Quick Genius GP Series Horizontal Windlass (PDF)

INSTALLATION MANUAL

Model code, technical data, gypsy and rope/chain match, cable and breaker sizing, installation, clutch, drum and automatic free-fall operation, annual service, component lists and OSP spare kits for the Quick Genius GP2 500, 1200, 1500 and 2000 horizontal windlasses (rope and chain on a single gypsy).

DocumentQuick Genius GP Series Horizontal Windlass Installation & User's Manual

FormatPDF · 20 pages · 2.8 MB

LanguageEnglish

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Specifications Electrical Installation Operation Maintenance Spare Parts Components Products

Quick Genius GP Series Horizontal Windlass — Installation & User's Manual

Technical Data

Model code example GP2 1200 250 12 D: series name – model – power (W) – voltage (V) – D = drum, – = cover (no drum), F = free fall. The model number is not the motor power: GP2 500 = 150 W, GP2 1200 = 250 W, GP2 1500 = 500 W, GP2 2000 = 800 W.

	GP2 500	GP2 1200 (D / FF)	GP2 1500 (D / FF)	GP2 2000 (D / FF) 12 V	GP2 2000 (D / FF) 24 V
Motor power	150 W	250 W	500 W	800 W	800 W
Motor voltage	12 V	12 V	12 V	12 V	24 V
Maximum instantaneous pull	220 kg 485.0 lb	550 kg 1212.5 lb	680 kg 1499.0 lb	900 kg 1984 lb	900 kg 1984 lb
Maximum work load	70 kg 154.3 lb	170 kg 374.8 lb	250 kg 551.0 lb	350 kg 772.0 lb	350 kg 772.0 lb
Work load	35 kg 77.2 lb	50 kg 110.2 lb	85 kg 187.0 lb	120 kg 265.0 lb	120 kg 265.0 lb
Current at work load (1)	29 A	35 A	76 A	96 A	50 A
Maximum recovery speed (2)	38.9 m/min 83.7 ft/min (as printed)	31.2 m/min 102.4 ft/min	25.5 m/min 83.7 ft/min	29.6 m/min 97.1 ft/min	29.6 m/min 97.1 ft/min
Recovery speed at work load (2)	28.5 m/min 33.8 ft/min (as printed)	25.1 m/min 82.3 ft/min	10.3 m/min 33.8 ft/min	20.0 m/min 65.6 ft/min	20.1 m/min 65.9 ft/min
Minimum motor cable section (3)	4 mm² AWG 12	10 mm² AWG 7	10 mm² AWG 7	16 mm² AWG 5	10 mm² AWG 7
Circuit breaker (4)	40 A	40 A	50 A	80 A	40 A
Weight without drum	6 kg 13.2 lb	8 kg 17.6 lb	10.2 kg 22.4 lb	10.2 kg 22.4 lb	10.2 kg 22.4 lb
Weight with drum	–	9 kg 19.8 lb	11.5 kg 25.3 lb	11.5 kg 25.3 lb	11.5 kg 25.3 lb
Weight, Free Fall	–	10.9 kg 24.0 lb	10.9 kg 24.0 lb	10.9 kg 24.0 lb	10.9 kg 24.0 lb

Deck thickness 20 ÷ 40 mm (3/4" ÷ 1" 9/16) for all models. (1) After an initial period of use. (2) With a gypsy for 6 mm chain. (3) Minimum value for a total cable length L ≤ 20 m; size the cable for the actual run. (4) DC circuit breaker, delayed-action (thermal-magnetic or hydraulic-magnetic). Longer shafts and studs for thicker decks are available on request. The GP2 500 is built without drum or free fall. Two of the GP2 500 ft/min figures do not match their m/min values (as printed).

