500 VW OWNERS MANUAL
Contents
1. 1295 51591 iessooeu pue Buoys ejuepiooe 12810 9 0 5 pue Buu jo sjeuluus Jemod sjuawauinbal DOSN Yum ul jno suoyejjejsui BON UOISIADY UONE OI 9S19A91 0 Z4 O1 yOyimsjoO 3 punom seues TT3MXVN TI3MXVIN 23 500 VW Windlass R320 R259 10 1 5 Extent of Clutch Nut Lever Extent of Motor 101 50 4 578 3 1 18 0 133 5 3 13 245 9 9 14 50 1 31 32 565 2 9 16 150 50 5 12 13 40 1 4 7 55 2 1 6 322 50 12 9 13 172 6 7 9 Figure 1 500 VW Windlass Overall Dimensions 500 VW Windlass 24 25 36 35 34 Figure 2 500 VW Windlass Assembly Drawing 500 VW Windlass 500 VW Windlass Parts No MAU Qty Part to order Includes items 1 Cap 1 P101651 1 4 5 9 22 x2 2 Label 500 1 3356 2 3 Clutch Nut 500 1 P101652 2 3 4 Screw 3 8 x 1 1 P101651 1 4 5 9 22 x2 5 Washer 1 P1012. 30 jeu esodind sayo Aur 10 JOU Isnw 3095000 jnouyA s1012euo2qns Bu suosad Aue 0 parg2iunuuio2 Si 40 poueo pardos sq you uodn ad jsnui TISMXVIN jo Auadoud jenuepriuos ay aie pue ubisep pue q pi 21 500 VW Windlass o J eres PT JUSUBUO y JOY ureiBerg Bun VN ON Assy uondioseg jenuew SSEIPUIM sjuewembal Jojonpuoo Jemod 404 5 22 Wg peeoxe 2012108 pue leyeq Jojnpuoo Jamod sjueuoduics jooud uomu qN uim PE TIIMXVIA TIIMXVN BUIAOY jeuondo TIAMXVIA 07 peeoxe o jou 1exeeJq pue asnos Jamod Jojonpuoa jo i il du LMOLD OLd Ol Lr YLI Jexeelq ejqeneso dwy 01 1461 1014 jeued El 0o Uoneis OUD uonels Jeuonippv TISMXVIN TIFMXVIN MOV 9L oN 2216 Jojonpuoo NMOG dn Seuoiws o03 TIJAMXV
3. If the anchor is fouled do not use the Windlass to break it out With the chainstopper taking the load use the boats engine to break the anchor loose Do not use the Windlass as a Bollard In all but the lightest conditions engage the chainstopper after completing the anchoring manoeuvre In heavy weather conditions always use a heavy anchor snub from the chain directly to a Bollard or Sampson Post DO NOT USE THE CHAINSTOPPER OR WINDLASS AS A MOORING POINT ALWAYS TURN THE ISOLATOR SWITCH OFF BEFORE LEAVING BOAT When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THIS COULD DAMAGE THE WINDLASS Abuse is not covered by Warranty The Circuit Breaker and Isolator Switch Panel provides high current protection for the main supply cables and also the means to isolate the circuit When the Isolator Switch is ON red indicator light shows the system can be activated at either the footswitches or the remote control station When the system is not being used ensure that the Isolator Switch is turned OFF 10 Never proceed at speed with a bow mounted self launching anchor in position without first ensuring that your winch clutches are fully engaged and having made fast the anchor and engaged your chainstopper 500 VW Windlass 5 DO NOT DEPEND ON THE WINDLASS TO HOLD THE ANCHOR IN ITS BOW ROLLER A NYLON LINE SHOULD BE
4. 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 CHAINSTOPPER THE WINDLASS SHOULD BE USED IN CONJUNCTION WITH A MAXWELL CHAINSTOPPER OF THE APPROPRIATE SIZE 500 VW Windlass 7 INSTALLATION WHERE TO LOCATE THE WINDLASS The MAXWELL 500 VW Windlass operates in dual direction power UP DOWN UP is clockwise rotation when looking down on the Windlass The deck plate should be mounted pointing in the direction of the incoming chain This arrangement allows the chain to have maximum engagement with the chainwheel The Windlass must be positioned to allow the chain to have a clear run from the fairlead or bow roller on to 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 If it can be arranged the chain locker bulkhead should pass between the chain outlet in the deckplate and the Windlass gearbox This will keep the gearbox motor and wiring away form flaying chain Access for servicing from inside the cabin area can usually be arranged through a locker The chain locker must be of s
