Muir VRC4500 Quick guide

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VRC4500 - VERTICAL WINDLASS
INSTALLATION AND INSTRUCTION MANUAL
(MUST BE READ PRIOR TO INSTALLATION AND OPERATION)
DESIGNED, MANUFACTURED AND SUPPLIED BY:
Muir Engineering Group Pty Ltd (HEAD OFFICE)
100 Browns Road, Kingston 7050 Tasmania Australia Tel:
ITN’L (61-3), AU [phone]
Fax: ITN’L (61-3), AU [phone]
Email: [email protected] Web: www.muir.com.au
T h e w o r l d p o w e r i n w i n d l a s s e s & a n c h o r i n g s y s t e m s

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CONTENTS
SECTION 1 SYNOPSIS
Scope of supply
SECTION 2 GENERAL DESCRIPTIONS
Line Type
Gearbox Description
Motor Description
SECTION 3 WINDLASS INSTALLATIONS
Installation
Operation
Safety
Maintenance
Lubrication
Bolt Torque Settings
SECTION 4 APPENDIXES
Motor Specifications
Gearbox specifications
Exploded / general layout drawings
Warranty

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SCOPE OF SUPPLY
Equipment Supplied includes the following items
GENERAL DESCRIPTION
The VRC4500 Model Vertical Windlass is powered by an electric motor through a single stage
worm drive reduction. The windlass consists of a gypsy and capstan mounted on a stainless steel
drive shaft supported by low friction bearings, mounted on a Stainless Steel base plate.
The clutch handle fitted into the Clutch Nut is used to de-clutch the drive and free wheel the chain
gypsy. The brake band controls the run of the anchor and chain. The capstan is keyed directly to
the drive shaft and the gypsy is driven by engaging the clutch. All components are of bronze or
stainless steel construction.
LINE: 12.5mm U2 (Kenters)
GEARBOX:
Manufacturer: STM
Description: Single Stage 90 Degree Worm Wheel Gearbox
Model: RMI 110 F2
Ratio: 70:1
MOTOR:
Manufacturer: WEG
Model: 440V / 4kW / 3Ph / 50Hz
ITEM / FEATURE
DESCRIPTION
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6 x VRC4500 Vertical Windlass
Fitted with a single gypsy.
Gypsy to suit 12.5mm U2 STUD LINK
Fluted Capstan Finish
Electric Motor
Cone Drive
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Polished 316 Stainless Steel Finish
3
Stainless Steel Clutch handle
4
35 degree Brake
5
Installation manuals

