[C320-list] Removing the Maxwell 500

[Warren Updike]

Scott is quite right.  When I pulled our VC500, the drum wouldn't come off.
18 year-old grease probably holding it on.  I used a 3-leg puller
(HarborFreight.com) to coax it loose.  (Similar to pulling a prop.)  The
unit cannot be removed without removing the drum.  
My problem was corroded contacts and fried brushes.  The winch pulls a lot
of current, maybe as much as the starter, and dirty contacts will cause
excessive heat.  I took the unit to a repair shop and they were able to
replace the brushes and the burned contact.  Works well ever since.  
Even if you don't pull the unit, it's a good idea to check the contacts
whenever you have the space open.  Even dress them with a dielectric grease
to prevent corrosion.
BTW, I changed the gear oil while it was out.  Maxwell recommends the drum
shaft be greased every year and the oil changed every 3.  I'll take bets
that there is no 320 following that schedule.

Warren & Pattie Updike
1994 C320 #62 "Warr De Mar"

-----Original Message-----
From: Scott Thompson [mailto:surprise at thompson87.com] 
Sent: Friday, May 17, 2013 6:34 PM
To: C320-List at Catalina320.com
Subject: Re: [C320-list] Removing the Maxwell 500

These links to documents I put on the Association website a long time ago
might be helpful:

Exploded parts view: http://www.catalina320.com/filemgmt/index.php?id=112
Manual: http://www.catalina320.com/filemgmt/index.php?id=113

The former is for the VC500 model (no chain gypsy) and the latter is for the
VW500 model, which includes a chain gypsy, but my understanding is that the
drum assembly is the same on both models. The VW500 model has a longer shaft
and a few extra parts. Based on your description I suspect you have the
VC500.

I believe that the drum should NOT turn when rotated with a pipe wrench
because it is keyed to the shaft and shaft rotation is more or less
impossible because of the use of a worm gear in the transmission. But
rotating it is not required for removal. Rather you need to move it off the
shaft without rotating it, i.e. by moving it parallel to the shaft and
internal key. In other words, it should just slide off the shaft. If the
drum won't move parallel to the shaft there could be internal corrosion or
sand preventing it from sliding on the shaft.

What I would do is insert a lever (try a large screwdriver at first) between
the drum and mounting plate and try to pry the drum away from the mounting
plate. If that fails try levering in more than one place, or get a bigger
lever. When it moves, it will probably give all at once, so arrange for some
protection of the gelcoat in case it goes flying off the shaft with gusto.
Also avoid using the fiberglass itself as a fulcrum. You want the intense
point-loading to be entirely metal to metal.

I don't think it is possible to remove the windlass in one piece, or to
remove it without first removing the drum, even with a willingness to do
damage to the windlass. The problem is that the motor / transmission is on
one side of the bulkhead but is bolted to the mounting plate on the other
side, and the bolts are hidden by the drum. You need to remove the drum,
then the bolts holding the motor, then the motor itself (which requires
access to the rear, obtained by removing the plywood panel from the front of
the V-berth and then lying on your back looking upward), and only then the
mounting plate.

Been there.

Scott Thompson
Surprise, #653

On 5/16/2013 10:27 PM, Gene Helfman wrote:
> We've decided to replace our non-functional Maxwell 500 (1997 c320) 
> with a newer, larger model with a chainwheel, the Maxwell VW10.  I'm 
> now trying to get the old 500 out and am stuck.  Does anyone know how 
> to remove the rope drum?  I've taken off the outer cap, screw, and 
> washer and can't figure out what to do next.  It doesn't help that the 
> drum appears to be frozen in place and can't be rotated, even with a 
> pipe wrench.  I'm not afraid of breaking things if necessary, although 
> if I can get the whole thing off the boat in one piece I'd be happy to 
> offer it up to anyone gratis for spare parts.
>
> gene
>
> *Satori*, #398
>