Maxwell 6000 Series Manual
VERTICAL WINDLASSES
6000 SERIES
Copyright: Maxwell Marine Ltd
All rights reserved
Printed in New Zealand
P19137
12/12/07
Maxwell Marine International Ltd reserves the right
to make engineering changes to all products without
notice. Illustrations and specications not binding as to
detail.
Contents
1.0 INTRODUCTION 4
1.1 PRE-INSTALLATION NOTES 4
1.2 PRODUCT VARIATIONS 5
1.3 SPECIFICATIONS 6
2.0 INSTALLATION 8
2.1 SELECTION OF POSITION FOR THE WINDLASS 8
2.2 PREPARATION OF MOUNTING AREA 9
2.3 PREPARATION OF THE WINDLASS 10
2.4 INSTALLING THE WINDLASS 11
2.5 SELECTION OF MOTOR STARTER 13
2.6 POWER CONNECTIONS TO AC MOTOR 14
2.7 POWER CONNECTIONS TO DC MOTOR 15
2.8 POWER CONNECTIONS TO HYDRAULIC MOTOR 15
2.9 INSTALLATION OF CONTROLS 16
2.10 NOTE TO BOAT BUILDER 17
3.0 USING THE WINDLASS 18
3.1 PERSONAL SAFETY WARNINGS 18
3.2 LOWERING THE ANCHOR UNDER POWER 19
3.3 RETRIEVING THE ANCHOR UNDER POWER 19
3.4 LOWERING THE ANCHOR UNDER MANUAL CONTROL 19
3.5 OPERATING THE WARPING DRUM INDEPENDENTLY 20
4.0 MAINTENANCE 21
4.1 WINDLASS MAINTENANCE 21
4.2 BAND BRAKE MAINTENANCE 22
4.3 RECOMMENDED LUBRICANTS 22
4.4 SPARE PARTS 23
4.5 TOOLS FOR MAINTENANCE 23
5.0 TROUBLESHOOTING 24
APPENDIX A - Dimensional drawings 26
APPENDIX B - Spare parts 29
APPENDIX C - Installation schematics 38
APPENDIX D - Network of Agents and Distributors 42
APPENDIX E - Warranty Form 47
1.0 INTRODUCTION
1.1 PRE-INSTALLATION NOTES
• Read this manual thoroughly before installation
and using the windlass. Failure to adhere to
the correct procedures, recommendations and
guidelines described in this Owner’s Manual
may invalidate the warranty.
• Be mindful that the correct selection of
windlass for each application, together with
correct installation, normal care in use and
maintenance, are essential for long life and
reliable performance.
• Inspect your windlass carefully when unpacked.
Any damage or lack of components should be
reported immediately to your Maxwell distributor.
• The windlass is supplied with chainwheel, as
specied on purchase order. Make sure it is the
appropriate one for the chain being used on
board. Correct t of the chain to chainwheel is
essential for reliable and safe operation of the
windlass. This can be guaranteed only when
calibrated chain to a recognised international
standard is used and the chain is correctly
identied to Maxwell, or if a chain sample
is provided to Maxwell to develop a custom
chainwheel.
• The windlass is designed for use in conjunction
with chain stopper and tensioner of the
appropriate size. Their use is an important safety
feature.
• For side pocket anchors, a chain roller should
be installed above the hawse pipe to ensure
smooth and quiet travel of the chain from deck
to hawse pipe. The roller requires a central
groove to align chain and at faces (for longer
chains) to support and avoid bending the chain
links.
• The connection of the power lines and control
circuitry to the windlass must be done by
skilled technicians, to ensure reliable and safe
operation of the windlass.
4
5
1.2 PRODUCT VARIATIONS
There are two options of above-deck arangements or
“topworks”, combined with four types of drives.
The types of topworks are:
VWC - vertical windlass with chainpipe
VWCLP - vertical windlass with chainpipe, low prole
Each of the above topworks is available as clockwise
or anticlockwise conguration (see description of
Denition of rotation in Section 2.1).
Beside friction clutch, which can be used for controlling
chain speed while free falling anchor, the windlasses
can also be equipped with an external band brake.