VRC4500/5000 VERTICAL WINDLASS INSTALLATION
4
LOCATING THE WINDLASS
When installing the windlass it is important to consider the
following requirements for efficient operation of the whole
anchoring system.
A clear and horizontal Chain Path
Correct Positioning and Locker Depth
Ma imizing the Wrap of Chain around the Gypsy
Position of the Motor and Gearbo Under deck
Insulation of Dissimilar Metals
The windlass should be positioned centrally over the chain
locker. This helps to ma imize the fall of chain down to the
locker as it piles up when retrieving the anchor (See the fall
depth table).
It is a common mistake to locate the windlass too far
forward, or too close to the bulk head, where there is
insufficient room for the chain and anchor stowing. In
installations where this is not possible a length of 'lead in'
tube with a belled end and a bore of at least 2 times the
chain width can be used to guide the chain to the centre of
the chain locker. This e tension needs to be a minimum of
45
0
to 90
0
from the under deck. Angles less than 45
0
will
increase chain drag within the tube.
The gear drive can be fitted in multiple positions to allow the
chain to fall away from the motor. If the motor is positioned
near the falling chain then the lead in tube is also
recommended to protect the motor from water.
Chain Size
Minimum Fall De th To
To Of Hea ed Chain
Up to 1/2” (13mm) 36” (914mm)
5/8” to 7/8”(16 to 22mm) 48” (1220mm)
1” (25mm) and Above 48” (1220mm) or Greater
When fitting the base plate all mating surfaces should be
coated with sealant, to ensure enough is applied allow it to
squeeze out as the mounting bolts are tightened.
After fitting the base plate in the desired position the
windlass can be reassembled using the assembly
instructions on the following page.
The chain pipe should be fitted last making sure to match the
height of the chain from the gypsy. Ideally this should line up
with the chain after it has wrapped 180 degrees around the
gypsy; this angle of wrap should not be less than 140
degrees for the correct operation. Refer to diagram in
appendi for correct chain pipe and peeler setup
If the windlass is to be mounted on a steel or alloy deck an
insulator, preferably some form of rigid plastic must be used
to avoid contact of dissimilar metals. It is also advisable to
insulate the mounting bolts with plastic sleeves.
If the vessel has a curved deck an appropriately shaped
mounting block must be used.
Reassemble the windlass, fitting the shaft and top assembly
complete, (refer e ploded view) using a waterproof grease to
lubricate all parts and running gear.
It is important to thoroughly lubricate all mating surfaces with
grease suitable for marine applications before use. As the
windlass will be operating in an e tremely corrosive
environment it is also highly recommended that corrosion
protection be used on the e ternal surfaces of the motor,
gear drive and adaptor, and also in any areas where water
may lie to protect against moisture in the chain locker (See
the maintenance section for additional information).
ELECTRICAL INSTALLATION
Ensure all wiring is completed as per supplied wiring
diagram and that all circuit components and wire is suitable
for the system rating. To maintain the manufacturer’s
warranty on the windlass a suitably rated overload protection
must be installed to protect the motor.
HYDRAULIC INSTALLATION
To ensure minimal pressure loss or heat build up, it is
recommended that hydraulic piping of the following minimum
size is used.
Length of Line
Pi e S
ize (Outside Diameter)
Up to 30’ (9.1m) 5/8” (16mm)
Over 30’ (9.1m) 3/4” (19mm)
To maintain the manufacturer’s warranty on the windlass a
pressure relief valve must be installed to the hydraulic circuit.
Muir also recommends that a counterbalance valve be
installed to the hydraulic motor to prevent runback.
4500

VRC4500/5000 VERTICAL WINDLASS OPERATION
5
Note 1: For round base model windlasses the brake locator is mounted to the deck.
Note 2: Tighten and slacken brake band to positions to centralize brake band position before drilling locator to deck.
 This operation can be performed from above and below deck. The deck plate in each case remains in place
 The reduction gear and motor assembly can be removed by first undoing the lock bolt located under the gear
drive in the end of the main shaft.
 By undoing the bolts located between the gear drive and
adaptor flange the reduction assembly can be removed.
(The adaptor is bolted internally to the base plate.)
 To remove the drive shaft and top assembly, first to remove
the drive key from the lower section of the shaft, the top
assembly and running gear can be lifted clear of the base
plate supported by the chain gypsy
DISMANTLING THE TOP ASSEMBLY
COMMISSIONING PROCEDURE
1. Ensure all electrical wiring to controls and motor is completed to the specification outlined in the wiring
diagram supplied.
2. Grease all nipples as shown on the diagram above. (And as describe in page 8).
3. Check that the gear drives is filled with the correct quantity and type of oil as detailed in the Appendi .
4. Disengage the clutch by turning clutch nut anti clockwise.
5. Disengage the brake using hand wheel.
6. Rotate the motor by power or by the motor shaft to ensure windlass is free to rotate.
7. Start the windlass with no load and ensure that direction of rotation is correct and check that windlass is
operating with no undue noise or vibration.
8. Continue running-in the motor and gear drive for 30 minutes. Re check gear drives oil level and grease points.
9. If the torque limiter is present by the factory refer to gearbo information for detail on adjustment
1 The base must secured to the deck using the bolts (studs)
provided. The deck structure must be suitable reinforced to
support the winch. It is important to stiffen the underside of
the deck with a doubling plate.
2 Remove chain pipe and spacer (if fitted) from deck.
Note: During pre-assembly chain pipe, make sure the peeler
lines up with core of the gypsy to ensure correct fitting.
3 Remove bolt and plug from top of the clutch nut.
4 Wind the clutch nut off the shaft anti clockwise then remove
the capstan.
5 Remove the chain gypsy.
6 Remove brake 45 degree hand wheel assembly.
7 Lift the brake band after releasing bracket. Taking care to align
with the brake mount.
8 Lift off bottom cone and remove seal.
9 Remove reduction bo and shaft from deck adaptor by
removing adaptor bolts
10 Remove gearbo adaptor bolts and separate base and
adaptor. Undo the motor mounting bolts and remove the
motor and torque limiter (if supplied). Undo gearbo bolts on
gearbo adaptor and lift off the gearbo .
For gearbo lifting, refer to section 4 – gearbo specification.
GREASE NIPPLES (IF FITTED)
SEE NOTE IN LUBRICATION
SECTION
GREASE NIPPLE