5. 2 33 2 34 2 35 1 36 Tension Pin 1 P101619 23 24 25 35 PM Motor DM717M 12V 1 P10068 36 a PM Motor DM718M 24V 1 P10069 36 38 Bush 1 SP3518 38 39 Plug 1 SP3519 39 500 VW Windlass 26 40 E o Sz o S Qo location Figure 3 Gearbox 56 1 Assembly Drawing 27 500 VW Windlass Gearbox 56 1 Parts No Component description Qty Parts to order Includes items 40 Oil Seal 2 P90006 40 x2 42 45 46 54 41 Gearbox Top 1 P101624 41 43 42 O Ring 1 P90006 40 x2 42 45 46 54 43 Bush 2 3145 43 44 Worm Wheel 56T 1 3584 44 45 Sight Glass 1 P90006 40 x2 42 45 46 54 46 O Ring 1 P90006 40 x2 42 45 46 54 47 Wormbox 1 P101625 43 47 48 Capscrew M6 x 40 4 SP0159 38 49 Bearing 1 P90007 49 51 52 53 50 Worm 56 1 1 3400 50 51 Bearing 1 P90007 49 51 52 53 52 Circlip 1 P90007 49 51 52 53 53 Circlip 1 P90007 49 51 52 53 54 Oil Seal 1 P90006 40 x2 42 45 46 54 500 VW Windlass 28 AAA 5 205 0030 TOO 1 507 Tiv 29529 u E sw 11 11 renim 2 90 90 91 3LON 335 INO SNLLLND 330438 NO SNOISNIWIO JO 3SV3 d ILVIdWSL V Sv 03SN JI ped jo 511 0 uo peoedsinb3 0
6. 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 8 On GRP or wooden decks seal the edges of the holes with epoxy to avoid ingress of moisture 9 Remove the gearbox from the spacer tube by undoing the Locknut and quick release clip 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 10 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 11 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 12 Smear a coating of grease on the shaft and spacer tube Fit the gearbox motor assembly to the bottom of the spacer tube to engage with the teeth on 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 See also gearbox assembly dra
7. 6 SPIOH MANI 660 913 SY3I4O9OLOHd SANIHOVW Xv3 40 540443 009 NOLLONGONd3S OL v1VO ILVINIOVNI 318ISNOdS33 LON SI INIYYN TIIMXVN 53294 OL JUYNOS 8 1ITIVIVA 38 150 531 1108 2030 DNITINIO 8 ONLLLNO 380438 10438 SNOISN3MIQ 100 2 NOLLYTIVLSNI ONVISESONO OVAU 5 10 Ste TIVAD3HO 930 ONLLLNO 3 038 I 3 2 lo pem S3LON 3LON A8 G3I4IO3dS SIHSINIS TIY 53903 dMVHS ONY 58418 TIY 3AOWSM gt gt ASV LANOA 31 lt lt S3HISWITIIW NI SNOISNJWIG TIY 2661 seu2uiM JybuAdo LIMITED WARRANTY Warranty Maxwell Marine International Ltd provides a three year limited warranty on all windlasses for pleasure boat usage and a one year limited warranty for those systems used on commercial or charter vessels Warranty service and parts are available around the world Contact your nearest Maxwell office for a complete list of service centres and distributors This warranty is subject to the following conditions and limitations 1 This Warranty will be null and void if a there is any neglect or failure to properly maintain and service the products b the products are serviced repaired or maintained improperly or by unauthorised persons c loss or damage is attributed to any act matter or omission beyond the reasonab
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9. Size to Winch Back to Battery Cable Length Correction mm AWG mm AWG Up to 10 m 33 14 6 22 4 10m 15m 33 49 22 4 7m 20m 49 65 26 3 s 10m 25m 65 82 34 2 24v systems Total Cable Length From Battery Engine room Size to Winch Back to Battery Cable Length Correction mm AWG mm AWG Up to 25 m 82 8 5 8 Engine Room size correction is based on the ambient temperature of the engine room to be 60 500 VW Windlass Tu PREPARATION OF MOUNTING Standard units will accommodate deck thickness up to 55mm 2 1 6 IMPORTANT 1 ITIS IMPERATIVE THAT THE DESIGNER INSTALLER ENSURES THAT THE DECK AND UNDERDECK PAD ARE OF SUFFICIENT THICKNESS AND STRUCTURAL STRENGTH TO SUSTAIN THE LOADS CAPABLE OF BEING IMPOSED ON OR BY THE WINDLASS THE UNDERDECK PAD SHOULD SPREAD THE LOADS AS WIDELY AS POSSIBLE AND IF USE CAN BE MADE OF A BULKHEAD OR CROSS MEMBER TO PROVIDE STIFFENING THIS SHOULD BE DONE 2 ITIS VERY IMPORTANT THAT THE ABOVE DECK PAD TOP SURFACE OR DECK AREA COVERED BY THE GASKET SUPPLIED AND THE UNDERDECK AREA AGAINST WHICH THE LOAD WASHERS SEAT ARE SMOOTH FLAT AND GENERALLY PARALLEL 3 The gasket supplied with the Windlass can be used for accurately spotting the mounting holes and marking the cut outs After spotting bore the necessary holes These must be drilled parallel to each other and square to the mounting fa
