Maxwell VWC 1000 50TDC User manual

1000 & 1500 Windlass
Manual

VETUS–MAXWELL APAC Ltd
Copyright Vetus-Maxwell APAC Ltd. All rights
reserved.
Vetus-Maxwell APAC Ltd reserves the right to make
engineering refinements on all products without notice.
Always consult manual supplied with product as details
may have been revised.
Illustrations and specifications are not binding as to
detail.
P103103 Rev.5.00 01/10/12

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 1
Table of Contents
Preliminary Information .............................................................................................................. 2
Introduction............................................................................................................................... 2
Components ............................................................................................................................. 2
Important Safety Information .................................................................................................... 3
Parts of the Windlass ............................................................................................................... 4
Parts of the Gearbox ................................................................................................................ 8
Ordering Spare Parts.............................................................................................................. 10
Chain Selection Guide............................................................................................................ 11
Installation.................................................................................................................................. 12
General Requirements ........................................................................................................... 12
Installation Instructions ........................................................................................................... 13
Wiring Instructions.................................................................................................................. 16
Operation.................................................................................................................................... 21
Anchoring Tips........................................................................................................................ 21
Lowering the Anchor............................................................................................................... 21
Raising the Anchor ................................................................................................................. 21
Free falling the Anchor ........................................................................................................... 22
Raising the Anchor Manually .................................................................................................. 22
Using the Warping Drum ........................................................................................................ 22
Maintenance ............................................................................................................................... 23
Trouble Shooting Guide............................................................................................................ 25
Reference Information............................................................................................................... 26
Specifications ......................................................................................................................... 26
Dimensions............................................................................................................................. 27
Typical Greasing Instructions ………………………………………………………………………28
Additional Resources
The following resources are included at the back of this manual:
Deck Cutout Details
Warranty Form
Contact Details (on back cover)
Note: For your nearest retailer, service agent or representative please refer to our website
www.maxwellmarine.com

21000 1500 Windlass Vetus-Maxwell APAC Ltd
Preliminary Information
Introduction
Congratulations on your purchase of a Maxwell windlass. Please read these instructions carefully to
enable you to correctly install and maintain the windlass for years of trouble-free operation.
Note
Failure to follow the correct installation, operation or maintenance instructions will jeopardise your safety
and could invalidate the warranty.
Components
In addition to this instruction manual, the following components may be included with the windlass:
•Windlass
•Remote up/down control panel
•Circuit breaker/isolator panel
•12V or 24V reversing solenoid
•Clutch Lever
•Deckplate gasket
•Motor Bolt Kit
•Template (At rear of manual)
•Small parts:
•Nuts
•Flat washer
•Spring washer

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 3
Important Safety Information
•Make sure your windlass has been correctly specified before installation - Personal safety may
depend on it. The windlass must have a maximum pull capacity of at least three times the
combined weight of the anchor and chain.
•For automatic operation to be possible, the anchor must be self launching.
•Never use the windlass under power with the lever inserted in the clutch nut.
•Keep hands, feet, loose clothing and hair well clear of the windlass and rope/chain during
operation.
•While raising the anchor, run the boat's engine above idle. This will minimise the power drain on
the batteries.
•Never operate the windlass from a remote station without having a clear view of the windlass.
•When operating the chainwheel pawl, keep fingers away from incoming chain.
•Do NOT use the windlass as a mooring point. When anchoring or mooring, secure the line directly
to a bollard or deck cleat.
•Do NOT use the windlass to pull the boat forward when raising the anchor. Use the boat's engine
to drive the boat up to the anchor.
•Do NOT attempt to break free a fouled anchor with the windlass. Secure the line to a bollard or
cleat and use the boat's engine to break the anchor out.
•Always firmly tie down the anchor when under way or in heavy seas. Do not rely on the windlass as
a securing device.
•Always turn the circuit breaker/isolator switch off when the windlass is not in use and before you
leave the boat.
•Tie the end of the anchor chain rode to a secure fixture in the chain locker.
•Do NOT use the windlass to haul a person up a mast.

