The Maxwell HWVC 3500 Series is a horizontal windlass designed for anchoring and mooring operations on boats. It is available with electric DC drives (12V or 24V) or a hydraulic drive, offering various chainwheel and drum arrangements to suit different vessel requirements.
Function Description
The windlass's primary function is to deploy and retrieve anchors and manage docking lines. It can operate the chainwheel and warping drum independently or simultaneously, depending on the model and configuration. The clutch mechanism allows for controlled lowering of the anchor under power or manually, and an emergency crank mechanism is provided for manual retrieval in case of power loss.
Important Technical Specifications
The HWVC 3500 Series windlass boasts a maximum pull capacity of 1590kg (3500lb) across all drive types.
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Electric DC Drive 12V:
- Line speed at normal working load: 8.7m/min (29ft/min)
- Current at normal working load: 110-160A
- Current at stall: 450A
- Motor power: 1.2kW (1.6HP)
- Weight (Single drum/chainwheel): 56.7kg (124.7lb)
- Weight (Double drum/chainwheel): 72.6kg (159.7lb)
- Weight (Vertical drum/chainwheel): 94.5kg (207.9lb)
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Electric DC Drive 24V:
- Line speed at normal working load: 11m/min (36ft/min)
- Current at normal working load: 66-88A
- Current at stall: 240A
- Motor power: 1.2kW (1.6HP)
- Weight (Single drum/chainwheel): 56.7kg (124.7lb)
- Weight (Double drum/chainwheel): 72.6kg (159.7lb)
- Weight (Vertical drum/chainwheel): 94.5kg (207.9lb)
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Hydraulic Drive:
- Line speed at normal working load: 12m/min (39ft/min)
- Recommended hydraulic oil flow: 40l/min (11USgal/min)
- Maximum hydraulic oil flow: 48l/min (13USgal/min)
- Continuous pull capacity: 1590kg (3500lb)
- Maximum hydraulic oil pressure: 138bar (2000psi)
- Motor port size (pressure and return): 7/8"-14UNF
- Weight (Single drum/chainwheel): 48.5kg (106.7lb)
- Weight (Double drum/chainwheel): 64.4kg (141.7lb)
- Weight (Vertical drum/chainwheel): 79.9kg (175.8lb)
- Hydraulic oil characteristics: Viscosity ISO 32-68 (at 20°C). Suitable oils include Shell Rimula X 15W-40, Penzoil SAE 10W-40, Texaco 1814 SAE 10W-40, BP Autrans T0410, Shell Myrina M 15W-40, Texaco 2109 SAE 15W, and BP HLPHM 32-68.
- Gearbox oil quantity: 0.35 litres (GR XP 320).
The rated capacity and chain speed are based on a chainwheel for 10mm chain, with performance potentially varying by up to ±10% with other chainwheel sizes.
Usage Features
The windlass can be operated using deck-mounted footswitches, a hand-held pendant controller (single or dual speed), a helm switch, or a chain counter. These control accessories are wired in parallel to the directional valve (for hydraulic windlasses) or the starter unit (for electric windlasses) and can operate on 12V or 24V power supply. An isolator switch is recommended for footswitches to prevent accidental operation.
Personal Safety Warnings:
- Always maintain a clear view of the windlass, anchor, and chain during operation.
- Keep hands, feet, loose clothing, cordage, and hair clear of moving parts.
- Never operate the windlass under power with the clutch handle inserted.
- Do not engage the pawl while the chain is running.
- Motor up to the anchor position before retrieving it from the bottom; do not use the windlass to pull the boat to the anchor.
- If the anchor is fouled, use the boat's engine to break it loose, with the chain stopper taking the load.
- When lowering the anchor manually, use the friction clutch to control chain speed.
- Ensure the power supply is isolated when the windlass is not in use.
- Engage the chain stopper when the windlass is not in operation; do not use the windlass as an anchoring point.
- Do not switch immediately between directions of rotation without waiting for the windlass to stop.
- Take care not to overspeed the windlass when lowering the anchor under power, especially in deep water or with heavy tackle. Manual deployment is preferred in such cases.
Lowering the Anchor Under Power:
- Ensure the clutch is fully engaged by turning the clutch nut lever clockwise firmly.
- Remove the clutch handle.
- Release the pawl.
- Disengage the chain stopper and chain tensioner (if fitted). Momentary jogging in the "up" direction may be needed to disengage the chain stopper pawl.
- Lower the anchor under power using the pendant control, helm switch, or footswitch.
- Turn off the isolator switch for controls when finished. The windlass operates only while the button/switch is held.
Retrieving the Anchor Under Power:
- Ensure the clutch is engaged and the pawl is released.
- Remove the clutch handle.
- Release the chain stopper and/or tensioner (if fitted).
- Operate the windlass to raise the anchor.