10. USED TO SECURE THE ANCHOR INTO ITS STOWED POSITION WHEN UNDERWAY AND WILL NEED TO BE REMOVED BEFORE OPERATION OF THE WINDLASS ALTERNATIVELY A PIN THROUGH THE BOW ROLLER AND THE SHANK OF THE ANCHOR CAN BE USED FOR SECURING Most Windlass models have clutches for the manual pay out of ground tackle in the event of a loss of power It is therefore prudent to secure the anchor to the boat by the means described above 500 VW Windlass 6 APPLICATION THE MAXWELL 500 VW WINDLASS IS DESIGNED FOR ALL CHAIN SYSTEMS USING UP TO A MAXIMUM CHAIN SIZE 6MM 14 SHORT LINK CHAIN WARNING BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED BEFORE INSTALLATION YOURS AND OTHERS SAFETY MAY DEPEND ON IT MAXWELL WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF A WINDLASS BY OTHERS INCLUDING DISTRIBUTORS AND AGENTS IF IN DOUBT SEND FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT FOR APPRAISAL AND WRITTEN RECOMMENDATION 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 CHAIN FIT CORRECT FIT OF CHAIN TO CHAINWHEEL IS ESSENTIAL FOR THE WINDLASS TO OPERATE PROPERLY
11. cover for your nearest MAXWELL distributor or visit our website www maxwellmarine com When ordering spare parts and for technical support please quote the following Windlass Model Serial Power Supply 12V 24V Descriplion aeree Quantity Required 500 VW Windlass 19 Typical Greasing Instructions Note Picture shows typical winches greasing instructions apply to all types using this motor gearbox and spacertube arrangement TA 2 grease here Grease must be applied to motor face gearbox locating lugs spacer tube gearbox thread shaft and clutch cone faces where shown Use CRC 3097 or equivalent spray to coat all under deck components to help guard against corrosion Failure to do so will void warranty Apply Apply grease here ue grease here Apply Apply grease here grease here Apply grease here 500 VW Windlass 20 101 orps eas 189085 LAB youBeyy jueueunad J04 weeg YN AlddNS AUALLVE 24 WE jou 1005 pue Alspeq jeuondo TIJMXVIA LA cortas vom TBAXYN sjueuoduioo jooid uoniuBi peaoidde qn um ying
12. the lever and stow 500 VW Windlass 16 USING THE WARPING DRUM The vertical Capstan can be used independently of the chainwheel This is ideal for handling mooring lines docking lines or a second anchor To use proceed as follows 1 Insert the lever into the clutch and back off in a counter clockwise direction until it stops The capstan will now operate whilst the chainwheel remains stationery Take several turns of line around the drum in a clockwise direction Whilst pulling on the tail have someone operate the Remote Control Station by holding the switch UP The capstan will rotate in a clockwise direction Increasing or decreasing the load on the tail whilst the Remote switch 15 held will increase decrease the rate at which the line will be hauled in Extra turns around the drum will increase the grip and require less load on the tail CAUTION ENSURE THAT FOOTSWITCH IS NOT OPERATED ACCIDENTALLY WHILST EXTRA TURNS ARE BEING TAKEN KEEP FINGERS CLEAR DON T PUT SO MANY TURNS ON THE DRUM THAT EASING THE LOAD ON THE TAIL WILL NOT ALLOW THE ROPE TO SLIP ON THE DRUM 500 VW Windlass 147 MAINTENANCE Carrying out the following simple maintenance procedures will provide years of trouble free service from the windlass and will ensure that the warranty remains valid Service Intervals Strip and grease clutch Remove windlass components grease with suitable lubricant Split gearbox from space