41000 1500 Windlass Vetus-Maxwell APAC Ltd
VW and VWLP Windlass Parts
Fig 1: VW and VWLP Windlass Parts

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 5
VW and VWLP Windlass Parts
Item No. Component description Qty Part to order Includes items
1 Cap 1 P101615 1,3,4,7,10,15,25(x2)
2 Label - 1000 1 6424 2
Label - 1500 1 6425 2
3 Screw - 3/8" x 1" 1 P101615 1,3,4,7,10,15,25(x2)
4 Washer 1 P101615 1,3,4,7,10,15,25(x2)
5 Clutch Nut 1 *P101621 or P101622 1,2,5
6 Drum - VWC 1 3436 6
7 Circlip 1 P101615 1,3,4,7,10,15,25(x2)
8 Clutch Cone 2 P101623 8(x2)
9 Chainwheel 1 3173 9
10 "V" Ring Seal 1 P101615 1,3,4,7,10,15,25(x2)
11 Retaining Collar 1 **P101664 or P101665 or P101666 11,28,29
12 Emergency Crank Lever 1 P20044 12
13 Pin - Pawl 1 P101620 13,14,15
14 Pawl 1 P101620 13,14,15
15 Washer 1 P101615 1,3,4,7,10,15,25(x2)
16 Cheese Head Screw - M8 x 16 2 P101626 16(x2),17(x1)
17 Stripper 1 P101626 16(x2),17(x1)
18 Deckplate 1 **P101627 or P101628 or P101629 11,18,20(x4),21(x4),22(x4),23(x4),28,29
19 Gasket 1 3474 1
20
Stud - 50TDC 4 P101612 20,21,22,23
Stud - 100TDC 4 P101613 20,21,22,23
Stud - 150TDC 4 P101614 20,21,22,23
21 Washer 4 **P101612 or P101613 or P101614 20,21,22,23
22 Spring Washer - 3/8" 4 **P101612 or P101613 or P101614 20,21,22,23
23 Nut - 3/8" 4 **P101612 or P101613 or P101614 20,21,22,23
24
Shaft - VW - 50TDC 1 6152 24
Shaft - VW - 100TDC 1 6151 24
Shaft - VW - 150TDC 1 6150 24
Shaft - VWLP - 50TDC 1 6203 24
Shaft - VWLP - 100TDC 1 6204 24
Shaft - VWLP - 150TDC 1 6205 24
25 Key - VW 2 P101615 1,3,4,7,10,15,25(x2)
25 Key - VWLP 1 P101615 1,3,4,7,10,15,25(x2)
26 Circlip 1 P101619 26,27,38,41
27 Key 1 P101619 26,27,38,41
28 Bearing 1 **P101664 or P101665 or P101666 11,28,29
29
Spacer Tube - 50TDC 1 **P101664 11,28,29
Spacer Tube - 100TDC 1 **P101665 11,28,29
Spacer Tube - 150TDC 1 **P101666 11,28,29
30 Locknut 1 P100088 30,31,32
31 O-Ring 1 P100088 30,31,32
32 Collar 1 P100088 30,31,32
33 Gearbox - 1000 - 44:1 1 P100900
Gearbox - 1500 - 56:1 1 P102730
34
Motor - 12v - 1000W - with 1000 VWC/VWLP 1 P11112 34
Motor - 24v - 1000W - with 1000 VWC/VWLP 1 P11114 34
Motor - 12v – 1200W - with 1500 VWC/VWLP 1 P11165 34
Motor - 24v - 1200W - with 1500 VWC/VWLP 1 P11166 34
Motor - Hydraulic 1 P14366 34
35 Bolt - Hex Hd M8x25 - With 12 or 24V Motor 2 P12487 35(x2),36(x2),37(x2),42(x1)
36 Washer - Spring - M8 -With 12 or 24V Motor 2 P12487 35(x2),36(x2),37(x2),42(x1)
Washer - Spring - M8 -With Hydraulic Motor 2 P12488 36(x2),37(x4),39(x2),40(x2)
37 Washer - Flat - M8 -With 12 or 24V Motor 2 P12487 35(x2),36(x2),37(x2),42(x1)
Washer - Flat - M8 -With Hydraulic Motor 4 P12488 36(x2),37(x4),39(x2),40(x2)
38 Clip 1 P101619 26,27,38,41
39 Bolt - Hex Hd M8x30 - With Hydraulic Motor 2 P12488 36(x2),37(x4),39(x2),40(x2)
40 Nut - M8 - With Hydraulic Motor 2 P12488 36(x2),37(x4),39(x2),40(x2)
41 Tension Pin 1 P101619 26,27,38,41
42 O-Ring 1 P12487 35(x2),36(x2),37(x2),42(x1)
**P101621 = 1000, P101622 = 1500
**P101627 = 50mm TDC, P101628 = 100mm TDC, P101629 = 150mm TDC
**P101612 = 50mm TDC, P101613 = 100mm TDC, P101614 = 150mm TDC
**P101664 = 50mm TDC, P101665 = 100mm TDC, P101666 = 150mm TDC