Gypsy	Chain size	Rope size
6 mm	6 mm DIN 766, 6 mm ISO	1/2" (12.7 mm)
7 mm – 1/4"	7 mm DIN 766, 7 mm ISO, 1/4" G4, 1/4" BBB	1/2" (12.7 mm)
8 mm	8 mm DIN 766, 8 mm ISO	1/2" (12.7 mm)
5/16"	5/16" G4	1/2" (12.7 mm)

ISO = ISO EN 818-3. Rope sizes refer to 3-strand polyester rope with the rope/chain splice made to the Quick system; the splice must be tightly woven so it runs smoothly into the gypsy.

Electrical System

Motor feed: battery → hydraulic-magnetic circuit breaker (see table) → reversing contactor box → motor (M1, M2). Cable section is for the total length L = L1 + L2 + L3 + L4 + L5.
Reversing contactor box: mod. T6411-12 (12 V), T6415-12 (12 V) or T6415-24 (24 V). Install it where no water can reach it.
Control circuit fuse: 4 A (12 V), 2 A (24 V). Controls connect with brown, black and blue leads to A1, A2 and C.
Recommended Quick accessories (not included): control board UP/DOWN controls, push-button panel, foot switches, hydraulic-magnetic circuit breaker, chain counter, RRC radio control.
Fit at least two controls, so the windlass can still be run if one is damaged.

Before You Drill

In the box: windlass, reversing contactor box, base gasket, lever, assembly screws, manual and warranty, drilling template.
Tools: drill with Ø 9 mm (23/64") and Ø 11 mm (7/16") bits, Ø 40 mm (1" 9/16) hollow mill, 13 mm hex wrench.
Roller alignment: align the gypsy with the bow roller. Too much negative chain angle can foul the base; up to 5° positive tilt is allowed.
Deck level: top and bottom deck faces as parallel as possible; compensate if not, or the motor loses power. The deck must be within the thickness range.
Chain locker: nothing in the way of cables, rope and chain under deck; the drawing shows 40 cm (16") of fall to the heap. A shallow locker jams the chain.
Install with the product disconnected from the electrical system, in good light, by qualified personnel.

Installation Procedure

Drill the holes with the drilling template.
Open the rope/chain hole, then finish and seal it (marine paint, epoxy resin or gel) so the chain runs free; the drawing shows the edge finished at 45°.
Set the upper section with the gasket between deck and base, fit grower and nut on each stud and tighten to 8÷10 Nm.
Connect the windlass cables to the reversing contactor box.

Operation

Clutch, Weighing and Casting

Clutch: the handle (C) in the bush (D) of the drum or in the gypsy cover; counter-clockwise disengages, clockwise re-engages.
Weighing: engine on, clutch engaged, handle removed, press UP. Watch the last metres of chain to protect the bow.
Casting electrically: press DOWN; the chain pays out evenly under control.
Casting manually: release the clutch and let the gypsy run. The GP manual says to turn the handle counter-clockwise to slow the chain (as printed).
Once anchored, make the chain fast to a strong point or take the load with a rope, never on the windlass.
Troubleshooting: if the windlass stops and the breaker has not tripped, wait a few seconds and retry without holding the button. If the breaker has tripped, reset it and wait a few minutes. If it is still blocked, move the boat to free the anchor.

Drum (1200/1500/2000) and Free Fall

Before warping, make the anchor rope or chain fast to a bollard or strong point; keep hands clear of the drum.
Drum: open the clutch with the lever (at least 2 turns of the bush counter-clockwise), remove the lever, take at least 3 turns on the drum, run the windlass keeping the rope under tension; the tension sets the winding speed.
Free fall on: clutch closed; turn cover A until the hole for pin B faces up, cut the power, hold the chain on a stopper, pull knob C until pin B is fully out, release the chain, restore power.
With free fall on, holding DOWN opens the clutch and the gypsy runs free; release DOWN where the anchor can drop clear. Hold UP to slow or stop it. Weigh anchor as normal.
Free fall off: same preparation, then press pin B towards the gypsy centre with a suitable tool. The chain is then lowered electrically or manually only.

Never run the motor with the handle in the drum or gypsy cover. Secure the chain with a retainer before sailing and isolate the windlass under way.

