P7033603AV 912-712-315 Owners Manual.indd
Contents
1. the same winch 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 hold or support the load once a job is complete or to permanently secure the load Damage could occur to the winch or the load 13 Never wrap the winch cable around the load Use an Ecostrap or chain to prevent the cable from kinking or fraying 2006 Carefree of Colorado P7033603AV 12 06 Operating Instructions 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 Always block the vehicle wheels to help prevent the vehicle from rolling when pulling a load with the winch 16 Do not operate the winch under the influence of drugs alcohol or other medication Secure the boat to AWARNING the trailer after winching the boat onto the trailer or personal injury could occur Specifications Various load conditions will affect winch performance The line pull required for NOTE The noise level of this winch in operation is below 98db A Chart 1 Approximate Rolling load capacities a specific application depends on the weight of the load conditio2. 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 AWARNING Always unplug the wiring harness to prevent accidental starting before attempting to install service relocate or perform any maintenance 2 Never use the winch to lift or move Model 315 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 AWARNING 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 Models 712A 912 The cable fasteners A DANGER on this or any winch are not designed to hold rated loads Always leave a minimum of five wraps of cable on the drum at the bottom layer to achieve a rated load 8 Inspect the entire cable for weak or worn condition or kinking short tight twist or curl before each use 9 When replacing the cable always use a Powerwinch cable with
3. Never attach the A CAUTION circuit breaker to the battery ground terminal 2 Run the wire under the vehicle to the battery attaching at suitable intervals to the vehicle frame Use nylon wire ties not supplied to secure the wire to the vehicle frame about every 18 inches If no wire ties are available use electrician s tape Avoid sharp edges or places where the wire might rub 3 Attach the ground wire black to the vehicle frame using a 5 16 bolt and lock nut Before attaching the wire clean the metal with a wire brush steel wool or sandpaper 4 Remove the knock out plug in the spare tire well and draw the excess wire up into the vehicle PERMANENT WIRING FOR MODEL 315 To permanently wire the winch refer to Figure 2 follow the outlined procedures 1 Strip approximately 3 8 of insulation from each wire end 2 Grasp one end of the red and black wires insert the wires into rubber boot and the plug cover 3 Attach the red wire to the gold terminal and attach the black wire to the silver terminal 4 Firmly tighten the two screws that hold the wires in place Screw the plug cover into the plug base and slide the rubber boot firmly over the plug 5 Run the red and black wires under or through the vehicle Drill holes to feed the wires and be sure to protect the wires from damage by using grommets not supplied Worn wire insulation can cause short circuits At 10 interval
4. Operating Instructions 315 712A and 912 Please read and save these instructions Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with instructions could result in personal injury and or property damage Retain instructions for future reference Powerwinch Boat Trailer Winch Description Trailer winches are used for launching and loading boats This winch features power in free wheel out capabilities A lanyard cord is supplied for remote operation Unpacking When unpacking inspect carefully for any damage that may have occurred during transit Make sure any loose fittings bolts etc are tightened before putting unit into service General Safety Information Danger means a A DANGER hazard that will cause death or serious injury if the warning is ignored AWARNING Warning means a hazard that could cause death or serious injury if the warning is ignored Caution means a A CAUTION hazard that may cause minor or moderate injury if the warning is ignored It also may mean a hazard that will only cause damage to property 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
5. fully loaded Do not use the A DANGER A DANGER pii to hold the weight of the boat while in transit Always secure the boat to the trailer before towing the boat and trailer 6 Remove the winch cable hook from the bow eye and power in the cable Secure the cable hook to prevent personal injury or property damage EMERGENCY HAND CRANK The emergency hand crank is included on some models This emergency hand crank should only be used when there is no power source i e dead battery The emergency hand crank should never be used to help a running motor To use the winch in manual mode follow the procedures outlined below 1 Unplug the winch from the wiring harness 2 Turn the clutch control knob clockwise until tight DO NOT overtighten the knob or clutch damage will occur See Figure 5 Emergency Hand Crank XN Emergency Hand Crank x Figure 5 3 Remove the outer nut shown in Figure 5 and place the emergency hand crank on the shaft 4 Tighten the outer nut firmly against the hand crank After using the emergency hand crank follow the procedures outlined below 1 Remove the outer nut shown in Figure 5 and remove the emergency hand crank off the shaft 2 Tighten the outer nut firmly against the inner nut Maintenance LUBRICATION The cable should be lubricated a minimum of once a year with Whitmore s Wire Rope Spray WD40 or a similar product Spray the shaft and t