61000 1500 Windlass Vetus-Maxwell APAC Ltd
VWC and VWCLP Windlass Parts
Fig 2: VWC and VWCLP Windlass Parts

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 7
VWC and VWCLP Windlass Parts List

81000 1500 Windlass Vetus-Maxwell APAC Ltd
Gearbox Parts (44:1 & 56:1)
Fig 3: Gearbox Parts (44:1 & 56:1)
Drainage Slot
Location of serial number

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 9
Gearbox Parts List (44:1 & 56:1)
Item Component description Qty Parts to order Includes items
50 Oil Seal
2
P90006
50(x2),52,56,57,64
51 Gearbox Top
1
P101624
51,53
52 O-ring
1
P90006
50(x2),52,56,57,64
53 Bush 2 3145
54
Wormwheel 44:1
1
3403
Wormwheel 56:1
1
3584
55
Capscrew - M6 x 40
4
SP0159
56
Sight Glass
1
P90006
50(x2),52,56,57,64
57 O-Ring 1 P90006 50(x2),52,56,57,64
58
Wormbox
1
P101625
53,58
59
Bearing
1
P90007
59,61,62,63
60
Worm 44:1
1
5950
Worm 56:1
1
3400
61 Bearing 1 P90007 59,61,62,63
62
Circlip
1
P90007
59,61,62,63
63
Circlip
1
P90007
59,61,62,63
64
Oil Seal
1
P90006
50(x2),52,56,57,64

10 1000 1500 Windlass Vetus-Maxwell APAC Ltd
Ordering Spare Parts
When ordering spare parts, please refer to the parts list above and quote the following details.
Windlass Model
VWC
VWCLP
VW
VWLP
50TDC
100TDC
150TDC
Serial number (located on gearbox housing – Fig 3 Page 8)
Power supply
12V
24V
Hyd
Part details
Part number Description Quantity
Refer back cover for contact details.

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 11
Chain Selection
THE MAXWELL WINDLASSES ARE DESIGNED FOR ALL CHAIN SYSTEMS USING: 6-10mm (1/4” –
3/8”) short link
Your Windlass should have a rating of approximately 3 times total combined weight of the anchor and
chain.
The ground tackle should have been selected taking into account:
a) Boat size, displacement and windage.
b) Conditions of operation such as maximum depth of water, type of bottom and weather conditions.
c) Holding power and size of anchor, taking special note of the manufacturers’ recommendations.
CORRECT FIT OF CHAIN TO CHAINWHEEL IS ESSENTIAL FOR THE WINDLASS TO OPERATE
PROPERLY.
A range of chainwheels is available to suit your windlass.
The correct fit can only be guaranteed where a standard chain known to us is used. Alternatively a
450mm (18”) or 12 links (whichever is longer) sample must be forwarded to us to match fit. Where
patterns to suit are not held by us we are able to manufacture to instructions and reserve the right to
charge cost thereof.
THE WINDLASS SHOULD BE USED IN CONJUNCTION WITH A MAXWELL CHAIN STOPPER, OR
SNUBBER, OF THE APPROPRIATE SIZE.

