Maxwell 300 & 500 VC Windlass — Owner's Manual

Location & Mounting

1. Wire for clockwise rotation looking down on the drum; use only clockwise rotation for 3-ply twisted rope. Give the rope a clear run from the bow roller or turning block (concave radius or vee) onto the drum, and leave access below deck for the supply cables.
2. Footswitch at least 500mm (20") from the capstan, below-deck part dry, breather holes clear, arrow showing the direction of operation; ideally outside the rope/anchor locker. Breaker/isolator panel in a dry place within 1.8 metres (72") of cable length from the battery.
3. Standard units suit decks up to 55mm (2 1/6"). Deck and under-deck pad must take the loads; the deck area under the gasket and the under-deck seat for the load washers must be smooth, flat and parallel.
4. Deck drilling template (drawing 6156 at the back of the manual): Ø95 cut-out and 3 holes Ø9.0 equispaced on a Ø115 PCD. Print the PDF at 100% and check the marked-out dimensions before cutting. Hole saws; on GRP run the drill in reverse first; seal GRP or wooden hole edges with epoxy.
5. Undo the locknut and quick-release clip to remove the gearbox from the spacer tube; with the gearbox horizontal the oil should show half way up the sight glass (top up with SAE 90, do not over fill).
6. Seal to the deck with the gasket supplied (non-conductive gasket on aluminium boats), fit the nuts and washers and tighten progressively and evenly – no power tools, do not over tighten.
7. Grease shaft and spacer tube, fit the gearbox/motor to the bottom of the spacer tube and hand-tighten the plastic locknut. If the unit can tilt, put the gearbox drainage slot at the lowest point.
8. Turn the shaft (or use the crank handle) to align the keyways, insert the key and fit the quick-release clip with the eyelets facing down and away from the keyway.

Electrical

• Install to USCG, ABYC, NMMA or other local requirements. Hold the lower motor nut while tightening the upper nut.
• The footswitch is wired directly in the control circuit of the 12 and 24 Volt capstans. Seal terminals after testing with CRC2043 “Plasti-Coat”, CRC3013 “Soft Seal” or CRC2049 “Clear Urethane”.
• Steel or aluminium boats: insulate the deckplate, studs and under-deck fixings from the deck, and the anchor and chain from the hull. The motor is of the isolated earth type, so no separate earth is needed.

Maximum 10% voltage drop over the total length. *Engine room correction based on an engine room ambient of 60° C.

Using the Capstan

• Turn the isolator “ON” at the breaker/isolator panel; the capstan is then worked from the footswitch. Turn it “OFF” after use and before leaving the boat.
• Take several turns clockwise around the drum, pull on the tail and press the footswitch. More or less load on the tail speeds up or slows the haul; extra turns add grip. Never put on so many turns that easing the tail will not let the rope slip.
• Run the engine while using the capstan; motor up to the anchor; never break out a fouled anchor with the capstan, and never use it as a bollard or mooring point.
• The breaker protects against excessive current and short circuit, not against heat from prolonged or overloaded use: give the motor time to cool.

Maintenance

• Gearbox oil: 70ml (2.4 fl oz), SAE viscosity grade 90 -110 (e.g. Shell Omala 320, Castrol Alpha SP 320). Check the level every six months at the sight glass.
• Main shaft and bearing: lithium or lithium complex marine grease; no soap based grease. On installation the shaft must be coated in marine grease (Shell Nautilus NLG12, Castrol Boating Grease, Valvoline Val Plex EP or equivalent).
• Grease the motor face, gearbox locating lugs, spacer tube, gearbox thread and shaft; coat under-deck components with CRC 3097 (failure to do so voids the warranty). Spray the motor and connections periodically with CRC Soft Seal.