Maxwell Freedom 500, Freedom 500M, Freedom 800, Freedom 800M Installation Manual
Freedom Windlass
Installation and Operation Manual
Copyright Maxwell Marine International, 2008.
All rights reserved.
Maxwell Marine International reserves the right to make
engineering refinements on all products without notice.
Illustrations and specifications are not binding as to detail.
Part No: P103102
160210
Freedom Windlass 1
Table of Contents
Preliminary Information .............................................................................................................. 2
Introduction ............................................................................................................................... 2
Components ............................................................................................................................. 2
General Layout ......................................................................................................................... 3
Important Safety Information .................................................................................................... 4
Identifying your Windlass ......................................................................................................... 5
Parts of the Windlass ............................................................................................................... 7
Parts of the Gearbox and Capstan ........................................................................................... 8
Parts List .................................................................................................................................. 9
Ordering Spare Parts ............................................................................................................. 11
Rope and Chain Selection Guide ........................................................................................... 12
Installation .................................................................................................................................. 13
General Requirements ........................................................................................................... 13
Installation Instructions ........................................................................................................... 16
Rope Splicing Notes ............................................................................................................... 19
Wiring Instructions .................................................................................................................. 20
Operation .................................................................................................................................... 25
Loading the Rope/Chain ......................................................................................................... 25
Anchoring Tips ....................................................................................................................... 25
Lowering the Anchor............................................................................................................... 26
Raising the Anchor ................................................................................................................. 26
Free falling the Anchor ........................................................................................................... 26
Raising the Anchor Manually .................................................................................................. 26
Using the Capstan Drum for Rope Warping .......................................................................... 27
Maintenance ............................................................................................................................... 28
Trouble Shooting Guide ........................................................................................................... 31
Reference Information .............................................................................................................. 32
Specifications ......................................................................................................................... 32
Dimensions ............................................................................................................................. 33
Typical Greasing Instructions ................................................................................................. 34
Additional Resources
The following resources are included at the back of this manual:
Deck Drilling Template
Deck Drilling Template - Performance Plate
Warranty Form
Contact Details (on back cover)
2 Freedom Windlass
Preliminary Information
Introduction
Congratulations on your purchase of a Maxwell Freedom 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 also invalidate the warranty.
Components
In addition to this instruction manual, the following components are included with the Freedom
windlass:
• Windlass in two components:
• Topworks assembly
• Motor and gearbox
• Remote up/down control panel
• Circuit breaker/isolator panel
• 12V or 24V reversing solenoid
• Manual crank handle
• Performance plate
• Deckplate gasket
• Small parts:
• Nuts
• Flat washer
• Spring washer
• Key
• Quick release clip
• Spare pressure arm kit
These components are illustrated in “Figure 1 - Freedom windlass components” on page 3.
Freedom Windlass 3
Figure 1 - Freedom windlass comp o n ents
(Optional extras include: footswitches, warping capstan and rope/chain counter).
General Layout
Solenoid pack
Footswitch
Remote control
panel
Circuit breaker/isolator
Battery
+ -
Figure 2 - General layout
4 Freedom Windlass
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.
• Correct fit of the chain to the chainwheel is essential. See "Rope and Chain Selection Guide"
on page 12.
• 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.
• Do NOT use the windlass as a bollard. 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.
• Keep the anchor rope/chain in good condition, free from knots and twists. Inspect the rope
regularly for chafe. Where this has occurred, repair by cutting away the affected portion and
re-splice.
Tip: The rope can be swapped end-for-end to extend its life.
• Tie the end of the anchor rope/chain rode to a secure fixture in the chain locker.
• Do NOT use the windlass to haul a person up a mast.
Freedom Windlass 5
Identifying your Windlass
Before ordering spare parts, use the steps below to identify the model of your windlass.
1. Standard or Capstan
There are two different styles of Freedom windlass – standard (low profile) and capstan.
Standard Capstan
Figure 3 - Standard and ca p stan versions
2. Chainwheel identificati o n
To determine which model of chainwheel you have look at the number in the bi-square on the top of
the windlass as shown below. There are 4 models of chainwheel: Freedom 500, 500M, 800 and
800M.
Freedom 500
Figure 4 - Chainwheel identification
6 Freedom Windlass
3. Motor size – 500 and 800 and Voltage – 12V and 24V
To determine whether you have a 12 Volt or 24 Volt motor, check the badge on the motor.