VRC4500/5000 VERTICAL WINDLASS OPERATION
6
BOLT TORQUES
It is important that all bolts are tightened appropriately to ensure service reliability and structural integrity. The
following are suggested torque/preload values for the general bolt sizes found on Muir Windlasses. Muir also
recommends the use of thread locking compounds on threads to reduce loosening and corrosion.
Bolt Tightening Torque and Pre Load
Stainless Steel Class 70 M8 M10 M12 M16 M20 M24
Tightening Torque (Nm) 16.6 35 61.2 152 296.4 512.8
Pre Load (Nm) 10.8 17.2 25 46.6 72.7 104.8
LOWERING THE ANCHOR
It is important that the windlass operator understands
the operation and safety instructions included before
controlling the equipment supplied to ensure safe,
correct and efficient use. Always keep clear of running
gear and chain when operating.
The windlass can be powered up and down; this gives
the option of using the power system to release the
anchor chain, or by releasing the clutch and controlling
the chain release with the brake band.
Before attempting to lower the anchor by the free
wheel method, apply the brake, ensure the gypsy is
disengaged by rotating the clutch nut in an anti
clockwise direction until the dog clutch is clear. The
chain stopping device can now be disengaged (if
fitted), check the area is clear then proceed to lower
the chain and anchor by slowly releasing the brake
and using the brake to control the rate of descent.
Once the anchor is set at the required depth the brake
must be tightened and the chain stopper must be
engaged to take the load off the windlass while at
anchor.
If powering down, engage the clutch drive by turning
the hand wheel in a clockwise direction until the clutch
is engaged, release the brake band by turning the
handle anti-clockwise.
When using the brake, it is first necessary, after
ensuring the brake is applied (turning the handle
clockwise), to release gypsy drive by rotating the
windlass clutch, with the lever handle, anticlockwise.
This applies to both cone and dog clutch.
A chain stopping device must be fitted forward of the
windlass to take the mooring load off the windlass as
this will result in serious damage being done to the
winch.
By slowly releasing the brake the fall of the anchor can
be controlled. Once the anchor is set at the required
depth the gypsy pawl or chain lock ( if fitted) and brake
band can be tightened. It is recommended that a chain
lock be fitted forward of the windlass to take the load
off the windlass main shaft. Do not leave the anchor
load directly on the running gear as this may result i8n
serious damage to the drive gears. Always ensure the
chain lock then the brake band takes the load in that
order.
If this is not possible use a snubber line forward of the
windlass to take loading off the windlass. Make sure
that the brake is fully engaged while at anchor.
RETRIEVAL
Before lifting the anchor ensure the clutch and brake
are fully engaged and locked into position before
releasing chain securing device. Engage the clutch by
tightening the clutch top (turn the lever handle
clockwise). The anchor can now be raised by
operating the control.
Clutch O eration
To ensure correct engaging of the dog clutch is as
follows:
1. Ensure the four drives are aligned correctly
and will not contact when the clutch is
engaged. This can be done in two ways:
-By utilizing the controls to inch the windlass,
or by using the brake to correctly align the
drive.
2. Engage the drive by turning the clutch nut
clockwise until they are fully engaged.
3. Slowly slacken the brake to allow the gypsy to
rotate. This will allow the faces of the drive to
contact and become fully engaged
4. When engaged the brake may be slackened
fully and windlass operated.
The above functions will allow the drive to be
successfully engaged to operate the windlass in the
recovery operation to retrieve the chain. Should the
windlass be required to lower the chain the above
functions must be reversed.