6. he cable as the cable is being wound Remove the cover and lubricate the gears a minimum of once a year with a lithium base grease Be careful not to get grease on the clutch lining Operating Instructions Cable A Fastener lt Counterbore Cable Drum Insert New Cable Figure 6 Cable Replacement CABLE REPLACEMENT Always unplug the AWARNING wiring harness to prevent accidental starting before attempting to install service relocate or perform any maintenance To replace the cable follow the outlined procedures Use an exact replacement Powerwinch cable The winch rating and cable strength are carefully matched Never replace the cable with rope 1 Unplug the wiring harness Loosen the clutch knob and free wheel the cable out 2 Remove the two cover rods and the four cover screws 3 Cut the old cable approximately 2 from the drum and push the remaining cable and fastener through the drum to remove See Figure 6 4 Insert the new cable into the drum shaft hole at the end opposite the counterbored end Draw the cable through the hole and out the counterbored side of the shaft 5 Push the cable through the fastener until the cable end is flush with the end of the fastener 6 Crimp the fastener onto the cable and pull the cable through the drum shaft until the fastener seats inside the counterbore 7 Install the cover two cover rods and the four c
7. in the Owner s Manual supplied with the Product F There is no other express warranty Implied warranties including those of merchantability and fitness for a particular purpose are limited to two 2 years from date of purchase 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
8. n of the trailer rollers and the degree of the loading ramp incline The chart below is based on a single line pull and is a guideline to aid in calculating pulling requirements incline incline 315 16 500 10 005 712A 24 000 13 340 912 40 000 23 345 e A 10 incline or 6 is 1 foot rise in 10 ft 7 530 5 250 10 040 6 800 17 570 11 900 e To convert from pounds Ibs to kilos kgs divide by 2 2 e Capacity can be increased almost doubled by using a pulley block 2 790 2 295 1 935 3 720 3 060 2 580 6 510 5 355 4 515 Chart 2 Winch and boat capacities Double Line Pull Approximate Boat Weight Approximate Boat Size Single Line Capacity 315 1 650 Ib 712A 2 400 Ib 912 4 000 Ib 4 300 Ib 7 500 Ib 4 000 Ib 7 500 Ib 11 500 Ib 14 17 ft 17 23 ft 23 30 ft Boat size and weight is approximate and varies depending on boat type When calculating boat weight be sure to use fully loaded weight including boat motor fuel water gear etc Chart 3 Winch specifications Line Speed Capacity FPM 315 15 712A 14 912 8 270 1 225 1 450 1 Circuit Voltage Breaker Volts Amps 12 30 12 60 12 60 Unit Weight Ibs Depth Height Width 22 10 10 8 34 10 10 8 39 10 10 8 Operating Instructions Installation MOUNTING The winch can be mounted on the trailer in the same position and location as an existing hand winch Af
9. nd 912 only 2 Worn gears or clutch lining Replace gears or lining Technical Information For information on the operation or repair please call AU 1800 059 899 or NZ 0800 876 526 Replacement Parts Information For information regarding where to order replacement parts call the above numbers Please have the following information available Winch Model Number Winch Serial Number Part Number and Description Address correspondence to Trail Com AU Limited Trail Com Limited Unit 5 25 27 South Link 15 Oak Road Dandenong Melbourne ve Manukau Auckland Victoria 3175 New Zealand Operating Instructions Limited Warranty A This Limited Warranty is given by the Powerwinch Division of the Scott Fetzer Company the Company to the original purchaser the Purchaser of a Powerwinch Product the Product specified in this manual This Limited Warranty is not transferable to any other party B Responsibilities of the Company under this Limited Warranty 1 Repair or replace at the discretion of the Company any part or parts of the Product found by the Company to be defective within a two 2 year period from the date of purchase 2 The Company will pay the transportation charge for shipment back to the Purchaser of any Product received for legitimate Warranty repair C Responsibilities of the Purchaser under this Limited Warranty 1 Complete fully and accurately and return to the Company the Wa
10. o the end of the black wire Run the red wire with the circuit breaker to the battery and clip the wire to the hot positive side of the battery Clip the black wire to the vehicle frame or negative side of the battery Gold Circuit z Breaker Battery S Silver lt Terminal Terminal ggle Switch Terminal 12 Volt Car Or Truck Battery NOT SUPPLIED Ox gt Lock Washer Nut n pome Power Socket Figure 2 Permanent Wiring For Model 315 Operating Instructions Operation UNLOADING To unload the boat and follow the outlined procedures Clear the area A WARNING around and behind the boat of people animals and obstructing objects before loading or unloading or personal injury could occur 1 Attach the winch cable hook to the bow eye on the boat Always stand clear AWARNIN G of the area behind and between the load or anchor point and the winch Serious injury could occur if the cable breaks The clutch control knob on the side of the winch controls the loading and unloading operation See Figure 3 Turning the knob counterclockwise releases the brake and allows the cable to free wheel out Turn COUNTER CLOCKWISE To Release Brake Clutch Control Knob Figure 3 2 Turn the clutch knob slowly in a counterclockwise motion to release the brake on the winch 3 Allow the boat to slide off the t
11. over screws and connect the wiring harness 8 Power in the cable with a light load to help wind the cable straight into the drum LEVELWIND PLATE 1 When powering in the cable the motor will continue to run for a few seconds after releasing the switch especially without a load Be sure to allow for the extra cable when powering in Do not let the cable hook go into the winch and bend the level wind plate Troubleshooting Chart Symptom Possible Cause s Corrective Action a Start checking the wiring at the battery Bypass the circuit breakers and test the winch If the winch operates replace the circuit breakers Winch will not operate 1 Disconnected or bad wiring or bad circuit breakers b Check the wiring insulation for worn or bare spots that may be causing a short c Check all connections for tightness a Check the male connection at the end of the wiring kit by using 2 Bad plug probe light across the two prongs inside the plug If the light illuminates the wiring is correct b Remove the two cover connecting screws and rods the cover containing the female socket Plug the male socket into the female socket Use a probe light across the two connections on the underside of the female socket Replace the appro prite socket if the light does not illuminate If the light illuminates check the switch and or motor Clutch does not hold 1 Worn or broken roller clutch Replace roller clutch Models 712A a
