TRAC Small Craft Trailer Winch User Manual
Contents
1. The transmitter is not properly oriented to the winch 5 Transmitter or receiver is bad 1 Winch is not connected to 12v battery 2 Bulb is burned out 3 Bulb is loose in the retaining clips or there is a loose connection 1 Electric brake may not be working correctly 2 Motor or control unit is bad 3 Duplex gear is locked up on the shaft and unable to remove easily 1 Program or reprogram wireless remote according to the instruction manual 2 Replace the battery 3 Get closer to the winch recommended operating range is 10 15 feet 3 4 5m from center of the winch 4 Position the remote above the level of the winch 5 Contact service center to replace wireless remote 1 Wire winch to 12v battery using the supplied wiring harness 2 Replace bulb with new one 3 Attached bulb so that it is secure within the bulb socket 1 Remove cover and make sure all wire connections are secure and battery is fully charged or vehicle is running if connected to vehicle s battery 2 Remove electric brake from side of motor by unscrewing the three screws that hold it on and unplugging the quick connect wire connector that runs from the electric brake to the control unit Set electric brake aside 3 Test unit with wired controller and wireless remote If winch runs better the electric brake was the culprit 4 Unplug motor from the control unit and test motor by putting power directly to the motor If motor2. before attempting to install service relocate or perform maintenance 2 Never use the winch to lift or move people or animals 3 Stand away from the winch when in use and keep children away from winch area at all times Always stand clear of the area behind and between the load or anchor point and the winch Serious injury could occur if the cable breaks 4 Always keep hands clear of cable spool drum area 5 Do not wear loose fitting clothing scarves or neck ties Loose clothing may become caught in moving parts and result in serious personal injury 6 Never use the winch for overhead lifting 7 Always wire the winch with circuit breakers Failure to use the breakers could cause overheating thus creating a potential fire hazard or motor damage A DANGER Always leave a minimum of five wraps of cable on the drum at the bottom layer to achieve a rated load 8 Inspect the cable for weak or worn condition or kinking short tight twist or curl before each use 9 When replacing the cable always use a Trailer winch cable with the rating and cable strength 10 Never substitute rope for cable Possible injury could occur 11 Do not attempt to pull a load greater than the rated load of the winch 12 Do not use the winch to solely hold or support the boat When the boat is on the trailer secure the boat with tie downs Always use tie down straps to hold the boat to the trailer Damage could occur to the winch or
3. INSTALLATION AND OPERATING INSTRUCTIONS TRAILER WINCHES For TRAILER WINCH Model T10121 C Small Craft Every installation can be different If you have any questions or difficulty installing this product TRAC is here to help First READ THIS MANUAL If you still need help call us from 9 am to 4 pm central time Monday Friday 615 462 6224 Note At this time we provide Phone Support in English only INSTALLATION AND OPERATING INSTRUCTIONS TRAILER WINCHES Trailer winches are used for launching and loading boats on trailers Please read and save these instructions Read carefully before attempting to install operate or maintain the winch Protect yourself and others by observing all safety information Failure to comply with instructions could result in personal injury and or property damage UNPACKING When unpacking inspect for any damage that may have occurred during transit Make sure any loose bolts nuts etc are tightened before putting unit into service SPECIFICATIONS Various load conditions will affect winch performance The line pull required for a specialized application depends on the weight of the load condition of the trailer and the incline of the loading ramp The chart below is a guideline only Lite Cruiser Lite Cruiser Cable Sem upto 24 73m Rolling Boat Weight 5 000 Ibs 7 000 Ibs 10 000 Ibs 10 000 Ibs a Wireless Remote Control w e e e Model Name S