- After retrieving the anchor, engage the chain stopper and/or tensioner (if fitted).
- Turn off the isolator switch for controls.
- It is good practice to motor over the anchor position to reduce chain tension and help break out the anchor.
- Exercise care when docking the anchor to avoid damage; jog the chain in the last few feet to seat the anchor home.
Lowering the Anchor Under Manual Control:
This method is used for quick deployment, "quiet ship" operations, or emergencies (power loss).
- Tighten the clutch.
- Release the chain stopper and/or chain tensioner (if fitted). If the pawl is engaged under tension, pull the chain slightly (power or manual) to release it.
- Slowly disengage the clutch by turning the clutch nut anticlockwise to increase speed, or tighten clockwise to slow down.
- Tighten the clutch nut firmly when the desired amount of chain is out.
- Always control chain speed; free-falling chain is dangerous.
Retrieving the Anchor Under Manual Control (Emergency Crank Mechanism):
This is a slow, emergency process.
- Check that the chain stopper is engaged (or pawl if no stopper).
- Insert the clutch nut lever into the clutch nut and release the clutch by turning anticlockwise.
- Insert the clutch nut lever (pawl end) into the emergency crank collar and engage the pawl with a dog in the chainwheel in the forwardmost position.
- Pull the lever back to bring in the chain, then engage the pawl and ease off the lever.
- Push the lever forward and re-engage with the chainwheel.
- Repeat until the anchor is retrieved.
Operating the Warping Drum Independently (if fitted):
Maxwell recommends footswitch control for warping operations.
- Engage the chain stopper (if fitted) and/or the pawl.
- Slowly disengage the clutch by turning the clutch nut anticlockwise.
- The drum can now be operated independently.
- Take several turns of the warping line around the drum and pull on the rope tail with sufficient manual force while operating the footswitch. Ensure the drum operates in the same direction as the line is wrapped.
- Do not engage more turns than necessary. Allow slipping at the drum to protect the capstan, lines, and vessel from sudden tension.
- Stay clear of lines and the capstan.
- Avoid "riding turns" (loaded line climbing on lower coils); remove by paying out until clear.
Maintenance Features
Every Trip:
- Ensure the clutch is correctly engaged.
- Wash down external parts with fresh water.
Every Three Months:
- Disassemble all external components (as per Section 5.1).
- Clean components and check for damage.
- Grease components with lithium complex base, waterproof grease, especially the conical surface of clutch cones and mating faces of the chainwheel.
- Clean chromed surfaces with kerosene-damp cloth, then spray with "CRC 3037 Long Life," "CRC 6-66," or "WD-40" to maintain the chrome finish.
- Re-assemble in reverse order.
- Inspect below-deck components for corrosion, clean, touch up paint if necessary, and spray with "CRC 3013 Soft Seal."
Every Year:
- Perform all "Every Three Months" maintenance.
- Remove gearbox/spacer tube and motor (as per Section 5.2).
- Ensure drainage slots are clear by flushing with cold water.
- Remove and service the DC motor. Replacement brush sets are available (P100807 - 12V, P100808 - 24V).
Every Three Years:
- Perform all "Every Year" maintenance.
- Remove spacer tube from the gearbox, clean it and the top of the gearbox, and apply Res-Q-Steel on mating faces.
- Drain oil from the gearbox using the two lowest plugs.
- Replace seals.
- Replace plugs. Lay the gearbox horizontally with one plug facing upwards, remove it, and fill the gearbox with new oil (approximately 800ml / 27 fl oz).
- Maxwell recommends flushing the gear case with a manufacturer-recommended flushing liquid before filling with new oil.
Recommended Lubricants:
- Greases: Lithium complex based grease (NLGI No.1 to No.3 consistency). Do not use soap-based grease. Never mix greases; if in doubt, remove old lubricant and clean parts thoroughly before applying new grease.
- Gearbox Oils: API GL-4 or lower (low sulphur) single weight gear oil (SAE 90 to 110w). Quantity: 0.35 litres (DC and Hydraulic drives). GR XP 320. Never mix different types of oil.
- Anti-Corrosive Coatings: CRC 3013 Soft Seal, Boeshield T9, Lanocote.
- Anti-Seize Coating: International Paints Res-Q-Steel.
Tools for Maintenance:
- Set of metric hexagon keys.
- Ring / open end spanner 13, 17, 19mm and 9/16".
- Flat screw driver 10mm blade width.
- Circlip pliers.
Spare Parts:
Maxwell recommends carrying a modest quantity of spare parts, especially smaller items prone to loss during maintenance. A list of recommended spare parts includes O-rings, disc springs, retention clips, keys, washers, and circlips. For specific part numbers, refer to Appendix B and contact a Maxwell distributor. Always quote the windlass serial number when ordering.
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