13. 500 VW OWNERS MANUAL COPYRIGHT 1991 MAXWELL MARINE LTD ALL RIGHTS RESERVED PATENTS PENDING PRINTED IN NEW ZEALAND Manual Product Code No P103114 11 02 10 MAXWELL MARINE INTERNATIONAL Ltd reserves the right to make engineering refinements on all products without notice Illustrations and specifications not binding as to detail 500 VW OWNERS MANUAL CONTENTS INTRODUCTION SPECIFICATIONS PERSONAL SAFETY WARNINGS APPLICATION INSTALLATION Location Windlass Footswitches Reversing Solenoids Breaker Isolator Panel Remote Control Control Circuits Main Electrical System Preparation of Mounting Preparing the Windlass Mounting the Windlass Assembling the chainwheel OPERATION OF THE CONTROL SYSTEM OPERATING THE WINDLASS MAINTENANCE Servicing of Gearbox Servicing of Motor ORDERING SPARE PARTS INSTALLATION DRAWINGS Typical Greasing Instructions Wiring Diagram Dual Direction Wiring Diagram Single Direction 500 VW Overall Dimensions Assembly Drawings and Parts 500VW Windlass Gearbox 56 1 Additional Resources Deck Cutout Details Warranty Form Contact Details On Back Cover A INSTALLATION OPERATING INSTRUCTIONS AND SERVICE MANUAL 500 VW WINDLASS INTRODUCTION You now own a Windlass from MAXWELL S premier range designed for automatic anchor handling Used in conjunction with MAXWELL S Remote Control you will have complete command of the anchor ra
14. 651 1 4 5 9 22 x2 6 Drum 300 500 VC VW 1 6016 6 7 Clutch Cone 2 P101653 7 x2 8 Chain Wheel 1 3132 8 9 A Ring Seal V28 1 P101651 1 4 5 9 22 x2 10 Retaining Collar 1 P101663 10 26 30 11 Screw M6x12 1 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 12 Spring Washer M6 1 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 13 Stripper Arm 500 VW 1 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 14 Deckplate 300 500 VC VW 1 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 15 Gasket 300 500 VC VW 1 6474 15 16 Stud M8x83 3 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 17 Washer 3 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 18 Spring Washer 3 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 19 Nut M8 3 P101654 10 11 12 13 14 16 x3 17 x3 18 x3 19 x3 26 30 20 Clutch Nut Lever 1 3381 20 21 Shaft 500 VW 50TDC 1 6475 21 22 Key 2 P101651 1 4 5 9 22 x2 23 Key 6 35x6 35x57 1 P101619 23 24 25 35 24 Circlip 1 P101619 23 24 25 35 25 Quick Change Clip 1 P101619 23 24 25 35 26 Bearing 1 P101663 10 26 30 27 Locknut 1 P100088 27 28 29 28 O Ring 1 P100088 27 28 29 29 Collar 1 P100088 27 28 29 30 Spacer Tube 300 500 50TDC 1 P101663 10 26 30 31 Gearbox 500 1500 56 1 1 P102730 31 32 Bolt Hex Hd M8x25 2 P12487 32 x2 33 x2 34 x2 35 x1 33 Washer Spring M8 2 P12487 32 x2 33 x2 34 x2 35 x1 34 Washer Flat M8 2 P12487 32 2 33 2 34 2 35 1 35 O Ring 1 P12487 32
15. INSERTED IN THE CLUTCH NUT WHEN THE WINDLASS IS NOT IN USE MAKE SURE THE WINDLASS IS ISOLATED FROM THE POWER SUPPLY BY TURNING THE WINDLASS ISOLATOR SWITCH TO OFF NEVER OPERATE THE WINDLASS FROM A REMOTE STATION WITHOUT A CLEAR VIEW OF THE WINDLASS AND HAVING MADE SURE THAT EVERYONE IS WELL AWAY FROM THE WINDLASS IF YOUR WINDLASS DOES NOT A REMOTE CONTROL STATION AND 15 OPERATED FROM THE FOOTSWITCHES ONLY ALWAYS IMMEDIATELY AFTER USE TURN THE WINDLASS ISOLATOR SWITCH TO OFF THIS WILL PREVENT ACCIDENTAL WINDLASS OPERATION IF YOU OR PASSENGERS ACCIDENTALLY STAND FOOTSWITCHES 500 VW Windlass IMPORTANT HINTS FOR SAFE USE OF WINDLASS BE SURE YOUR WINDLASS HAS BEEN CORRECTLY SPECIFIED AND INSTALLED YOURS AND OTHERS SAFETY MAY DEPEND ON IT THE WINDLASS