Maxwell CAPSTAN 8000 Series User manual

CAPSTAN
8000 SERIES


Copyright: VETUS-Maxwell APAC Ltd.
All rights reserved
Printed in New Zealand
P19136 Rev. 11.00
31/01/2019
VETUS-Maxwell APAC Ltd. reserves the right to
make engineering changes to all products without
notice. Illustrations and specifications not binding as
to detail.

1
Contents
1.0 INTRODUCTION 2
1.1 PRE-INSTALLATION NOTES 2
1.2 PRODUCT VARIATIONS 2
1.3 SPECIFICATIONS 3
2.0 INSTALLATION 4
2.1 SELECTION OF POSITION FOR THE CAPSTAN 4
2.2 PREPARATION OF MOUNTING AREA 4
2.3 PREPARATION OF THE CAPSTAN 5
2.4 INSTALLING THE CAPSTAN 5
2.5 POWER CONNECTIONS TO HYDRAULIC MOTOR 6
2.6 SELECTION OF MOTOR STARTER 6
2.7 POWER CONNECTIONS TO AC MOTOR 7
2.8 INSTALLATION OF CONTROLS 8
2.9 NOTE TO BOAT BUILDER 8
3.0 USING THE CAPSTAN 9
3.1 PERSONAL SAFETY WARNINGS 9
3.2 OPERATING THE CAPSTAN 10
4.0 MAINTENANCE 10
4.1 CAPSTAN MAINTENANCE 10
4.2 RECOMMENDED LUBRICANTS 10
4.3 SPARE PARTS 11
4.4 TOOLS FOR MAINTENANCE 11
5.0 TROUBLESHOOTING 12
APPENDIX A - Dimensional drawings 13
APPENDIX B - Spare Parts 16
APPENDIX C - Installation schematics 19
APPENDIX D - Warranty Form 23
Note: For your nearest retailer, service agent or representative please refer to our website
www.maxwellmarine.com

2
1.0 INTRODUCTION
1.1 PRE-INSTALLATION NOTES
 Read this manual thoroughly before installation
and using the capstan. 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 capstan
for each application, together with correct
installation, normal care in use and maintenance,
are essential for long life and reliable
performance.
 The capstan can be used for all types of rope
hauling operations.
 Inspect your capstan carefully when unpacked.
Any damage or lack of components should be
reported immediately to your Maxwell distributor.
 The connection of the power lines and control
circuitry to the capstan must be done by skilled
technicians, to ensure reliable and safe
operation of the windlass.
 Although mooring capstans are normally used in
one direction only, Maxwell capstans can be
used in both directions with equal load handling
capacity.
Picture 1.1 Picture 1.2
Electric AC vertical drive Electric AC horizontal drive
Picture 1.3
Hydraulic drive
1.2 PRODUCT VARIATIONS
There are 3 options of drives available for this
capstan:
Electric AC with vertical motor.
Electric AC with horizontal motor.
Hydraulic motor.
Although mooring capstans are normally used in one
direction only, certain Maxwell capstans can be used
in both directions. The static hold capacity might be
slightly lower in one direction, due to the internal
construction of the gearbox.





3
1.3SPECIFICATIONS
General
Maximum pull capacity
3630kg (8000 lb)
Electric AC Drive
Line speed
15m/min (50ft/min)
Current at continuous pull rating (@400V)
12A
Current at start up (@400V DOL)
64A
Motor power
5.5kW (7.3 HP)
Weight of capstan –vertical drive
150kg (331lb)
Weight of capstan –horizontal drive
185kg (408lb)
Hydraulic Drive
Low pressure / High flow
High pressure / Low flow
Line speed @ recommended flow
12m/min (39.4ft/min)
Recommended hydraulic oil flow
54l/min (14.3USgal/min)
36l/min (9.5USgal/min)
Maximum hydraulic oil flow
75l/min (19.8USgal/min)
Maximum hydraulic oil pressure
138bar (2000psi)
179bar (2600psi)
Motor port size (pressure and return)
1/2” BSP
Case drain port size
¼”G (BSPP)
Maximum case drain pressure
1.7 bar (25 psi)
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