12 1000 1500 Windlass Vetus-Maxwell APAC Ltd
Installation
General Requirements
Foredeck layout
Make sure that the area of deck between the windlass and the bow roller is clear of obstructions.
The bow roller should have a central groove suitable for the chain size.
Use a chain guide if necessary to prevent the chain from running against the deckplate and potentially
causing damage to the windlass.
Anchor and chain considerations
When purchasing an anchor, make sure it fits into the bow roller and is self-launching.
Use a swivel between the anchor and the chain to prevent the line from twisting as the anchor is raised or
lowered.
To prevent build up of chain on deck causing possible damage, the bow roller must allow the anchor to
free fall immediately when the anchor is deployed.
Make sure that at least three links of chain are exposed when the anchor is docked.
The chain must gravity feed into the locker. If the chain outlet cannot be positioned directly over the
locker, heavy wall flexible plastic pipe can be used to direct the chain to the required area. It is important
that the chain slips through easily, completely unaided. It may be necessary to provide the pipe with a
bell mouth or to bell mouth the entrance to the chain outlet from the locker to assist the free flow of the
chain from the locker.
NOTE: Make sure you securely fasten the end of the chain to the boat.
Required clearances
Ideally the outlet for the chain should be directly over the chain locker. The chain should have at least
300mm (1ft) clear fall to allow the chain to straighten before passing through the windlass.
Position the windlass clear of pulpit, lifelines and bulwark so that there is room to swing the Clutch Lever.
Refer to Figures on page 27 and 28 for overall dimensions
The chain locker must be of such a size that the chain will heap up and feed out naturally without fouling
the windlass motor.
Allow access for conveniently connecting the supply lines under deck after the windlass is bolted in
position.
It should be noted that the gearbox can be indexed at different positions in relation to the deck plate. Be
sure to select the most convenient position and allow for the best run for the chain to clear the motor.
Aligning the windlass
“UP” is the clockwise rotation when looking down on the windlass.
The windlass must be positioned to allow the chain to have a clear run from the bow roller to the
chainwheel.
The deck plate should be mounted pointing in the direction of the incoming chain and with the left hand
side parallel to the line of the incoming chain. This arrangement allows the chain to have maximum
engagement with the chainwheel.
The bow roller should have a vertical groove to suit the profile of the chain. This will align the chain so
that it enters the chainwheel without twisting.

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 13
Installation Instructions
Before you start
Before installing the windlass, identify any bulkheads, wiring or piping under the deck. This may
determine where the windlass can be positioned. Ensure the deck is flat, if not; a plinth will be required to
ensure the windlass sits on a flat surface.
If the windlass is installed horizontally, on a bulwark (mainly VW type), make sure that the gearbox is
installed with worm on the lower side to ensure good lubrication of the gears. The stripper should also be
positioned at the lowest end of the deckplate
Deck thickness
It is imperative that the deck and under-deck pad (not supplied) are of sufficient thickness and structural
strength to support the loads imposed on or by the windlass.
An under-deck pad should spread the load as widely as possible.
Preventing electrolysis
For aluminium boats, it is essential that the deckplate be insulated from the deck with a non-conductive
gasket (not supplied), that the mounting studs pass through insulators (not supplied), and that the under-
deck fastenings are insulated from the deck with fibre washers (not supplied).
It is also important that the anchor and chain are insulated from the hull, including rubber lining the chain
locker and insulating the fixing for the end of the rode to the hull.
Without these precautions, severe electrolysis can occur.
Because the motor is of the isolated earth type, it is not necessary to separately earth the windlass.
Locating the chain stopper
The chain stopper should be positioned and aligned in a convenient position between the windlass and
the bow roller, so that it clears the anchor stock. The chain should pass through the stopper without
being deflected.
Installation procedure
** ATTENTION**
Please note, when installing winch and in particular the chain wheel. The shaft and bronze clutch cones
MUST be coated in Shell Nautilus NLG12 Marine Grease, Castrol Boating Grease, Valvoline Val Plex EP
or equivalent grease. See “Typical Greasing Instructions” on Pg 30.
1. Use the Deck Cutout Details drawing as a guide for marking and cutting the holes.
Tip: On GRP boats, running the drill in reverse first will reduce chipping of the gel coat.
Using hole saws, cut the holes for the spacer tube and chain pipe.
2. On GRP or wooden decks, seal the edges of the holes with epoxy to avoid ingress of moisture.
3. Remove the gearbox from the spacer tube by undoing the Locknut. With gearbox held horizontally,
check that oil is showing half way up the sight glass. If necessary, top up with SAE 90 (Shell
Omala 320, Castrol Alpha SP320 or equivalent), by removing the sight glass and adding the
required amount. DO NOT OVER FILL!
4. Use the gasket supplied to seal the windlass to the deck. For aluminium boats fit a non-conductive
gasket to insulate the deckplate from the deck to prevent electrolysis.