SHOULD BE USED IN CONJUNCTION WITH A CHAINSTOPPER OF THE APPROPRIATE SIZE FOR AUTOMATIC OPERATION TO BE POSSIBLE THE ANCHOR MUST BE SELF LAUNCHING MAXWELL WILL NOT IN ANY WAY BE HELD RESPONSIBLE FOR SELECTION OF A WINDLASS BY OTHERS INCLUDING DISTRIBUTORS AND AGENTS IF IN DOUBT SEND FULL DETAILS OF YOUR CRAFT TO OUR SALES DEPARTMENT FOR APPRAISAL AND WRITTEN RECOMMENDATION 1 Run the engine whilst raising or lowering the anchor Not only 15 this a safety precaution it also helps minimise the drain on the batteries Always motor up to the anchor while retrieving the chain Do not use the Windlass to pull the boat to the anchor
16. TE THE REVERSING SOLENOID This unit is used ONLY when a Dual Direction control system is being installed Refer drawing P101842 P101841 The Reversing Solenoid should be located in a dry area in close proximity to the Windlass IT MUST NOT BE LOCATED IN THE WET ENVIRONMENT OF THE CHAINLOCKER Locating close by the Windlass considerably shortens the total length of the main power supply conductors required WHERE TO LOCATE THE BREAKER ISOLATOR PANEL The Maxwell Breaker Isolator Panel is used when either the Dual Direction system Refer drawing P101842 P101841 or the Single Direction System Refer drawing P101844 is used The Breaker Isolator Panel is selected to provide limited protection only for the motor and full protection for the supply cables This unit also provides the means for isolating the electrical system from the battery refer Drawing P101841 P101842 and P101844 This should be mounted in a convenient and accessible dry location within 1 8 metres 72 of cable length from battery This equipment or equivalent is mandatory to meet U S C G requirements WHERE TO LOCATE THE CONTROLS The remote control stations can be positioned as required i e Bridge Helm Cockpit or Foredeck to suit your requirements Mount the panels where the terminals project into a dry area and if mounted in an area where the face is exposed to the weather i e Fly Bridge the mounting must be bedded down with sealant They may be wir
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19. aried by the laws of different countries In addition the purchaser may also have other legal rights which vary from country to country To make a claim under this Warranty contact your nearest Maxwell Marine office or distributor Proof of purchase and authorisation from Maxwell will be required prior to any repairs being attempted To be eligible for warranty protection please either complete the form below at the time of purchase and return it to the appropriate retailer or supplier of the goods Purchaser or fill out the electronic Warranty Form on our website www maxwellmarine com Name Address Telephone Facsimile Supplier Dealer Name Address Telephone Facsimile Windlass Model Serial Number Date of Purchase Boat Type Windlasses Supplied m With boat Name L O A Fitted by boat yard dealer Built by Purchased from dealer chandler
20. ce DON T SPOT THROUGH THE GASKET WITH THE DRILL THIS WILL DAMAGE THE GASKET NOTE For boats of steel or aluminium construction it is very important that the deckplate is insulated from the deck with the non conductive gasket provided that the mounting studs pass through insulators and that the underdeck fixings are insulated from the deck It is also important that the anchor and chain is insulated from the hull including rubber lining the chain locker and insulating the 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 Windlass as the electric motor is of the isolated earth type 500 VW Windlass 12 PREPARING THE WINDLASS 4 Remove the Windlass from the packaging Refer to the appropriate assembly drawing provided for the Windlass being installed and proceed as follows 5 Remove deckplate studs washer and nuts MOUNTING THE WINDLASS 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 6 Clear the underside of the deckplate Make sure the mounting area on the deck is properly prepared and is clean 7 Use the Deck Cutout Details drawing as a guide for marking and cutting the holes Tip