4
2.0 INSTALLATION
2.1 SELECTION OF POSITION FOR THE CAPSTAN
Position of the mooring capstan should be selected
together with positions of fairleads for mooring rope.
The capstan can operate in both clockwise and
anticlockwise direction, depending on how the
connections to the motor are made (refer to diagrams
in Appendix C). However, it is recommended to use it
in one direction only. The direction should be chosen
depending on position of fairleads, to ensure clear
run of the rope from fairlead to the drum. If this is not
possible, turning fairleads should be used to route
the mooring line.
When positioning the capstan, also allow an easy
access to the drive for connecting power supply lines
to the motor. Note that the gearbox can be indexed
through a number of different angles in relation to the
capstan deckplate (see Picture 2.1). Be sure to select
the most convenient arrangement at installation.
A footswitch is the most practical and the safest way
of operating a mooring capstan. To ensure safe
position of the operator while tailing from the warping
drum, footswitches should be positioned at least
500mm (20”) away from the capstan.
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 motor starter should be located in a dry area in
close proximity to the capstan. It must not be located
in the wet environment of the chain locker.
The breaker/isolator panel (DC powered capstans
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.
! Definition of rotation
Clockwise and anticlockwise rotation is
defined as viewed from above the capstans.
Most capstans are used in one direction only.
! Use only clockwise rotation for handling
3-ply twisted rope, otherwise problems may
occur in laying the rope.
! If using the capstan for hauling an anchor
line, make sure the other end of the line is
securely fastened to the boat.
Picture 2.1
Positions of drive, relative to topwork
2.2 PREPARATION OF MOUNTING AREA
It is of paramount importance that the vessel has
sufficient deck reinforcing and total structural
strength to sustain the loads that can be transmitted
to the mounting area of the mooring capstan. This
should be equal to the loading of the equipment to
beyond breaking strength of mooring lines.
The mounting area for the capstan must be perfectly
flat and rigid. Structural grade fillers can be used to
level this area if initial flatness is inadequate. The
capstan should be installed so that lower end of the
cylindrical part of the drum is level with the centre of
hawse ring / fairlead (see Picture 2.2).
Standard units will accommodate deck thickness up
to 100mm (4”). Extra clearance models are available
to accommodate deck thickness of up to 200mm
(8”). It should be noted that keeping the deck
thickness to no more than 75mm (3”) and 175mm
Picture 2.2
Alignment of capstan and fairlead

5
(7”) respectively will considerably simplify servicing.
This will allow access to gearbox mounting bolts,
allowing the gearbox to be removed without
dismantling the topworks.
A drawing showing the deck cutout details is
enclosed with these instructions to assist in marking
out for all the drilling and cutting in the deck, required
for installing the capstan. Before drilling and cutting,
check the marked out area is dimensionally correct
and make any necessary corrections.
! Boats with steel/aluminium construction.
It is very important to insulate the deckplate
from the boat with a non conductive gasket.
Mounting studs and fixings under the deck
should be insulated. Anchor and chain
should also be insulated, including rubber
lining, chain locker and fixing for the end of
the chain to the hull.
Without these precautions severe
electrolysis can occur.
It is not necessary to separately earth the
Capstan, as the electric motor is of the
isolated earth type.
2.3 PREPARATION OF THE CAPSTAN
Remove capstan from its packing case.
Disassemble the capstan in the following order (refer
to drawing in Appendix B):
 Remove the cap from the top of the capstan,
taking care not to damage the polished surface.
 Undo and remove the retaining screw and
retaining washer under the cap, using a 17mm
socket spanner.
 Remove drum retaining nut, drum, key, retention
clips and deck seal.
 Undo and remove the M12 Hex Hd Bolts and
spring washers from the spacer tube 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 capstan by
the factory, but supplied in a plastic bag in the
packing case.
Maxwell strongly recommends generous application
of a high quality anti-corrosive paste or coating to the
mating sections of main shaft, drive key, flanges,
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 CAPSTAN
Refer to the drawings 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, main shaft and inside the spacer tube.
Proceed with installation in the following order:
 After cutting holes for the capstan in the deck,
apply an appropriate bedding/sealing compound.
If used, place the deck gasket on the deck and
! When installing the Capstan, the shaft
MUST be coated in Shell Nautilus NLG12
Marine Grease, Castrol Boating Grease,
Vavoline Val Plex EP or equivalent grease.