4. below the label Tighten retaining ring by threading the ring tight to the bottom of the winch This will hold the bolts while you Align the bolts with the bolt holes on the winch stand Install flat lower the winch onto the trailer s winch stand washer lock washer and nut NOTE The cable as it exits the winch and the bow eye on the boat should be at the same height when the boat If the bow eye is too high extra stress is exerted on the boat s bow is in the fully loaded position on the trailer eye and stern If the winch is too low it will pull the boat into the bunks instead of along them To achieve equal height of the winch and boat raise or lower the winch stand In most cases the trailer manufacturer will have an adapter or optional winch stands TRAC does not offer winch stands due the great variety of trailers A CAUTION Eight 8 inches 20cm clearance is required between the winch and bow eye to prevent the cable hook from being drawn into the winch drum If necessary relocate winch stand or bow stop to obtain clearance Typical Installation To permanently wire the winch refer to figure below and follow the outlined procedures 1 Attach circuit breaker to positive battery post A CAUTION Never attach circuit breaker to battery negative 2 Run positive wire not included through or under the vehicle to from the battery to the rear of the vehicle Attach at suitable intervals to t
5. d not reach 30 amps There are so many variables such a ramp angle boat weight resistance on the trailer bunk roller etc that we do not know if your rig would work or not Many of our customers are successful using this circuit but we do not know if your boat and trailer would work or not Wiring your vehicle with a high current 60 amp circuit is best However if you want to try the 30 amp circuit in your round plug on your tow vehicle it is up to you To use this circuit you would need to ground the winch s negative black wire to the trailer frame The positive wire would be connected to the 30 amp circuit on your round plug on your vehicle A round plug adaptor can be purchased we do not sell them check any store that sells trailer lights to plug into the receptacle on your vehicle The receptacle on your vehicle plug does NOT have a high current ground black wire so the trailer and vehicle frame must complete the ground circuit while the positive wire does run through the round plug Q Where does the circuit breaker go A The circuit breaker gets attached to the positive battery post Never attach the circuit breaker to battery negative If for some reason the circuit breaker cannot be placed at the battery post it can be spaced up to 6 inches 15cm away from the post by adding a short length of battery wire between the post and the breaker Q Why don t you include the vehicle wiring A Weare trying to keep winch costs l
6. eration UNLOADING To unload the boat follow these procedures Clear the area around and behind the boat of people animals and obstructing objects before loading or unloading or personal injury could occur 1 If it is not already attached attach winch cable hook to the bow eye on the boat Always stand clear of the area behind the boat and between the winch and boat if the cable breaks of the winch controls the free spool function and is Serious injury could occur The clutch control knob on the side sometimes used to unload the boat or to pull cable out of the winch 2 To free spool and let cable out loosen the wing nut and turn the clutch knob counterclockwise to release the clutch and allow the cable to free wheel out 3 Allow the boat to slide off the trailer a slight push may be necessary to start the boat down the trailer If needed turn the clutch knob clockwise to use the brake to slow the boat at launch 4 When the boat is in the water release the winch cable hook from the bow eye Be sure to keep constant pressure on the cable when rewinding the cable with no load A loose cable may rewind improperly and damage the level wind plate Secure the cable hook to prevent personal injury or property damage LOADING AWARNING 1 Align the boat to trailer Always stand clear of the area between the boat and winch Serious injury could occur if the cable breaks 2 Free spool the winch cable out o
7. essary relocate the winch stand or bow stop to obtain clearance Q What is the best way to power the winch A There are three ways to power the winch 1 The best way is to use the vehicle s battery The tow vehicle s engine alternator generator puts out about 17 volts and plenty of current amps to power the winch This allows the winch to achieve maximum pulling power To use the vehicle s battery a vehicle wiring kit Item T10135 can be used to route the power from the vehicle s battery to the rear of the vehicle where a plug system can be used The winch power cable can be plugged into this system 2 A deep cycle marine battery can be placed in the rear bed of a pick up truck and the winch connected to it Use good judgment to secure the battery while trailering 3 A deep cycle marine battery can be installed on the trailer tongue Be sure to use an adequate battery box and means to secure the battery during trailering Q Can use the trailer light plug on my tow vehicle A The older style 4 FLAT plug four electrical connections in a straight row cannot be used The winch draws too much current for these light weight wires The new style 7 point round connectors typically have a 30 amp circuit The trailer winches can draw up to a maximum of about 35 amps So if the winch is maxed out it would cause the circuit breaker to break the circuit If the boat was light or trailer had rollers it is possible the winch woul