21. ed directly to or linked together in series to the Reversing Solenoid Refer P101841 P101842 500 VW Windlass 9 CONTROL CIRCUITS Footswitches if required and remote control circuits are to be wired using 1 5mm 16AWG cable A manually resettable ignition proof fuse or breaker is to be fitted within 1 metre 40 of the power source on line 2 of the control cable conductor The above requirements are mandatory to meet USCG ABYC and NMMA After all connections have been made and system tested seal terminals against moisture by spraying with CRC2043 Plasti Coat CRC3013 Soft Seal or CRC2049 Clear Urethane Refer to drawing P101842 P101841 or P101844 for wiring details 500 VW Windlass 10 MAIN ELECTRICAL SYSTEM Cable lengths given are from the battery terminal to the terminal on the windlass motor via the solenoid box and back to the battery Where a portion of cable runs through the engine room a size increase should be made as indicated After all connections have been made and system tested seal terminals against moisture by spraying with CRC2043 Plasti Coat CRC3013 Soft Seal or CRC2049 Clear Urethane All installations must be carried out in accordance with USCG ABYC NMMA or other local electrical requirements Recommended conductor sizes allow for a maximum 10 voltage drop over the total length 12v systems Total Cable Length From Battery Engine room
22. film PLEASE LET YOUR CUSTOMER RECEIVE THE WINDLASS FROM YOU IN THE SAME TOP QUALITY CONDITION THAT YOU RECEIVED IT FROM US 500 VW Windlass 14 OPERATION OF THE CONTROL SYSTEM DUAL DIRECTION SYSTEM Refer drawing P101842 or P101841 This system provides means of controlling the Windlass via a Reversing Solenoid which is actuated by a self centering UP DOWN toggle switch type remote control or the footswitches An indicator light on the remote control glows when the power is ON and the system can be operated SINGLE DIRECTION SYSTEM Refer drawing P101844 Turning the Isolator Switch ON on the panel readies the system for use The windlass can now be operated by the footswitch WARNING When using the Windlass DO NOT SWITCH IMMEDIATELY FROM ONE DIRECTION TO THE OTHER WITHOUT WAITING FOR THE WINDLASS TO STOP AS THIS COULD DAMAGE THE WINDLASS Abuse is not covered by Warranty The Breaker Isolator Panel provides protection for the main supply cables and means to isolate the circuit WARNING When the Isolator Switch is ON the system can be activated at either the footswitches or the remote When the system is not being used ensure that the Isolator Switch is turned OFF WARNING This system provides protection for the motor from excessive current and short circuit It does not provide protection against excessive heat build up due to prolonged operation or repeated operation under overload conditions Make sure you gi
23. ising or lowering The compact deck saving vertical design allows 180 degree wrap of the chain ensuring maximum engagement with the chainwheel and allows working of mooring or docking lines from any direction A clutch allows manual control for lowering the anchor under free fall and independent operation of the drum IMPORTANT FAILURE TO ADHERE TO THE CORRECT APPLICATION INSTALLATION OPERATION AND TO CARRY OUT THE MAINTENANCE SERVICE AS DESCRIBED HEREIN COULD JEOPARDISE YOUR SAFETY AND INVALIDATE THE WARRANTY Your MAXWELL Windlass is a precision engineered product Please read these instructions carefully 500 VW