VRC4500/5000 VERTICAL WINDLASS OPERATION
7
RAISING THE ANCHOR
Before lifting the anchor ensure that the clutch is fully
engaged and locked into position before releasing the
brake band and then the chain stopping device.
The anchor can now be lifted by operating the control.
IMPORTANT NOTES ON SAFE OPERATION
The windlass is not to be used for lifting people aloft.
Ensure no one is swimming nearby as anchor is lowered or retrieved.
Ensure that hands, feet, hair and clothing are kept clear of the windlass and chain when in operation.
DOG CLUTCHES DO NOT SLIP: To avoid damage to the gearbo , windlass or vessel by bringing the anchor
up hard against the vessel it is practical to mark the chain in several positions, appro 5 meter intervals from
the anchor to alert the operator to the anchor position. As the anchor breaks the water the control should be
released and the windlass inched until the anchor is in the stowed position.
Under no circumstances should the winch be operated if it is stalled or overloaded.
Never engage the clutch as the anchor is free falling, use the brake band to control the speed.
Engage the chain stopper and devils claw when traveling to ensure that the anchor is held secured
Vessel movement or vibration may cause the anchor to drop whilst the vessel is underway. If a devils claw is
not fitted, a tensioned line must be fitted.
If easy anchor retrieval is impaired by high winds, heavy seas or the anchor is snagged, ease the load by
motoring slowly into the wind. The winch is not designed to proper the vessel.

VRC4500/5000 VERTICAL WINDLASS MAINTENANCE
8
ELECTRIC OR HYDRAULIC MOTORS
Although these motors are water resistant some
protection from the sea air and should be provided by
spraying the outside with water repellent spray every
6-8 weeks or covering the motor with a protective
coating. Any damage to the e ternal paint should be
repaired immediately
GEARBOX
Prior to operating the windlass it is necessary to fill the
gearbo with lubricant to the level mark on the sight
glass. Once filled check the oil level every 6-8 weeks.
Refer to the appendi for gearbo information and
recommended lubrication intervals.
The gearbo assembly is water resistant and should
be protected in the same way as the motor.
CORROSION PREVENTION
As the windlass will be operating in an e tremely
corrosive environment it is highly recommended that
Denso Tape (grease tape) be used on the e ternal
surfaces of the Hydraulic motor, hose ends, gearbo
and adaptor, and corrosion protection be used in any
areas where water may lie (e.g. top of gearbo output
shaft) to protect against moisture. Products such as
TECHTYL under body anti-corrosion film are ideal for
this application.
LUBRICATION
Before using the windlass ensure all grease nipples
are checked and lubricated and that the gearbo is
filled to the required level or quantity.
It is important to thoroughly lubricate all mating
surfaces with grease suitable for marine applications
Greasing points for the various parts of the windlass
are as follows:
1. Brake band Grease ni les: Located on each
brake band lug to lubricate thread and shaft. Apply
1-2 pumps to each. NOTE: Alternate design (NO
GREASE NIPPLES) – disassemble shaft, grease
shaft and brake band lugs, reassemble.
2. Base Grease ni le: Located in the top flange of
the base plate, lubricates the rotation of the shaft in
the base plate bearing. Apply 3-4 pumps.
It is recommended that lubrication is erformed on
a regular basis, at least 4-6 times a year, and
increased if usage is higher than normal.
GENERAL MAINTENANCE
Twice yearly it is recommended that the above deck
running gear is disassembled, all salt crust removed,
the parts thoroughly cleaned, greased and the
windlass reassembled.
It is good practice to wash salt water off all running
parts with fresh water, after every use to avoid
corrosion. The use of a close fitting cover when the
winch is not in use is highly recommended.
Ensure the main drive shaft remains greased at all
times.
Before installation always store the unit vertically or in
a similar position as to install.
RECOMMENDED LUBRICANTS
Worm Wheel Gearbox Oils
Ty e of oil Manufacturer
Tivela S 320 SHELL
Blasia S 320 AGIP
Klübersynth GH 6 320 KLUBER
Glygoyle 320 MOBIL
Alphasyn PG 320 CASTROL
Carter SY 320 TOTAL
A more comprehensive list may be found in the
Appendi es of this manual.
Grease
An e treme lithium based grease with anti corrosion
properties and suitable for marine use is
recommended. E.g. BP Energrease MM-EP2
Hydraulic Fluid
We recommend CASTROL AWS32 or equivalent