Maintenance

Switch off the motor power and make the anchor rope or chain fast before working on the windlass.
Wash salt deposits off with fresh water regularly.
Once a year, drum version: loosen the bush (B) with the handle (A), pull off the drum, remove the top clutch cone (D), undo the screws (E) and remove the chain stripper (F), remove the gypsy (G) and the bottom clutch cone (H).
No-drum version: remove the gypsy cover with the handle, then the same sequence from the top clutch cone.
Clean, then grease the shaft thread and the gypsy seats of the clutch cones with marine grease.
Clean any oxide off the motor and contactor terminals and grease them.
Any further disassembly by qualified personnel, with the gearbox cold.

Quick Genius GP2 500 exploded view

Quick Genius GP2 1200 exploded view

Quick Genius GP2 1500/2000 exploded view

OSP Spare Parts

Quick Genius GP2 OSP spare parts kits

Code	Pos.	Description
FVSSB070516MA00	1A	OSP gypsy GP2 500/1200 5/16"	Ask us to source it →
FVSSB0706G0MA00	1B	OSP gypsy GP2 500/1200 6 mm	Ask us to source it →
FVSSB070714MA00	1C	OSP gypsy GP2 500/1200 7 mm – 1/4"	Ask us to source it →
FVSSB0708G0MA00	1D	OSP gypsy GP2 500/1200 8 mm	Ask us to source it →
FVSSB07CMG00A00	1E	OSP gypsy GP2 500/1200 rope	Ask us to source it →
FVSSBGP20006A00	1F	OSP gypsy GP2 1500/2000 6 mm	Ask us to source it →
FVSSBGP20008A00	1G	OSP gypsy GP2 1500/2000 8 mm	Ask us to source it →
FVSSBGP20714A00	1H	OSP gypsy GP2 1500/2000 7 mm – 1/4"	Ask us to source it →
FVSSBGP20516A00	1I	OSP gypsy GP2 1500/2000 5/16"	Ask us to source it →
FVSSBGP20CM0A00	1M	OSP gypsy rope 1500/2000 GP2	Ask us to source it →
FVSSCFG00000A00	2	OSP clutch cone kit GP2	Ask us to source it →
FVSSTCMG0000A00	3A	OSP pressure lever kit GP2 500/1200	Ask us to source it →
FVSSTCGP2200A00	3B	OSP pressure lever kit GP2 1500/2000	Ask us to source it →
FVSSLVSDN000A00	4	OSP straight nylon windlass lever	Ask us to source it →
FVSSCPBBASG0A00	5	OSP gypsy cover "Series 2"	Ask us to source it →
FVSSGPGFFS00A00	6A	OSP pin guide kit GP2 500/1200 FF	Ask us to source it →
FVSSGPGFF000A00	6B	OSP pin guide kit GP2 FF 1500/2000	Ask us to source it →
FVSSCPBBGFF0A00	7	OSP gypsy cover "GP2" FF complete	Ask us to source it →
FVSSMSE0800XA00	8	OSP windlass drum "Series 2" stainless steel	Ask us to source it →
FVSSGMSDCP05000	9	OSP drum bush "Series 1-2"	Ask us to source it →
FVSSGP1200FFA00	10A	OSP trans. kit 1200 GP2 FF	Ask us to source it →
FVSSGP1520FFA00	10B	OSP trans. kit 1500/2000 GP2 FF	Ask us to source it →
FVSSGP051200A00	11A	OSP trans. kit without drum 500/1200 GP2	Ask us to source it →
FVSSGP152000A00	11B	OSP trans. kit without drum 1500/2000 GP2	Ask us to source it →
FVSSGP1520D0A00	12	OSP trans. kit with drum 1500/2000 GP2	Ask us to source it →
FVSSFSGP2120A00	13	OSP fixing kit GP2 500/1200	Ask us to source it →
FVSSFSGP2200A00	14	OSP fixing kit GP2 15/2000	Ask us to source it →
FVSSGP212GC0A00	15	OSP casing gasket kit GP2 500/1200	Ask us to source it →
FVSSGP220GC0A00	16	OSP casing gasket kit GP2 15/2000	Ask us to source it →