14 1000 1500 Windlass Vetus-Maxwell APAC Ltd
5. Fasten the windlass to the deck using the nuts and washers
supplied. Tighten the nuts progressively and evenly. Do NOT use
power tools. Make sure the installation is firm, but do not over tighten
the nuts.
6. Smear a coating of grease on the shaft and spacer tube. Fit the
gearbox/motor assembly to the bottom of the spacer tube. Orientate
the motor away from the incoming chain and then tighten the plastic
locknut by hand.
NOTE: If the unit is going to be mounted in such a way, that it may
be tilted, ensure the drainage slot on the gearbox is at the lowest
point to prevent excess water etc. sitting around the seals.
Drainage Slot
7. Rotate the shaft by hand (or by using the manual crank handle) to
align the keyway in the shaft with the keyway in the gearbox. Insert
the key into the keyway.
8. Fit the quick-release clip into the groove in the bottom of the shaft to
secure the key. Make sure the eyelets are facing down and away
from the keyway.
9. When tightening the cables to the motor, ensure the lower nut is
secure against turning when tightening the upper nut. This will
prevent damage occurring within the motor.
Upper Nut
Lower Nut

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 15
Assembling the chainwheel.
Refer Fig 1, page 4 for VW and VWLP Windlass and Fig 2, page 6 for VWC and VWCLP Windlass
1. With a pen knife or similar, carefully remove the Cap.
2. Remove the screw and retaining washer.
3. Remove the Clutch Nut, drum (except for low profile) and upper clutch cone.
4. Remove the stripper arm by undoing the two screws.
5. Grease the two clutch faces of the chainwheel and insert with the side that has two holes facing
upwards.
6. Assemble the components in the reverse order they were removed.
Assembling the motor.
1. Bring the motor up to the gearbox and align the roll pin with the slot in the worm.
2. Use parts from the “motor bolt kit” to assemble as per diagram on page 4.
Installing on a sloping or curved deck
Ensure that the windlass has the correct vertical alignment with the bow roller. If necessary, use a
mounting pad.
Important note to Boat Builders
Experience has shown that on long ocean deliveries as deck cargo, sulphur (from the ships exhaust and
condensation) settles and severely damages the chrome plating and stainless steel of the windlass by
breaking down the protective chrome oxide film.
We recommend, after completing installation, you spray the top works of the windlass with CRC 3097
“long life” and wrap the windlass with plastic film and tape.

16 1000 1500 Windlass Vetus-Maxwell APAC Ltd
Wiring Instructions
Electrical component layout
Figure 3 - Electrical component layout
Solenoid pack
The solenoid pack should be located in a dry area (not in the chain locker) close to the windlass.
Circuit breaker/isolator panel
This unit provides limited protection for the motor and full protection for the power supply cables. It also
provides the means to isolate the system from the battery.
Position the circuit breaker/isolator no further than 1.8 m (6 ft) away from the battery in an accessible and
dry location.
This equipment or equivalent is mandatory to meet USCG requirements.
Remote control panel
The remote control panel should be mounted in a convenient location (such as the bridge, helm or
cockpit) so that the operator can see the windlass. Mount and seal the panel so that the terminals project
into a dry area.
Optional footswitches
For safe operation, the footswitches must be at least 500 mm (20") from the windlass.
The below-deck part of the footswitch must be in a dry environment and the breather holes must be kept
clear.
The arrows on the footswitches should be arranged to indicate the direction of operation.
Circuit breaker/isolator
Battery
Remote control
panel
Footswitch
Solenoid pack

Vetus-Maxwell APAC Ltd 1000 1500 Windlass 17
Wiring schematic (series wound motor)

18 1000 1500 Windlass Vetus-Maxwell APAC Ltd
Wiring schematic (Hydraulics)