Picture 1.1
VWC topworks
Picture 1.2
VW topworks
The types of drives are:
Electric DC drive (24V)
Electric AC drive (horizontal motor)
Hydraulic drive
The above deck components of the windlass can come
in several different materials / nishes:
Chrome over polished bronze
Bare polished bronze
Stainless steel
Titanium nitride coated bronze or stainless steel
Picture 1.3
VWCLP topworks
Picture 1.4
Electric DC drive
Picture 1.6
Hydraulic drive
Picture 1.5
Electric AC drive
6
1.3 SPECIFICATIONS
General
Maximum stud link chain size 16mm
Maximum short link chain size 19mm (3/4”)
Maximum pull capacity at chainwheel 2730kg (6006lb)
Electric DC Drive
Chain speed at 1000kg load 10m/min (33ft/min)
Continuous pull capacity at chainwheel 680kg (1496lb)
Current at 1000kg load 215A
Motor power 3.5kW (48HP)
Weight of windlass 195kg (429lb)
Electric AC Drive
Vertical motor Horizontal motor
Chain speed 15m/min (49ft/min) 13m/min (43ft/min)
Continuous pull capacity at chainwheel 1490kg (3278lb) 1286kg (2829lb)
Current at continuous pull rating (@ 400V) 8.7A 8.2A
Current at start-up (@ 400V DOL) 47A 55A
Motor power 4kW (5.5HP) 4kW (5.5HP)
Weight of windlass 285kg (627lb) 247kg (543lb)
Hydraulic Drive
Chain speed (at Recommended ow) 14m/min (47ft/min)
Recommended hydraulic oil ow 41l/min (11USgal/min)
Maximum hydraulic oil ow 76l/min (20USgal/min)
Continuous pull capacity at chainwheel 2730kg (6006lb)
Maximum hydraulic oil pressure 138bar (2000psi)
Motor port size (pressure and return) 7/8” x 14tpi UNF - SAE 10
Minimum size of oil supply/return lines 16mm (5/8”)
Weight of windlass 153kg (337lb)
*See Appendix C for other options of ow and pressure.
Rated capacity and chain speed is based
on the chainwheel for 16mm chain. The
performance may vary slightly when other
chainwheels are used.
Hydraulic oil characteristics
Viscosity: ISO 32 - 68 (at 20ºC)
Suitable oils:
Shell Rimula X 15W-40
Shell Myrina M 15W-40
Penzoil SAE 10W-40
Texaco 2109 SAE 15W
Texaco 1814 SAE 10W-40
BP HLPHM 32-68
BP Autrans T0410
Castrol Hyspin AWS 32-68
Minimum 0.125% Zinc anti-wear additive.
7
Chainwheels
The chainwheel numbers consist of two parts: main
part number and sufx, for example 2514-001.
The main part number refers to the type of chainwheel
and the sufx refers to size and type of chain.
Types of chainwheels
2513 for windlasses without band brake
2514 for windlasses with band brake
Sufxes
Sufx Chain to t
001 16mm PWB, Campbel, EN818-3
002 14mm EN818-3; 13mm GR4
1/2” G40 (ISO) & G63 ACCO
003 16mm DIN 766; 5/8” G4 ACCO (ISO)
004 13mm PWB, Weissenfels
008 13mm DIN 766
010 14mm stud link
011 16mm stud link
012 12.5mm stud link
013 12mm EN818-3
There are other chainwheel models less commonly
used. Contact your Maxwell distributor for details.
8
2.0 INSTALLATION
2.1 SELECTION OF POSITION FOR THE WINDLASS
Windlasses of this size will often be installed in
pairs, giving an emergency backup in the event of
mechanical or electrical failure. In this case one of the
windlasses will normally be retrieving anchor running
clockwise and the other anticlockwise.
Position of the windlass should be selected together
Denition of rotation
The windlass is called a “clockwise windlass” if
it rotates clockwise, viewed from above, when
retrieving the ground tackle.
with positions of hawse pipe and spurling pipe.
The deckplate should be installed pointing with its
narrower end in the direction of the incoming chain.
That allows the chain to have maximum engagement
with the chainwheel.
Allow the chain a straight run from the bow roller to
the chainwheel with no more than a 2° deviation from
horizontal (Picture 2.1).
The bow roller should have a vertical groove to suit
the prole of the chain. Its centre line should be
tangentional to the chainwheel (Picture 2.2). This
will align the chain so that it enters the chainwheel
without twisting.
When positioning the windlass, make sure that there
Direction of chain entering the chainwheel
is room to swing the clutch lever, so that it will clear
the pulpit and life lines or bulwark.
The tting of a chain stopper is essential to take the
load off the windlass while the vessel is at anchor. It
must be correctly aligned with the direction of chain
and installed at appropriate height to avoid the chain
rubbing over chain stopper body or pawl. Make sure
the chain stopper clears the anchor stock.
A tensioner device to tension the anchor into its
pocket is recommended. If the anchor is not snug in
the pocket, it could cause damage to the pocket in a
heavy seaway.