GP2 500 Components

No.	Name
1	Windlass lever, nylon
2	Gypsy cover
3	Clutch cone
4A	Gypsy 6 mm
4B	Gypsy 7 mm – 1/4"
4C	Gypsy 8 mm
4D	Gypsy 5/16"
5	Screw
6	Grower
7	Chain stripper
8	Oil seal
9	Screw
10	Screw
11	Windlass cover
12	Pressure lever screw
13	Pressure lever spring
14	Pressure lever
15	Reed sensor
16	Casing gasket 150W
17	Bearing
18	Output shaft gear
19	Shaft
20	Pin
21	External snap ring
22	Bearing
23	Gear
24	Gear
25	Pin
26	Windlass base
27	Screw
28	Screw
29	Motor
30	Screw
31	Pressure lever pin
32	Pin
33	Washer
34	Roller shell
35	Gear
36	Crankshaft wheel
37	Gasket
38	Studs
39	Washer
40	Serrated washer
41	Nut
42	Hexagon hollow cylindrical screw
43	Spacer
44	O-ring

GP2 1200 Components

No.	Name
1	Windlass lever, nylon
2	Gypsy cover
3	Windlass clutch cone
4A	Gypsy 6 mm
4B	Gypsy 7 mm – 1/4"
4C	Gypsy 8 mm
4D	Gypsy 5/16"
5	Screw
6	Grower
7	Chain stripper
8	Bush
9	Drum
10	Oil seal
11	Screw
12	Grub screw
13	Windlass cover
14	Pressure lever screw
15	Pressure lever spring
16	Pressure lever
17	Reed sensor
18	Casing gasket
19	Bearing
20	Output shaft Z88 gear
21	Series shaft
22	Pin 8×16
23	Series long shaft
24	Key
25	External snap ring
26	Bearing
27	Gear
28	Gear
29	Windlass base
30	Screw
31	Motor
32	Screw
33	Pin
34	Pin
35	Washer
36	Roller shell
37	Gear
38	Crankshaft gear
39	Gasket
40	Studs
41	Washer
42	Serrated washer
43	Nut
44	Spacer
45	O-ring
46	Gypsy cover FF
47	Spring
48	Brake pin
49	Brake pin cover
50	Knob
51	Screw
52	Dowel
53	Pin
54	Spring
55	Free fall block
56	Screw

GP2 1500/2000 Components

No.	Name
1A	Motor 800W 12V
1B	Motor 800W 24V
1C	Motor 500W 12V
2	Solar gear
3	Pin
4	Fixed crown
5	Screw
6	Ring Ø 80
7	Fifth wheel
8	Planetary group
9	Mobile crown
10	Bearing
11	Snap ring
12	Key
13	Screw
14	Pressure lever
15	Pressure lever spring
16	Pressure lever screw
17	Pin
18	Washer
19	Idle gear
20	Bearing
21	Pin
22	Screw
23	Windlass base
24	Bearing
25	Snap ring
26	Output gear
27	Pin
28	Short shaft
29	Oil seal
30	Windlass cover
31	Assembled reed sensor
32	Chain stripper
33	Screw
34	Windlass clutch cone
35A	Gypsy "GP2" 6 mm
35B	Gypsy "GP2" 7 mm – 1/4"
35C	Gypsy "GP2" 8 mm
35D	Gypsy "GP2" 5/16"
36	Gypsy cover
37	Nylon windlass lever
38	Gasket/template
39	Stud
40	Washer
41	Serrated washer
42	Nut
43	Cable
44	Screw
45	Casing gasket
46	Long shaft
47	Key
48	Drum
49	Bush
50	Pin
51	Grower
52	Pin
53	Cable gland
54	Gypsy cover FF
55	Spring
56	Brake pin
57	Brake pin cover
58	Dowel
59	Pin
60	Spring
61	Knob
62	Screw
63	Free fall block
64	Screw