Freedom 500 - 600W 12V and 24V Freedom 800 – 1000W 12V and 24V
Figure 5 - Motor variants
4. Deck clearance
To determine the deck clearance of your windlass, measure from the bottom of the deckplate to the
centreline of the motor (DMC = Deck to Motor Centreline).
154mm DMC
For decks up to 65 mm thick
254mm DMC
For decks up to 165 mm thick
Figure 6 - Deck clearance variants
Freedom Windlass 7
Parts of the Windlass
Figure 7 - Parts of the windlass
8 Freedom Windlass
Parts of the Gearbox and Capstan
Figure 8 - Parts of the gearbox and capstan
Freedom Windlass 9
Parts List
Before ordering parts, please refer to "Identifying your Windlass" on page 5.
Item Description Qty Part to order Includes items
1 Handle 1 131/AI 1
2 M8 x 16 cheese head screw 1 P100087 2, 3, 5, 10, 16, and 18
3 M8 x 17 flat washer 1 P100087 2, 3, 5, 10, 16, and 18
4 Clutch nut 1 4376 4
5 Tab washer 1 P100087 2, 3, 5, 10, 16, and 18
6 Snap bush 1 See item 8 6 and 8
7 Chain wheel upper 500 1 P100030 6, 7, 8 and 9 see page 12 for rode selection gui de
7 Chain wheel upper 500M 1 P100031 6, 7, 8 and 9 see page 12 for rode selection gui de
7 Chain wheel upper 500MA 1 P100032 6, 7, 8 and 9 see page 12 for rode select i on gui de
7 Chain wheel upper 800 1 P100033 6, 7, 8 and 9 see page 12 for rode selection gui de
7 Chain wheel upper 800M 1 P100034 6, 7, 8 and 9 see page 12 for rode selection gui de
8 500 stripper 1 P100084 6 and 8
8 800 stripper 1 P100085 6 and 8
9 Chain wheel lower 500 1 P100030 6, 7, 8 and 9 see page 12 for rode selection gui de
9 Chain wheel lower 500M 1 P100031 6, 7, 8 and 9 see page 12 for rode selection gui de
9 Chain wheel lower 800 1 P100033 6, 7, 8 and 9 see page 12 for rode selection gui de
9 Chain wheel lower 800M 1 P100034 6, 7, 8 and 9 see page 12 for rode selection gui de
10 Belleville washer 1 P100087 2, 3, 5, 10, 16, and 18
11 Pressure arm clip 1 P100019 11, 12, 13, and 14
12 Clip insulator 1 P100019 11, 12, 13, and 14
13 Pressure arm blade 2 P100019 11, 12, 13, and 14
14 Pressure arm spine 1 P100019 11, 12, 13, and 14
15 Shaft 154mm DMC 1 P100016 15, 16, 17 and 18
15 Shaft 254mm DMC 1 P100047 15, 16, 17 and 18
15 Shaft 154mm DMC - capstan 1 P100017 15, 16, 17 and 18
15 Shaft 254mm DMC - capstan 1 P100048 15, 16, 17 and 18
16 O-ring 18 x 2mm 1 P100087 2, 3, 5, 10, 16, and 18
17 Clutch cone 1 See i tem 15 15, 16, 17 and 18
18 Quad ring 1 P100087 2, 3, 5, 10, 16, and 18
19 Plug 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
20 Deckplate bearing 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
21 Spacer tube retaining collar 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
22 Deckplate 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
23 Gasket 1 4169 23
24 Performance plate 1 4517 24
*P100022 = 154mm DMC, P100049 = 254mm DMC. See "Figure 6 - Deck c l earance variants" on page 6.