8. ew not refurbished TRAC Trailer Winch This limited warranty is not transferable to any other party TRAC will at it option repair or replace any part of the TRAC Trailer Winch which may be found by TRAC to be defective within two 2 years of original purchase TRAC does not pay for the shipping cost from original purchaser to TRAC You will have to ship the items to us for repair or replacement For warranty repair or replacement the purchaser will provide dated proof of purchase sales receipt and promptly notify TRAC of the request for warranty action The purchaser will notify TRAC by email at info TRAC Outdoor com or by calling 615 462 6224 for warranty action Purchasers will be provided a Return Goods Authorization RGA to include with return for warranty work which will be shipped at the purchaser s expense to the address provided The purchaser must use reasonable care in maintenance and operation of the product in accordance with this manual Failure to follow the instructions in the manual will void the warranty This warranty covers defects in material or workmanship of the TRAC Trailer Winch only This warranty does not cover failure that results from misuse improper installation accident abuse neglect modification or improper maintenance There are no other express or implied warranties Any damage to watercraft or trailer resulting from proper or improper use of this TRAC Trailer Winch is not covered under this warranty Costs of instal
9. he vehicle frame Use nylon wire ties not supplied to secure the wire to the vehicle frame about every 12 inches 30 5cm Avoid sharp edges or places where the wire might rub 3 Attach negative wire ground wire to the vehicle frame using a bolt and lock nut Before attaching the ground wire clean the metal with wire brush or sandpaper Asan option the negative wire can be run along with positive wire to battery negative terminal 4 At rear of vehicle install a suitable 12v socket such as used for a trolling motor Install the socket at rear of the vehicle and plug at end of the winch battery cable Optional Wiring An auxiliary battery may be used and can be installed on the trailer or secured in the bed of a truck If auxiliary battery is used it should be a Marine battery Batteries not designed for deep discharge deep cycle may not provide current required WIRED REMOTE Winch comes with a Wired remote control it is a hand held remote with 9 2 7m cord that plugs into the side of the winch Flectric 1 1 2 Round Hole Adaptor Negative Wire Black The winch comes with 9 2 7m of battery wire suitable to reach the rear of the tow vehicle or nearby battery Vehicle Wiring Kit item 1710135 can be purchased separately When the tow vehicle is running its alternator generator provides optimum voltage and current which will allow the winch to reach its maximum pulling power Winch Op
10. lation or repair by service centers or marine repair facilities are not covered by this warranty This is the exclusive remedy and any liability for any and all incidental or consequential damages or expenses whatsoever is excluded Some states do not allow limitations on how long an implied warranty lasts or do not allow exclusion or limitation of incidental or consequential damages the above limitations may not apply to you This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state If ordering a part provide the product model as well as the part number PARTS Fastener screw TRAC Outdoor Products Company 251A Mayfield Drive Antioch TN 37167 www trac outdoor com info trac outdoor com 615 462 6224