Windlass 2 SPECIFICATIONS PULL AT CHAINWHEEL CHAIN SIZE RATE AT NO LOAD RATE AT NORMAL WORKING LOAD POWER OPTIONS CURRENT Normal Working Load SUPPLY CABLES WEIGHT 225 kg 500 Ibs Short Link Max 6mm 72 25 m min 80 Feet min 18 21 m min 60 70 Feet min Product Code P100457 12VD C P100458 24 V D C 12V 80 120 Amps 24 V 40 60 Amps See Page 11 Product code P100457 10 20 kg 22 50 P100458 10 20 kg 22 50 500 VW Windlass IMPORTANT PERSONAL SAFETY WARNINGS WHEN USING YOUR WINDLASS AT ALL TIMES PRACTICE GOOD SEAMANSHIP AND AVOID ANY LIKELIHOOD OF INJURY OR ACCIDENT BY ADHERING TO THE FOLLOWING RULES AT ALL TIMES KEEP HANDS FEET LOOSE CLOTHING AND HAIR WELL CLEAR OF THE WINDLASS NEVER USE THE WINDLASS UNDER POWER WITH THE LEVER
24. le control of Maxwell or the purchaser Maxwell s liability shall be limited to repair or replacement as determined by Maxwell of the goods or parts defective in materials or workmanship Determination of the suitability of the product and the materials for the use contemplated by the buyer is the sole responsibility of the buyer and Maxwell shall have no responsibility in connection with such suitability Maxwell shall not be liable for any loss damages harm or claim attributed to a Use of the products in applications for which the products are not intended b Corrosion wear and tear or improper installation c Improper use of the product This Warranty applies to the original purchaser of the products only The benefits of the Warranty are not transferable to subsequent purchasers Maxwell shall not be responsible for shipping charges or installation labour associated with any warranty claims There are no warranties of merchantability fitness for purpose or any other kind express or implied and none shall be implied by law If any such warranties are nonetheless implied by law for the benefit of the customer they shall be limited to a period of three years from the original purchase by the user Maxwell shall not be liable for consequential damages to any vessel equipment or other property or persons due to use or installation of Maxwell equipment This Warranty sets out your specific legal rights allowed by Maxwell these may be v
25. r tube clean and re grease mating faces Spray fresh water into drainage slot on gearbox to breakdown and flush away any build up of salt debris that may have accumulated Service motor Recommended Lubricants Gearbox Oil Capacity 70ml 2 4 fl oz Type SAE viscosity grade 90 110 e g Shell Omala 320 Castrol Alpha SP 320 or other approved equivalent Mainshaft amp Bearing Marine Grease Lithium based or Lithium complex based e g Duckhams Keenol Castrol LMX Do not use soap based grease Above deck components CRC 3097 Spray Topworks The above deck parts of the windlass should be washed down with fresh water regularly Every three months remove the chainwheel set and lubricate the clutch faces and shaft bore inside the deckplate with marine grease Gearbox The gearbox is a self contained sealed unit We recommend that the gearbox be removed and serviced by an authorised Maxwell service technician every three years Visit our website www maxwellmarine com for a list of service centres and agents Check the gearbox oil level every six months using the sight glass 500 VW Windlass 18 Motor For maximum protection we recommend that the motor and electrical connections be sprayed periodically with CRC Soft Seal The motor should be serviced by a qualified electrician annually or more frequently in commercial applications ORDERING SPARE PARTS AND TECHNICAL SUPPORT Please refer back