6
the deckplate on top of it. Bolt the deckplate
down using capscrews, washers and the
insulating bushes. Tighten them evenly to 50Nm
(37ft-lb).
 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 and choosing the
most suitable orientation for the gearbox, bolt the
Deckplate and Spacer Tube together, from
above deck, using the M12 Hex Head Bolts and
Spring Washers. Tighten them evenly to 50Nm
(37ft-lb).
 Re-check that the position of the drive assembly
is satisfactory and convenient for connecting
power supply lines to the motor.
 Apply grease on the Deck Seal and slide it down
the Mainshaft, taking care to avoid damage to it.
Push it against the Deckplate by approx 1.5mm
after initial contact (see Picture 2.3).
 Insert the two Retention Clips into the groove in
the Mainshaft; apply some grease to help keep
them in position, if necessary.
 Apply anti-seize compound generously over the
Mainshaft and keyway. Insert Key into the
keyway on the Mainshaft.
 Assemble Drum making sure it sits nicely on the
retention clips (see Picture 2.4).
 Assemble the Drum retaining nut.
 Put the Retaining Washer on top of the
Mainshaft and secure it with the Retaining
Screw.
 Insert the Cap, with o-ring, into the Drum.
Picture 2.3
Deck Seal Assembly
Shaft
Retention Clip
Drum
Picture 2.4
Drum –Retention Clip Assembly
2.5 POWER CONECTIONS TO HYDRAULIC MOTOR
Basic hydraulic schematic is shown in Appendix C.
Port sizes on the hydraulic motor and minimum hose
sizes are specified in Section 1.3.
After connecting the power lines, spray all ports and
fittings with anti-corrosive waterproof coating, “CRC
3013 Soft Seal” or equivalent.
2.6 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 vessel’s 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
might cause an adverse effect to the rest of the
electrical system on board. See specifications for
! The selection of the type of motor starter
should be done by a qualified 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 capstans.

7
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 benefit 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 benefits like:
 infinite speed control
 running the windlass over its nominal speed
 accurate current overload and thermal overload
2.7 POWER CONECTIONS 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 fitting
must fit 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 as per
motor nameplate or motor card. Fit link plates
correctly, if required. 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 (see wiring diagram in Appendix C).
Our AC motors are equipped with a disc brake to
stop back winding when the windlass stops under
load. The brake should be wired as follows:
‘Direct on Line’ start, single speed motor
On single speed motors, the brake rectifier is already
connected to motor terminal block and no additional
wiring is required.
‘Direct on Line’ start, dual speed motor
In case of using a two-speed, pole changing motor, a
separate power supply for the brake is required.
Remove the existing connection from motor
terminals to the brake rectifier and bring in brake
power supply from contactor in the starter unit (see
wiring diagram of DOL starter in Appendix C).
VFD controller
If the VFD, controller is used, the brake also needs a
separate power supply from the VFD unit to ensure
appropriate timing of engaging and disengaging the
*Brake supply contactor should work in parallel
With motor supply contactor. The contacts
Should be suitable to open very inductive
loads
Picture 2.5
Brake Connections

8
brake. As above, remove the existing brake power
supply and connect the brake to the appropriate
terminals in the VFD unit (see wiring diagram of VFD
unit, supplied with the unit).
Replace the terminal box cover and sealing gasket.
Evenly tighten the four securing screws.
Check:
Is the direction of rotation of the motor correct?
Are cables satisfactorily fixed and out of the path
of chain?
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.
2.8 INSTALLATION OF CONTROLS
The recommended way of controlling a mooring
capstan is by footswitch. The footswitches are
available from Maxwell with plastic or stainless steel
covers.
An isolator switch for footswitches must be installed
in the wheelhouse, to prevent operating the capstan
by someone accidentally stepping on a footswitch.
Refer to wiring schematics in Appendix C for control
circuits. All control wiring should be done using no
smaller than 1.5mm² wire (AWG 16).
A manually re-settable, ignition proof 3A breaker or
fuse should be installed on the power supply line for
controls, within 1m (40”) from the main
breaker/isolator. These requirements are mandatory
to meet USCG, ABYC and NMMA rules.
After connecting the power lines, spray all ports and
fittings with anti-corrosive waterproof coating “CRC
3013 Soft Seal” or equivalent.
2.9 NOTE TO BOAT BUILDER
Experience has shown that, on long ocean
deliveries, sulphur from the ship’s exhaust can settle
on polished surfaces, which can affect the quality of
the finish.
Please ensure that, upon completion of installation,
the capstan is treated with suitable corrosion
protective coating (“CRC 3097 Long Life”) and
wrapped in plastic film. This ensures that your
customer receives the capstan from you in the same
top quality condition as you received it from Maxwell.