11. mall Craft Day Runner unieweight tobe 739 ves 274 aes 109 2s noa Winch Dimension LxWxH 8 25 x 9 x 6 75 8 25 x 9 x 6 75 9 5 x 9 5 x 8 9 5 x 9 5 x 8 ea 21 x 22 9 x 17 1cm 21 x 22 9 x 17 1cm 24 1 x 24 1 x 20 3cm 24 1 x 24 1 x 20 3cm Model Number T10121 C T10124 C T10128 C T10129 S vec notete otc MPS GENERAL SAFETY INFORMATION Throughout this manual potential safety hazards will be noted with the following terms Please read and understand these terms before operating the product A DANGER A CAUTION Danger means a hazard that WILL Warning means a hazard that COULD Caution means a hazard that MAY cause cause death or serious injury if the cause death or serious injury if the minor or moderate injury if the warning warning is ignored warning is ignored is ignored It may also mean hazard that will only cause damage to property The Following Safety Precautions Must Be Followed At All Times NOTE Note means any additional information pertaining to the product or its proper usage The following safety precautions must be followed at all times 1 Read all manuals included with this product carefully Be thoroughly familiar with the controls and the proper use of the equipment Only persons well acquainted with these rules of safe operation should be allowed to use the winch A WARNING Always unplug the wiring harness to prevent accidental starting
12. ove the cover and lubricate the gears once a year with marine grease Be careful not to get grease on the clutch lining Before removing the housings slice the printed label down the middle with a utility knife CABLE REPLACEMENT DANGER Ff ways unplug the wiring harness to prevent accidental starting before attempting to install service or perform any maintenance To replace the cable follow the outlined procedures Use an exact replacement TRAC cable The winch rating and cable strength are carefully matched 1 Unplug the power cord Loosen the clutch knob and free spool the cable out 2 It is not necessary to remove the cover in order to replace the cable however removing the cover does create more access to the drum shaft and make the installation easier 3 Remove the set screw on the cable spool and remove cable 4 Insert the new cable into the drum shaft hole and replace set screw and tighten Cable A Fastener Insert New Cable 5 Reassemble the cover halves back onto the winch if they were removed during the cable installation process 6 Power in the cable with a light load to help wind the cable straight and tight onto the drum COURTESY LIGHT OPERATION The trailer winches come equipped with a 12v Courtesy light The winch must be wired to a 12v battery in order for the light to function There is a push button switch located on the wired control of the winch that activates the light Push the bu
13. ow and not everyone requires the vehicle wiring A kit is available from TRAC Item T10135 visit our website TRAC Outdoor com for details Q What size gauge wire should use to wire my vehicle A Asa minimum 10 gauge wire is acceptable 8 gauge is best Q How much current amps does my winch use A It depends on the weight of your boat if you have roller or flat bunks on trailer angle of boat ramps etc The rough range is 20 to 35 amps Q Can l place a strap on my cable winch A No the spool is too wide and there is no good way to attach the strap to a cable drum Wedo make the Lite Cruiser with strap Item T10129 Q Dolneed to lubricate the winch A The cable should be lubricated a minimum of once a year with a Wire Rope Spray WD40 or a similar product Spray the spool and the cable as the cable is being wound You may remove the cover and lubricate the gears once a year with marine grease Be careful not to get grease on the clutch lining It is not necessary to lubricate the internal gears on a new winch Q Should it be this loud A It s an electric winch with steel gears and normally has gear noise It s normal Q Can winch the boat in manually if don t have electric power A Yes the manual crank comes with the winch and can be used to winch the boat onto the trailer Limited Warranty This limited warranty is provided by TRAC Outdoor Products Co TRAC to the original consumer purchaser purchaser of the n
14. r power out with control and attach the cable hook to the eye on the boat 3 The clutch control knob must be tight to winch the boat onto the trailer 4 Plug in the wired remote 5 Press and hold the retrieve button to begin retrieving the boat 6 Power in the cable IN until the boat touches the bow stop Secure boat to trailer with tie downs once the boat is fully loaded Optional Manual Clutch control knob crank handle Turn counter clockwise to release the Clutch Turn clockwise to tighten 4h DA NG E R Do not use the winch to solely hold the weight of the boat while in transit Always secure the boat to the trailer with tie down straps before towing the boat and trailer 6 Make sure clutch knob and boat to trailer straps are tight and secure MANUAL CRANKING You may manually crank the winch to retrieve a boat 1 Remove the crank handle from the housing 2 Remove the outer wing nut loosen the clutch knob and place the hand crank on the shaft Tighten wing nut against crank handle leave the clutch knob loosened 3 Turn crank handle clockwise to retrieve boat 4 After using the emergency hand crank remove it and replace in rear of housing 5 Replace wing nut and tighten Manual Crank Handle Maintenance LUBRICATION The cable should be lubricated a minimum of once a year with a Wire Rope Spray WD40 or a similar product Spray the shaft and the cable as the cable is being wound You may rem