Correct height of Chain Stopper
Ensure a minimum of 800mm (32") clearance
between the end of spurling pipe and the chain piled
up in the chain locker. This will assist kinks, which
may develop in outgoing chain, to shake free.
The chain must gravity feed into the locker. If the
chainpipe cannot be positioned directly over the
locker, a heavy wall pipe can be used to direct
the chain to the required area. It is important that
the chain slips through the pipe easily, completely
unaided, sharp corners should be avoided. It may
be necessary to provide the pipe with a bell mouth
or to bell mouth the entrance to the chainpipe from
the locker to assist the free ow of the chain from the
locker.
The chain locker must be of such a size and shape
that the chain will heap up and feed out naturally
without fouling.
Recommended free space in chain locker
Picture 2.1
Picture 2.2
Picture 2.3
9
If it can be arranged, the chain locker bulkhead should
pass between the chainpipe outlet in the deckplate
and the gearbox. This will keep the gearbox, motor
and power lines dry and away from aying chain.
Access for servicing from inside the cabin area can
usually be arranged through a locker.
Note that the gearbox can be indexed through a
number of different angles in relation to the windlass
deckplate. Be sure to select the most convenient
arrangement at installation and ensure incoming
chain well clears the gearbox, motor and power
supply lines.
To ensure safe position of the operator while tailing
from the warping drum, footswitches should be
positioned at least 500mm (20”) away from the
windlass.
The below deck portion of the footswitch should not
be exposed to water or wet environment and the
breather holes must be kept clear. The arrows on
the footswitches should be arranged to indicate the
direction of operation.
The motor starter (solenoid valves for hydraulic
windlasses) should be located in a dry area in close
proximity to the windlass. It must not be located in the
wet environment of the chain locker.
The breaker/isolator panel (DC powered windlasses
only) is selected to provide limited overload protection
for the motor and full protection for the supply cables.
It also provides the means for isolating the electrical
system from the battery.
This should be mounted in a dry place within 1.8m
(72”) of cable length from battery.
This equipment or equivalent is mandatory to meet
U.S.C.G. requirements.
Picture 2.4
Positions of drive, relative to topwork
2.2 PREPARATION OF MOUNTING AREA
It is of paramount importance that the vessel has
sufcient deck reinforcing and total structural strength
to sustain the loads that can be transmitted to the
mounting area of the windlass and chain stopper.
This should be equal to the loading of the equipment
to beyond breaking strength of the chain.
The mounting area for the windlass must be perfectly
at and rigid. A structural grade ller can be used
to level this area if initial atness is inadequate.
Mounting area for the chain stopper should be
prepared at the same time. The chain stopper has to
be installed at an appropriate height to ensure that
chain lays horizontally when it comes out of the chain
stopper and into windlass. Maximum allowed angle
deviation in vertical plane is ±2°.
If hawse pipe is angled outboard from deck to anchor
pocket, the chain stopper should also be angled by
half of the angle of the hawse pipe (Picture 2.5). That
will help to reduce twisting of the chain between the
chain stopper and the windlass and ensure good t of
the chain into the chainwheel. The chain stopper can
be installed vertically if the hawse pipe angle is less
than 4°.
A deck cutout detail drawing is enclosed with these
instructions to assist in marking out all the drilling and
cutting required for installing the windlass. Before
drilling and cutting, check the marked out area is
dimensionally correct and make any necessary
corrections.
The hole for mounting band brake guide (where
applicable) should be marked and drilled after
assembling the band brake on the windlass.
10
2.3 PREPARATION OF THE WINDLASS
Remove windlass from its packing case.
Disassemble it in the following order (refer to
drawing in Appendix B):
• Remove the Cap and O-Ring from the top of the
windlass, taking care not to damage the chromed
surface.
• Undo and remove the Retaining Screw and
Retaining Washer under the Cap, using a at
screwdriver.
• Undo and remove Clutch Nut, remove Drum and
Upper Clutch Cone .
• On VWC & VWCLP versions, undo Screws that
retain Chainpipe and remove it. On VW versions
undo Screws and remove Stripper.
• Remove Plungers, springs, upper spring holder,
Chainwheel, Lower Clutch Cone and Key. The
Lower Clutch Cone might be held by a Grub
Screw to the shaft. If that is the case, undo the
Grub Screw before removing the cone. Make sure
not to displace the two Retention Clips that were
supporting the Lower Clutch Cone.
• Carefully remove Deck Seal to avoid damage to
it.
• Undo Screws and remove the Deckplate.
• Refer to Appendix B of this Manual and identify
all parts. If any parts are damaged or missing,
contact your Maxwell distributor. Some smaller
parts might not be assembled on the windlass
by the factory, but supplied in a plastic bag in the
packing case.