(Parts list continued on next page)
10 Freedom Windlass
Parts List (continued)
Item Description Qty Part to order Includes items
25 Deckplate insert 1 *P100022 or P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
26 Nylon rivet 5mm 1 *P100022 or P 100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
27 M8 stud 154mm DMC 3 P100022 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
27 M8 stud 254mm DMC 3 P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
28 M8 x 32 x 2 flat washer 3 P100083 28, 29, 30, 36 and 37
29 M8 spring washer 3 P100083 28, 29, 30, 36 and 37
30 M8 hex nut 3 P100083 28, 29, 30, 36 and 37
31 Spacer tube 154mm DMC 1 P100022 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
31 Spacer tube 254mm DMC 1 P100049 11, 12, 13, 14, 19, 20, 21, 22, 25, 26, 27(x3), 28(x3),
29(x3), 30(x3), 31, 32, 33, and 34
32 Locknut 1 P100088 32, 33 and 34
33 O-ring 66 x 2mm 1 P100088 32, 33 and 34
34 Collar 1 P100088 32, 33 and 34
35 Gearbox 44:1 1 P100900 (See page 8 for exploded view) 35
36 1-4 in key 1 P100083 28, 29, 30, 36 and 37
37 Quick change clip 1 P100083 28, 29, 30, 36 and 37
38 M8 x 25 ss bolt 2 P12487 38(x2), 39(x2), 40(x2) and 41
39 M8 spring washer 2 P12487 38(x2), 39(x2), 40(x2) and 41
40 Ø5-8 x 5-16 washer 2 P12487 38(x2), 39(x2), 40(x2) and 41
41 O-Ring 1 P12487 38(x2), 39(x2), 40(x2) and 41
42 Motor 500 12V 600W 1 P10068 42
42 Motor 500 24V 600W 1 P10069 42
42 Motor 800 12V 1000W 1 P11112 42
42 Motor 800 24V 1000W 1 P11114 42
43 Unipoint 12V and 24V end
cap and brush kit
1 P10066 43
44 Cima 12V brush kit 1 P100807 44
45 Cima 24V brush kit 1 P100808 45
46 Ø5-8" x 1-1/4" washer 1 SP0421 46
47 1-4in key 1 3462 47
48 Capstan 1 4170 48
49 Oil seal 40 x 55 x 8mm 1 P90006 49, 51, 55, 56, 59 and 65
50 Gearbox top 1 P101624 50, 52 and 58(x4)
51 O-ring 90 x 2mm 1 P90006 49, 51, 55, 56, 59 and 65
52 Bush 1 P101624 52
53 Worm wheel 1 3403 53
54 Bush 1 3145 54
*P100022 = 154mm DMC, P100049 = 254mm DMC. See "Figure 6 - Deck c l earanc e variants" on page 6.
(Parts list continued on next page)
Freedom Windlass 11
Parts List (continued)
Item Description Qty Part to order In cludes items
55 Sight glass 1 P90006 49, 51, 55, 56, 59 and 65
56 O-ring 20 x 2 mm 1 P90006 49, 51, 55, 56, 59 and 65
57 Worm box 1 3133 57
58 M6 x 40mm capscrew 4 SP0159 58(x4)
59 Oil seal 40 x 55 x 8mm 1 P90006 49, 51, 55, 56, 59 and 65
60 Bearing 12 x 28 x 8mm 1 P90007 60, 62, 63 and 64
61 Worm 1 5950 61
62 Bearing 25 x 47 x 12mm 1 P90007 60, 62, 63 and 64
63 External circlip 1in 1 P90007 60, 62, 63 and 64
64 Internal circlip 47 x 1.85mm 1 P90007 60, 62, 63 and 64
65 Oil seal 25 x 47 x 7mm 1 P90006 49, 51, 55, 56, 59 and 65
66 Capstan Conversion Kit –
154mm DMC
1 P100018 10, 15, 16, 17, 18, 46, 47 and 48
Ordering Spare Parts
When ordering spare parts, please refer to the parts list above and quote the following details.
Freedom Model (marked in chainwheel bi-square, see "Identifying your Windlass" on page 5)
500
500M
800
800M
Serial number (located on gearbox housing)
Power supply
12V
24V
Part details
Part number Description Quantity
12 Freedom Windlass
Rope and Chain Selection Guide
Use the following table to select the correct rope and chain to suit your Freedom windlass.
Rope Type
Chain Type
12mm
3 strand or
8 plait
1/2”
3 strand or
8 plait
14mm
3 strand or
8 plait
9/16”
3 strand
5/8”
3 strand or
8 plait
¼” Acco G40 SL7
7mm DIN 766
- Freedom 500
(P100030)
- - -
6mm PWB Grade L
6mm Bradlink SGC
6mm DIN766
Freedom
500M
(P100031)
- - - -
5/16” Acco G40 SL
5/16” Weissenfels
- Freedom 800 *
(P100033)
- Freedom
800 *
(P100033)
Freedom 800
(P100033)
8mm PWB Grade L
8mm Bradlink
8mm DIN766
8mm Beaver
- Freedom
800M *
(P100034)
Freedom
800M
(P100034)
- -
* Not a recommended Rope/Chain combination
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