Maxwell 6000 Series Bedienungsanleitung
VERTICAL WINDLASSES
6000 SERIES
Copyright: Maxwell Marine Ltd
All rights reserved
Printed in New Zealand
Maxwell Marine International Ltd reserves the right
to make engineering changes to all products without
notice. Illustrations and specications not binding as to
detail.
P19137
12/12/07
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
• 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.
1.0 INTRODUCTION
1.1 PRE-INSTALLATION NOTES
4
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.
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 1.1
VWC topworks
Picture 1.3
VWCLP topworks
Picture 1.4
Electric DC drive
Picture 1.5
Electric AC drive
5
Picture 1.6
Hydraulic drive
Picture 1.2
VW topworks
1.3 SPECIFICATIONS
Rated capacity and chain speed is based
on the chainwheel for 16mm chain. The
performance may vary slightly when other
chainwheels are used.
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.
6
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.
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
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
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
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.
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.
Picture 2.1
Direction of chain entering the chainwheel
Picture 2.2
Correct height of Chain Stopper
Picture 2.3
Recommended free space in chain locker
Denition of rotation
The windlass is called a “clockwise windlass” if
it rotates clockwise, viewed from above, when
retrieving the ground tackle.
8
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
2.2 PREPARATION OF MOUNTING AREA
Picture 2.4
Positions of drive, relative to topwork
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.
9
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.
2.3 PREPARATION OF THE WINDLASS
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
Picture 2.5
Installation angle of chain stopper
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