Picture 2.5
Installation angle of chain stopper
11
Maxwell strongly recommends generous application
of a high quality anti-corrosive paste or coating to
the mating sections of main shaft, drive key, anges,
screw threads, dowels and other surfaces that are
likely to seize after being in contact for a prolonged
period of time.
Also ensure anti-corrosive coating is liberally applied
to the inside wall of the Spacer Tube.
2.4 INSTALLING THE WINDLASS
Refer to the drawing in Appendix B for help with
identifying components and installing them correctly.
Extra care should be exercised when handling
polished parts to avoid any damage to polished
surfaces.
When assembling the parts, apply an anti-seize
compound generously over all screw threads, keys
and keyways, Mainshaft and inside the spacer tube.
Proceed with installation in the following order:
• After cutting holes for the windlass in the deck,
apply an appropriate bedding/sealing compound
to the clean surface, place Deck Gasket and
bolt the Deckplate to the deck using Mounting
Screws, and Insulating Bushes. Tighten them
evenly to 80 Nm (60 ft lb). Heel Block should
already be assembled to Deckplate.
• Offer up, from below deck, the drive assembly
sliding the Mainshaft through the Deckplate,
taking care not to damage the deck bearing.
• After aligning them correctly, bolt the Deckplate
and Spacer Tube together, from above deck,
using the Hex Head Screws and Spring Washers.
Tighten them evenly to 80 Nm (60 ft lb).
• Re-check that the position of the drive assembly
is satisfactory and convenient for connecting
power supply lines to the motor. Also, make sure
that the drive is not in the way of chain coming
into the locker.
• If a chain counter is used, its sensor should be
tted into the Ø15mm hole in the Deckplate,
currently covered with a Plastic Plug. Make sure
the deck is drilled below for the sensor cable.
See brochure supplied with Chain Counter for
detailed assembly instructions.
• Grease Deck Seal and carefully slide it down
the Mainshaft. Push it against the Deck Bearing
(28) by approx 1.5 mm after initial contact (see
Picture 2.8).
Picture 2.6
Clockwise topwork
Picture 2.7
Anticlockwise topwork
clockwise
windlass
Picture 2.8
Positions of valves on hydraulic motors
When assembling hydraulic drives, take
care not to swap over the drives (couple the
clockwise motor and gearbox to anticlockwise
topworks). See letters on Picture 2.8 for drive
identication.
anticlockwise
windlass
• Insert the two Retention Clips into the groove in
the Mainshaft; apply some grease to help keep
them in position.
• Apply anti-seize compound generously over
the Mainshaft and keyway. Insert Key into the
keyway in the Mainshaft.
• Assemble the Lower Clutch Cone making sure it
sits nicely on the retention clips (see Picture 2.9).
Apply Lithium based marine grease generously
to the conical surface of the Lower Clutch Cone,
to assist with free falling the anchor.
• Install 6 springs and Plungers into holes in the
Lower Clutch Cone.
• Install Chainwheel, Upper Spring Holder and the
remaining 3 Plungers and springs.
• Install Band Brake (if applicable) on the
Chainwheel, putting its two stops one each side
of Heel Block. The Band Brake can be assembled
with its handle pointing either direction, choose
more convenient option.
• Make sure the band sits at on the shoulder at
the lower end of the Chainwheel and tighten the
brake by turning the Lead Screw. Slide shaft
guide (5 – Band brake) on Handle Shaft (6
– Band brake). Line up both parts of the Lead
Screw Assembly in one vertical plane and make
sure the bottom surface of the Shaft Guide sits
at on the deck.
• Mark up the position of the Shaft Guide on deck,
then remove the guide and drill Ø13mm clearance
hole in the deck for the retaining screw (not
supplied). The Shaft guide has a mounting hole
M12 x 25mm deep and should be retained from
under the deck with a M12 bolt of appropriate
length (depending on the deck thickness).
• Apply the same bedding/sealing compound as
used under the deck plate, replace the Shaft
guide and retain it from underneath.
• Slide the Retaining Nut (2 – Band brake) on
the Shaft (6 – Band brake) and insert the Pin (3
– Band brake) into the hole in the Shaft. Then put
on the Handwheel (1 – Band brake), making sure
the end of the Shaft comes into the square recess
in the Handwheel, and fasten it with the Retaining
Nut.
• Install Chainpipe and retain it with the 3 cap
screws. Note that there are three Spacers
supplied for the Stripper. They should be used
to adjust the position (height) of the Stripper.