12. railer a slight push may be necessary to start the boat down the run The following warning is for Model 315 ONLY Once the boat is AWARNI NG moving do not attempt to slow or stop the boat motion by turning the clutch knob The knob will free wheel with the outgoing cable Any contact with the clutch knob while in motion could result in personal injury The following statement is for Models 712A and 912 ONLY If needed turn the clutch knob counterclockwise 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 levelwind plate Secure the cable hook to prevent personal injury or property damage LOADING 1 Align the boat and trailer Always stand clear AWARNING of the area between the load or anchor point and the winch Serious injury could occur if the cable breaks 2 Free wheel the winch cable out and attach the cable hook to the eye on the boat 3 Turn the clutch control knob clockwise until finger tight to set the brake See Figure 4 Turn Clockwise To Set Brake Control Knob Figure 4 4 Step clear of the winch and winch cable area and power in the cable until the boat touches the bow stop 5 Secure the boat to the trailer once the boat is
13. rranty card included in the box Otherwise Purchaser will have to show dated proof of purchase to qualify for service under the provisions of the Limited Warranty 2 Promptly notify the Seller or the Company of any claim hereunder 3 At the Option of the Company return the Product to the Company for inspection Authorization must be given prior to any Product return Call or write to Trail Com AU Limited Trail Com Limited Unit 5 25 27 South Link ot 15 Oak Road Dandenong Melbourne Manukau Auckland Victoria 3175 New Zealand Free ph 1800 059 899 Free ph 0800 876 526 for authorization and complete instructions on how to return the Product directly to the Conpa ny 4 Use reasonable care in maintenance operation use and storage of the Product in accordance with the instructions contained in the Owner s Manual 5 Have Warranty work performed by a dealer or representative approved by the Company 6 Except as noted in B 2 transportation charges are the responsibility of the Purchaser D This Limited Warranty covers 1 Defects in workmanship or materials 2 Any part or parts of the Product sold or manufactured by the Company E This Limited Warranty does not cover 1 Any failure that results from improper installation of the Product 2 Any failure that results from accident Purchaser s abuse neglect modification improper maintenance or failure to operate and use the Product in accordance with the instructions provided
14. s join the red and black wires together using electrical tape or wire ties 6 Attach the 5 16 ring terminal to the end of the black wire and crimp together 7 Attach the 3 16 ring terminal to the end 12 Volt Car Or Truck Battery NOT SUPPLIED Vehicle Frame eo Ox 5 16 Lock Washer And Nut k Figure 1 Permanent Wiring Hookup for Models 712A and 912 Operating Instructions of the red wire and crimp together the circuit breaker and or motor which 2 Connect the could cause damage to the vehicle and AWARNING positive wire before winch grounding the black wire to the vehicle frame to prevent electrical arcing 8 Connect the red wire with the 3 16 ring terminal to the circuit breaker 11 Insert the plug into the power socket on the winch 3 TEMPORARY WIRING To temporary wire the winch follow the outlined procedures A complete wiring harness is available from the dealer Part Number P7866000Au for Models 712A and 912 Order part number P7865900AJ Never attach the for Model 315 A CAUTION red wire with the circuit breaker to the negative or ground battery terminal Incorrect wiring will short circuit and damage 9 Connect the circuit breaker to the battery terminal 10 Attach the black wire with the 5 16 ring terminal to the vehicle frame 1 Attach two large alligator type clips one to the circuit breaker and one t
15. ter removing the hand winch bolt the Powerwinch unit using a minimum of 2 3 8 Grade 5 machine bolts and lock nuts The Powerwinch Quick Mount Kit P7700000A is available from the dealer The cable hook on the winch and the bow eye on the boat should be at the same height when the boat is in the fully loaded position on the trailer If the bow eye is too high extra pull is required of the winch and extra stress is exerted on the boat s stern and bow eye 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 available for use with a winch A minimum of 12 A CAUTION inch clearance is required between the winch and the bow eye to prevent the cable hook from being drawn into the winch drum when the boat is in the fully loaded position on the trailer If necessary extend the bow stop to obtain the clearance When using a double line pull using a pulley block install an appropriate eye bolt on the winch stand as close as possible to the base of the winch If a Quick Mount Kit is used make sure the winch is in the forward position before installing the eye bolt PERMANENT WIRING FOR MODELS 712A AND 912 To permanently wire the winch refer to Figure 1 follow the outlined procedures 1 Attach the circuit breaker to the positive battery post or to the positive battery side of the starter solenoid See Figure 1
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