9
3.0 USING THE CAPSTAN
3.1 PERSONAL SAFETY WARNINGS
 As with all load carrying equipment, the
consequences of heavy overload, neglect or
misuse may be unexpected failure and exposure
of crew and/or vessel to risk. Operate the
capstan with extreme care at all times.
 Before testing the capstan for the first time,
check that all the wiring has been done correctly.
 When using the capstan at all times practice
good seamanship and adhere to the following
rules in order to avoid any likelihood of injury.
 For DC powered capstans, run the engine whilst
using the capstan. This is not only a safety
precaution but also helps minimise the drain on
the batteries.
 Do not use capstan as a bollard or mooring
point. When at the dock, always tie off directly to
a bollard or sampson post.
 At all times keep hands, feet, loose clothing,
cordage, your hair and other people on board
WELL CLEAR.
 When the capstan is not in use, make sure the
power supply is isolated, making an accidental
operation thereby impossible.
 The circuit breaker/isolator (DC powered
capstans only) provides high current protection
for the main supply cables as well as the means
to isolate the circuit.
! Use only clockwise rotation for handling
3-ply twisted rope, otherwise problems may
occur in laying the rope.
! If using the capstan for hauling an anchor
line, make sure the other end of the line is
securely fastened to the boat.
3.2 OPERATING THE CAPSTAN
 Turn “on” the breaker/isolator for main power
supply and the isolator for footswitches.
 Wrap several turns of line around the drum.
Make sure the drum is operated in the same
direction as the line is wrapped around it.
 Whilst pulling on the tail of the line, press the
footswitch. The capstan will start rotating.
Increasing and decreasing the load (tension) on
the tail will control the amount of slip and
therefore the speed at which the line will be
hauled in.
 The grip can be increased by adding extra turns
of line around the drum. Do not put too many
turns around it; this could result in line not being
able to slip even if the tail is loose.
 Whilst docking, wind and tide can impose
sudden and excessive line tension. It is
recommended to allow slipping to occur at the
drum. This will protect the capstan, docking lines
and vessel from damage.
 After hauling the rope, it should be transferred to
a bollard to relieve the load from the capstan.
 To operate a dual speed capstan at higher
speed, both “slow” and “fast” footswitch should
be pressed.
 When finished, turn off the isolator switch.
! As a safety feature the contacts on
footswitches are non-latching and the capstan
will continue to operate up or down only while
the switch is physically held in the engaged
position.
! Maxwell recommends all warping operations
be controlled by the footswitch. This makes it a
one-person operation and offers better control
of the capstan in case of emergency.
! Take care not to allow “riding turns”. This is
caused by the loaded line climbing on top of
lower loaded coils on the drum. A riding turn
can only be removed by paying the line out to
the point where the riding turn is created.

10

4.0 MAINTENANCE

! Failure to carry out the maintenance and
service, as described herein, will invalidate
warranty.
! Before doing any maintenance work on electric
motor, starter units and wiring, make sure the
power supply is switched off.
! Use synthetic oils only. Never mix two oils,
even if they are from the same manufacturer.
4.1 CAPSTAN MAINTENANCE

Every six months disassemble the above deck
components of the capstan (up to the Deckplate) as
described in Section 2.3. Clean all components and
check for damage. Grease the components using
lithium complex base, water proof grease.
Clean chromed surfaces with a cloth, damp with
kerosene. After cleaning spray them with “CRC 3037
Long Life” or alternatively, with “CRC 6-66” or “WD-
40”. Regular use of “CRC3097 Long Life” will assist
in maintaining the bright chrome finish.
Apply anti-seize compound on screw threads and
keyways.
Re-assemble in the reversed order.
Inspect the components below deck for corrosion,
chipped paint etc, clean them and touch up the paint
if necessary. Spray them for protection with “CRC
3013 Soft Seal”.
Check the electric power connections and spray
them with “CRC 3013 Soft Seal” for protection.
Check the oil level in gearbox and top up if
necessary. The oil in the gearbox should be changed
every 3 years. The quantity is indicated in Section
1.3.
The gearbox is a sealed unit. The motors can be
detached safely, without draining oil from the
gearbox. If removing the motor, spray its shaft with
an anti-corrosion spray before reassembling. The
drive pin is press fit into the motor shaft and can be
replaced if necessary.
4.2 RECOMMENDED LUBRICANTS