The correct height is when the Stripper is in, or
as close as possible to the centre of the central
12
Picture 2.9
Installing Deck Seal
Picture 2.10
Lower Clutch Cone Assembly
For effective operation of the band brake,
the friction lining must remain free from
contamination by any lubricant. Lithium
complex base grease should, however, be
applied to the lead screw thread.
Picture 2.11
Plunger and Spring Assembly
13
groove of the Chainwheel.
• Slide Upper Clutch Cone. Note that this cone has
friction lining, which SHOULD NOT be greased,
unlike the lower cone.
• Assemble Drum on top of the clutch cone (VWC
models only).
• Assemble Clutch Nut.
• Put Retaining Washer on top of the Mainshaft
and secure it with the Screw.
• Insert Cap into the Clutch Nut.
2.5 SELECTION OF MOTOR STARTER
Several AC motor starter options for windlasses are
available, each with characteristic current demands
and start load limitations. Maxwell recommends that
selection of the best motor start system be entrusted
to experienced persons familiar with anchoring
procedures and the vessels generating capacity.
"Direct On Line" starter is the simplest way of starting
an AC motor and it will allow the windlass to start
under full rated load. However, this method requires
relatively high momentary starting current, which the
generators may have adverse effect to the rest of
the electrical system on board. See specications
for current values at 400V in Section 1.3 and make
sure to recalculate it for the voltage used on board.
Start current may be limited to about half the above
amount by using a "Star-Delta" starter. However, start
torque is thereby limited to loads of about 25-30% of
the windlass rated capacity.
“Star-delta” and “soft starters” are not recommended
for starting windlass motors, as the motor torque is
severely limited during start up period. Since these
motors often have to start under load (when retrieving
the ground tackle), they might not be able to move
until they reach the full voltage and torque. The
benet of starting at lower current would therefore be
lost. Also, the motor brake would release immediately
on start-up, which could cause short movement of the
chain in opposite direction.
The Variable Frequency Drives (VFD) offer accurate
control of current during start up period while keeping
high motor torque. They also offer various other
benets like:
• innite speed control
• running the windlass over its nominal speed
• accurate current overload and thermal overload
control
The selection of the type of motor starter
should be done by a qualied electrical
engineer, taking into consideration the power
generating capacity on board.
Maxwell offers both advice and different types
of custom made starters to complement our
windlasses.
The “up” and “down” start contactors must
be mechanically or electrically interlocked
to safeguard the motor, in the event that an
accidental attempt is made to start the motor
in both directions simultaneously.
14
Both “Direct On Line” starters and Variable Frequency
Drives are suitable and available from Maxwell,
customised to suit the anchor windlass and stern
capstan application.
2.6 POWER CONNECTIONS TO AC MOTOR
Remove the motor terminal box cover and take care
not to misplace the sealing gasket and screws.
Select a suitably sized, waterproof cable gland for
the armoured supply cable. The selected gland tting
must t the terminal box, be capable of anchoring the
armoured cable, and allow an effective waterproof
entry seal to be made.
Make the line connections to motor terminals. Make
also an effective earth connection.
Separately and similarly, enter the 2 thermistor cables
to the motor terminal box, and connect to the two
auxiliary terminal connectors of the thermistor circuit.
Check:
• Is the direction of rotation of the motor correct?
• Are cables satisfactorily xed?
• Are cable entry points to motor terminal box
satisfactorily waterproofed?
Spray the cable gland, cable entry points and motor
terminal box with anti-corrosive waterproof coating
"CRC 3013 Soft Seal" or equivalent.
15
2.7 POWER CONNECTIONS TO DC MOTOR
The main power system is a two cable, ungrounded,
fully insulated, negative return system. The motor is
of the isolated earth type. This system is selected to
minimise electrolytic corrosion problems.
The DC motor has four power terminals, marked 1-4.
They should be connected to the starter box as per
schematic P101807 in Appendix C.
After connecting the cables, spray all terminals with
anti-corrosive waterproof coating, “CRC 3013 Soft
Seal” or equivalent.
2.8 POWER CONNECTIONS TO HYDRAULIC MOTOR
A basic hydraulic schematic is shown in Appendix C.
Port sizes on the hydraulic motor and minimum hose
sizes are specied in Section 1.3.
The motor is supplied with oil through two ports on
the Counterbalance Valve Block. They should be
connected to a bi-directional, solenoid controlled valve
(not supplied by Maxwell). The pressure line (when
retrieving the anchor) should be connected to the port B
and the return line to the port A (see Picture 2.8).
After connecting the power lines, spray all ports and
ttings with anti-corrosive waterproof coating, “CRC
3013 Soft Seal” or equivalent.
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