15. runs the control unit is bad If it doesn t then the motor is the problem 5 Check the duplex gear by removing the cotter pin and sliding the gear off its shaft Ifthe gear Slides freely it is good and can be slid back on If the gear is locked up on the shaft and unable to remove easily then this may not allow the motor shaft to power the winch correctly Frequently Asked Questions Q Can I mount the winch onanangle A Yes the winch can be installed at up to 15 degree angle tilted up or down but not much more than that or the cable will rub on the winch housing NOTE The winch should be installed so the cable strap as it exits the winch is even with the bow eye on the boat when the boat is in the fully loaded position on the trailer If the winch is too high extra stress is exerted on the boat s bow eye and rear of the trailer If the winch is too low it will pull the boat into the bunks instead of along them To achieve equal height of the winch and bow eye raise or lower the winch stand or reposition the winch Q How close can mount the winch to the bow eye A We recommend 8 inches 20cm clearance between the winch and bow eye to prevent the cable strap hook from being drawn into the winch drum There is such a wide variation between trailer and boat types that you may need more clearance or less might be acceptable Consider your application and position the winch so the hook remains outside the winch housing If nec
16. the boat if boat to trailer tie down straps are not used 13 Never wrap the winch cable around the load Use suitable chain to prevent the cable from kinking or fraying 14 Always wear leather gloves when handling the cable Steel cable can cause hand injuries A CAUTION After using the winch always disconnect the power cord from the socket to avoid moisture collection in the socket and prevent the possibility of short circuiting 15 Do not operate the winch under the influence of drugs alcohol or other medication Do not use the winch to solely secure boat to trailer during transit Use separate tie down straps to secure the boat to the trailer Winch Installation Install the electric winch in the same location as the existing hand winch Remove the hand winch from the winch stand Install the electric winch unit using three 3 3 8 10mm Grade 5 machine bolts nuts and washers included If the winch stand does not have three holes you may have to drill two holes for the two bolts which are located at the rear end end that has a printed label Locate the three mounting bolts that came in the box Remove the nut and 2 washers from the bolts Adjust retaining ring by unscrewing it to allow about 1 4 inch 6 5mm of space between the retaining ring and head of bolt Insert head of bolt into keyhole on bottom of winch Slide bolt head along the slot Two bolts are to be located at the rear end of the winch
17. tton VF turn light on and press Q the to turn it off To prevent damage to light do not operate light for longer than 20 minutes LIGHT BULB REPLACEMENT 1 Remove the two screws that hold the Lens against the winch cover 2 Remove the lens 3 Remove the bulb 4 Replace with new light bulb and reinstall lens The light bulb is a 5W halogen bulb melt the housing and void warranty Higher wattage may Halogen bulb Troubleshooting Guide Winch does not operate 1 Disconnected power wire 2 Disconnected control wire 3 Damaged Circuit Breaker Corrective Action 1 Start by checking the wiring at the battery Bypass the circuit breaker and test the winch If the winch operates replace the circuit breaker 2 Check wiring insulation for worn or bare spots that may be causing a short Check all connections for tightness 3 Load slips under retrieval 1 Clutch knob not fully tightened 1 Tighten clutch knob 2 Clutch lining worn or dirty 2 Replace clutch lining or clutch knob Transmitter will not operate winch but manual override switch will Light will not turn on Winch is making a clicking sound and not powering in or out running and stopping in brief short increments or running intermittingly 1 Transmitter was not programmed properly to the receiver 2 Battery in transmitter is low or dead 3 The transmitter is outside of its recommended operating radius 4
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