26. uch a size that the chain will heap up and feed out naturally without fouling NOTE Make sure you securely fasten the end of the chain to the boat IMPORTANT FOR AUTOMATIC OPERATION TO BE POSSIBLE THE ANCHOR MUST BE SELF LAUNCHING That is once the Windlass is operated to reverse out the chain the anchor must free fall or the bow roller arrangement be such that the anchor is automatically launched 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 through different positions in relation to the deckplate refer overall dimensionsdrawing Be sure to select the most convenient position and allow for the best run for the chain to clear the motor 500 VW Windlass 8 WHERE TO LOCATE THE FOOTSWITCHES Careful consideration should be given to the possibility of accidental operation of footswitches whilst operating the Windlass particularly in Capstan warping of anchor or mooring line It is therefore recommended that footswitches are placed well beyond arms reach from the Windlass say a minimum of 34 metre 30 THE BELOW DECK PORTION OF THE FOOTSWITCH SHOULD NOT BE EXPOSED TO WATER OR WET ENVIRONMENT AND THE BREATHER HOLES MUST BE KEPT CLEAR Ideally they should be external to the chain locker The arrows on the footswitches should be arranged to indicate the direction of operation WHERE TO LOCA
27. ve the motor time to cool Abuse is not covered by Warranty 500 VW Windlass 15 OPERATING THE WINDLASS LOWERING THE ANCHOR UNDER POWER Proceed as follows 1 Insert the lever into the clutch nut and check that the clutches are tightened down firmly by turning the nut clockwise REMOVE THE LEVER The Windlass may be operated under power by using the switch on the Remote Control Station Hold the switch DOWN until the required amount of chain 15 out RAISING THE ANCHOR UNDER POWER Proceed as follows 1 2 Carry out step 1 above The Windlass may be operated under power by using the switch on the Remote Control Station Hold the switch UP until the required amount of chain has been brought in Care should be taken when docking the anchor Jog in the last metre few feet carefully seating the anchor home LOWERING THE ANCHOR UNDER MANUAL CONTROL This method 15 generally used in tight anchorages an emergency situation where a fast dump is required Proceed as follows 1 2 Insert the lever into the clutch nut Standing well clear slowly back off the clutch nut This will release the chain Regulate the speed at which the chain goes out by tightening to slow or easing to increase CAUTION DO NOT ALLOW THE CHAINWHEEL TO FREE WHEEL AS THIS WILL ALLOW DANGEROUSLY HIGH CHAIN SPEEDS TO BUILD UP When the required amount of chain is out tighten the clutch nut firmly remove
28. wing Drainage Slot 500 VW Windlass 13 13 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 A 14 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 15 When tightening the cables to the motor ensure the lower nut is secure Upper Nut against turning when tightening the upper nut This will prevent damage occurring within the motor Lower Nut ASSEMBLING THE CHAIN WHEEL Refer Fig 2 500 VW windlass assembly drawing With a pen knife or similar carefully remove the cap Remove the screw and retaining washer Remove the clutch nut drum and upper clutch cone Remove the chain wheel Grease the two clutch faces of the chain wheel Assemble the components in the reverse order they were removed and ensure the side of the chain wheel with the two holes facing upward DAWNI IMPORTANT NOTE TO BOAT BUILDERS After completing installation we suggest that you spray the top works of the winch with CRC3097 Long Life Also protect the winch by wrapping with plastic film and tape Experience has shown that on long ocean deliveries as deck cargo sulphur from the ships exhausts settles and severely damages the chrome plating and stainless steel by breaking down the chrome oxide protective
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