it →
7431	Deckplate ACW	40	Ask us to source it →
7515	Gasket	41	Ask us to source it →
P103865	Bi-square handle 10"	42	View part →
P103319	Emergency handle – LP CW	43	View part →
P103323	Emergency handle – LP ACW	43	Ask us to source it →
P103320	Emergency handle – capstan CW	44	View part →
P103324	Emergency handle – capstan ACW	44	Ask us to source it →

Chainwheel assemblies (item 12)

Part No.	Description
P103317	10mm – 3/8" chainwheel CW (upper 7448 / lower 7447)	Ask us to source it →
P103325	11mm – 3/8" chainwheel CW (upper 7757 / lower 7756)	View part →
P103318	12mm/13mm – 1/2" chainwheel CW (upper 7452 / lower 7451)	View part →
P103328	13mm DIN 766 chainwheel CW (upper 8664 / lower 8663)	Ask us to source it →
P103321	10mm – 3/8" chainwheel ACW (upper 7447 / lower 7448)	Ask us to source it →
P103326	11mm – 3/8" chainwheel ACW (upper 7756 / lower 7757)	View part →
P103322	12mm/13mm – 1/2" chainwheel ACW (upper 7451 / lower 7452)	Ask us to source it →
P103329	13mm DIN 766 chainwheel ACW (upper 8663 / lower 8664)	Ask us to source it →

Maxwell RC12HD bottomworks exploded view

Part No.	Description	Item
7951	Shaft RC12HD – LP – 100TDC	50	Ask us to source it →
7952	Shaft RC12HD – capstan – 100TDC	50	View part →
7953	Shaft RC12HD – LP – 200TDC	50	Ask us to source it →
7954	Shaft RC12HD – capstan – 200TDC	50	Ask us to source it →
5497	Spacer tube RC12HD 100TDC	51	Ask us to source it →
7955	Spacer tube RC12HD 200TDC	51	Ask us to source it →
SP0171	Screw soc hd cap M8 × 30	52	View part →
SP0428	Washer flat M8	53	Ask us to source it →
SP5029	Gearbox W75U P80 100:1 B14	54	Ask us to source it →
SP5026	Flange input Bonfiglioli DC motor / hyd motor type 2	55	Ask us to source it →
SP5067	Flange input Bonfiglioli AC motor	55	Ask us to source it →
8426	Flange input Bonfiglioli hyd motor type 1	55	Ask us to source it →
SP0172	Cap screw M6 × 20	56	Ask us to source it →
7942	Motor adaptor – DC electric	57	Ask us to source it →
7957	Motor adaptor – hydraulic type 2	57	Ask us to source it →
8911	Bush	58	Ask us to source it →
SP5027	Motor – DC electric 24V	59	View part →
SP5160	Motor – DC electric 48V	59	Ask us to source it →
SP5068	Motor – AC electric 2.2kW 3ph 50Hz	59	Ask us to source it →
SP5719	Motor – AC electric 2.2kW 3ph 60Hz	59	Ask us to source it →
SP2273	Motor – hydraulic type 1 gearmotor (120bar)	59	Ask us to source it →
SP2274	Motor – hydraulic type 1 gearmotor (205bar)	59	Ask us to source it →
SP2271	Motor – hydraulic type 1 gearmotor (85bar)	59	Ask us to source it →
SP0996	Motor – hydraulic type 2 gerotor	59	Ask us to source it →
4577	Key – DC electric	60	Ask us to source it →
7974	Key – hydraulic type 2	60	Ask us to source it →
SP0175	Cap screw M6 × 25	61	Ask us to source it →
SP5044	Input bush splined W75 – DC motor	62	Ask us to source it →
SP5069	Input bush splined W75 – AC motor	62	Ask us to source it →
8619	Input bush splined W75 – hyd motor	62	Ask us to source it →
8620	Input bush splined W75 – hyd motor type 2	62	Ask us to source it →
SP0879	Circlip	63	View part →
4635	Key 8 × 7 × 124	64	Ask us to source it →
7361	Label serial number	65	Ask us to source it →
SP0523	Screw hammer	66	Ask us to source it →
SP2459	Cap screw M6 × 30	67	Ask us to source it →
SP3519	Plug plastic	68	Ask us to source it →
SP0254	Hex hd bolt M8 × 20 – hydraulic type 2	69	Ask us to source it →
SP0171	Cap screw M8 × 30 – hydraulic type 1	69	View part →
SP0280	Hex hd bolt M10 × 40 – AC electric	69	Ask us to source it →
SP5402	Flat washer – hydraulic type 2 only	70	Ask us to source it →
SP0434	Flat washer – AC electric	70	Ask us to source it →
SP0467	Washer spring M8	71	Ask us to source it →
SP0466	Washer spring M10 – AC electric	71	Ask us to source it →
SP0371	Nut hex – AC electric	72	Ask us to source it →