Greases
- Lithium complex base NLGI consistency No. 2
 CASTROL LMX
 DUCKHAMS Keenol
 FINA CERAN WR 2
 SHELL Retinex LX
 MOBIL Mobilgrease HP
Gearbox Oils
- ISO 3448 VG 150
 CASTROL Alpha MAX 150
 SHELL Omala Oil 150
 MOBIL Mobilgear 629
 BP MACH GR XP 150
 FUCHS Renolin CLP 150
Anti-Corrosive Coatings
 CRC 3013 Soft Seal
 Boeshield T9
 Lanocote

11
Anti-Seize Coating
 International Paints Res-Q-Steel
Never mix greases, use only one type. If in doubt,
remove the previous lubricant and clean the parts
thoroughly before applying the new one.
4.3 SPARE PARTS

Maxwell recommends a modest quantity of spare
parts to be ordered as familiarity with the capstan is
developed during installation. As small parts can be
lost during maintenance, keeping spares (and spare
tools) is recommended.
We recommend the following list of spare parts per
capstan to be carried on board:
Part No. Description Qty
P104751 Kit_ SS Cap (Ø80) and O-Ring
Includes:
4809 Cap 1
SP2769 O-Ring 1
2689 Retaining clip 2
3005 Drum key 1
If any other spare part is required, please refer to
Appendix B for the correct part number and contact
one of our distributors worldwide (Appendix D).
When ordering spare parts, please quote:
Capstan model
Serial number of the capstan
Part number (see Appendix B)
Part description
Quantity required
4.4 TOOLS FOR MAINTENANCE

We recommend the following tools be kept on board
for disassembling and assembling the capstan:
Set of metric hexagon keys (Allan keys),
sizes 8 and 10mm
Ring / open end spanner 17, 19 and 24mm
Flat screwdriver 10mm blade width
Circlip pliers

12
5.0 TROUBLESHOOTING
Problem
Possible Cause
Solution
Capstan does not rotate.
No electric power to controls.
Make sure the isolator switch for the
capstan controls is ON.
Check the fuse on power supply to
controls.
Make sure the wiring is correct and
check it for damage.
Check the power supply to controls
from the source, step by step, and
identify the point where it stops.
Incorrect or incomplete wiring.
Check wiring against diagrams
supplied.
No power supply to the capstan.
Check power supply lines.
Check main isolator switch.
Check hydraulic pump.
Capstan is not able to pull the
specified load.
Hydraulic relief valve not set
correctly.
Check valve setting.

13
APPENDIX A –Dimensional Drawings

14

15

16
APPENDIX B –Spare Parts –Topworks
Item No.
Description
Part No.
Qty
1
Cap
4809
1
2
O-Ring
SP2769
1
3
Bolt –Hx. Hd. M10 x 25 s/s
SP0281
1
4
Retaining washer
2680
1
6
Drum retaining nut (Stainless Steel)
5310
1
7
Drum (Stainless Steel)
5499
1
8
Cap Screw –M12 x 40
6417
8
9
Spring Washer - M12
SP0475
16
10
Insulating Bush
3012
8
11
Hex. Hd. Bolt –M12 x 70
SP3021
8
12
Topworks key
3005
1
13
Retaining Clips
2689
2
14
Deck Seal
SP0719
1
15
Deck Bearing
3004
1
16
Deckplate (Stainless Steel)
5559
1
17
Deck Gasket / Sealant
3978
1

17
Bottomworks –AC
Electric AC Drive Electric AC Drive
–Vertical Motor –Horizontal motor
Item
Description
Qty
Part no.
50
Mainshaft
1
6021
51
Spacer tube
1
5329
52
Spring washers M12 SS304
10
SP0475
53
Bolt - Hex Hd - M12 x 40 SS304
10
SP0299
54
Label
1
3041
55
Hammer screw
2
SP0523
56
Gearbox
AC - vertical
AC - horizontal
1
1
SP3307
SP3318
57
Bolt - Hex Hd - M14 x 50 SS304
4
SP0294
58
Spring Washer –M14
4
SP0481
59
Hex Hd Nut –M14
4
SP0336
60
Motor
400V 50Hz
400V 50Hz 2 Speed
1
1
SP3390
SP3322

18
Spare Parts –Hydraulic Bottomworks
Item No.
Description
Part No.
Qty
51
Spacer tube
5329
1
52
Spring washer –M12 s/s
SP0475
10
53
Bolt –M12 x 40 s/s
SP0299
10
54
Gearbox/Motor/Shaft
Low flow I
High flow I
High flow L
P104002
P104003
P104116
1
1
1