P7040104AV 915 OWNERS MANUAL.indd
Contents
1. FRAME eS 5 16 LOCK WASHER AND NUT Figure 1 Permanent Wiring Hookup 3 P7040104AV Installation continued 3 Run the wire under the vehicle to the battery attach ing 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 hot or moving engine parts manifold radia tor hoses etc 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 TEMPORARY WIRING To temporary wire the winch follow the outlined proce dures A complete wiring harness is available from the dealer Part Number P7866000AJ 1 Attach two large alligator type clips one to the cir cuit breaker and one to the end of the black wire 2 Run the red wire with the circuit breaker to the bat tery and clip the wire to the hot positive side of the battery 3 Clip the black wire to the vehicle frame or negative side of the battery Operation UNLOADING To unload the boat refer to Figure 2 and follow the outlined procedures MODEL 915 1 Attach the winch cable hook to the bow eye on the boat See Figure 2 Operation continued AWARNING CLEAR THE AREA AROUND AND BEHIND THE BOAT OF PEOP2. Remove the two cover connecting screws and rods See Figure 3 from 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 priate socket if the light does not illuminate If the light illuminates check the switch and or motor 3 Bad switch or motor Test the switch by using a jumper wire to bypass the switch Keep fingers away from the winch mecha nism If power gets to the motor replace the switch If no power gets to the motor replace the motor Clutch does not 1 Jam nuts too loose 1 Adjust the brake See brake adjustment section in hold this manual 2 Worn gears or clutch lining 2 Replace gears or clutch lining P7040104AV MODEL 915 Limited Warranty A This Limited Warranty is given by the Powerwinch Division of the instructions con tained in the Owner s Manual Scott Fetzer Company the Com pany to the original purchaser the Purchaser of a Pow erwinch Prod uct the Product spec ified in this man ual This Limited War ranty is not trans ferable to any other party 6 Except as noted in B 2 transportation charges are the re sponsibility of the Purchaser 5 Have Warranty work performed by a dealer or repre sentative ap proved by the Company B Responsibilities of the Company under this Limited Warranty 1 Re pair or replace at the discretion of the Co
3. IDENTAL OR CONSE QUENTIAL DAMAGES OR given prior to any Prod uct return Call the Company at EXPENSES WHAT SO EMER IS EXCLUDED AU 1800 059 899 NZ 0800 876 526 or write the iy 3 Company for authorization and complete instructions Some states do not allow limitations on how long an implied war on how to return the Product directly to the Company ranty lasts or do not allow exclusion or limitation of incidental or Trail Com AU Limited Trail Com Limited conse quential dam ages the above limitations may not apply to Unit 5 25 27 South Link 15 Oak Road you This Limited Warranty gives you specific legal rights and Dandenong Melbourne or Manukau Auckland you may also have other rights which vary from state to state Victoria 3175 New Zealand 4 Use reasonable care in maintenance operation use and storage of the Product in accordance with the All rights reserved This publication or parts thereof may not be reproduced in any form without written permission Powerwinch reserves the right to alter specifications on any product without notice
4. LE ANIMALS AND OBSTRUCTING OBJECTS BEFORE LOADING OR UNLOADING POSSIBLE INJURY COULD OCCUR 2 Remove the boat tie downs A WARNING ALWAYS STAND CLEAR OF THE AREA BETWEEN THE LOAD OR ANCHOR POINT AND THE WINCH SERIOUS INJURY COULD OCCUR IF THE CABLE BREAKS 3 Step clear of the winch and winch cable area Use the remote control switch and power out the cable until the boat is completely unloaded 4 Remove the winch cable hook from the bow eye and power in the cable LOADING To load the boat follow the outlined procedures 1 Align the boat and trailer 2 Power out the winch cable and attach the winch cable hook to the bow eye on the boat AWARNIN ALWAY STAND CLEAR OF THE AREA BETWEEN THE LOAD Figure 2 Operation Components 4 P7040104AV MODEL 915 Operation continued OR ANCHOR POINT AND THE WINCH SERIOUS INJURY COULD OCCUR IF THE CABLE BREAKS 3 Step clear of the winch and winch cable area Use the remote control switch and power in the cable until the boat hits the bow stop 4 When the boat is fully loaded secure the boat to the trailer with tie downs It is not recommeded to use the winch to hold the load because damage could occur to the winch 5 Remove the winch cable hook from the bow eye and power in the cable Maintenance LUBRICATION Once a year the cable should be lubricated with Whitmore s Wire Rope Spray WD40 or a similar prod uct Spray the drum and the
5. Powerwinch OPERATION AND PARTS MANUAL BOAT TRAILER WINCH MODEL 915 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 Description Trailer winches are used for launching and loading boats This winch features power in and power out capabilities with a hand held remote control device Unpacking When unpacking this product carefully inspect for any damage that may have occurred during transit General Safety Information The following safety precautions must be followed at all times 1 Read all manuals included with this product care fully 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 AWARNING hane UNPLUG THE WIRING HARNESS TO PREVENT ACCI DENTAL STARTING BEFORE ATTEMPTING TO INSTALL SERVICE RELOCATE OR PERFORM ANY MAINTENANCE 2 Never use the winch to lift or move people or ani mals 3 Stand away from the winch when in use and keep children free from winch area at all times AWARNING aways stan CLEAR OF THE AREA BETWEEN THE LOAD OR ANCHOR POINT AND THE WINCH SERIOUS INJURY COULD OCCUR IF THE CABLE BREAKS 4 Always ke
6. cable as the cable is being wound Remove the cover and lubricate the gears once a year with a lithium base grease Be careful not to get grease on the clutch lining Maintenance continued CABLE REPLACEMENT 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 AWARNING ALWAYS UNPLUG THE WIRING HARNESS TO PRE VENT ACCIDENTAL STARTING BEFORE ATTEMPT ING TO INSTALL SERVICE RELOCATE OR PER FORM ANY MAINTENANCE 1 Power out the cable using the remote control device and unplug the wiring harness 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 3 CABLE J FASTENER COUNTERBORE lt CABLE DRUM INSERT Figure 3 Cable Replacement 5 P7040104AV MODEL 915 Maintenance continued 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 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 co
7. connect 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 Specifications Various load conditions will affect the winch perfor mance The line pull required for a specific applica tion depends on the weight of the load condition of the trailer rollers and the degree of the loading ramp incline The chart on the following page is based ona single line pull and is a guideline to aid in calculating pulling requirements P7040104AV 12 06 P7040104AV MODEL 915 Chart 1 Approximate Rolling Load Capacities Level incline Surface 5 10 20 30 50 70 100 incline 0 3 6 11 17 26 35 45 Boat Wt in Ibs 32 000 20 010 15 060 10 200 7 830 5 580 4 590 3 870 e A 10 incline or 6 is 1 ft rise in 10 feet e To convert pounds to kilos divide by 2 2 e Capacity can be increased almost doubled by using a pulley block Chart 2 Winch and Boat Capacities Single Double Approximate Approximate Model Line Pull Line Pull Boat Weight Boat Size 915 3 200 Ibs 5 900 Ibs 9 500 Ibs 22 29 ft Boat size and weight are approximate and varies depending on boat type When calculating the boat weight be sure to use fully loaded weight i
8. e winch If a Quick Mount Kit is used make sure the winch is in the for ward position before installing the eye bolt PERMANENT WIRING To permanently wire the winch refer to Figure 1 follow the outlined procedures Rear Mounted Winch 1 Attach the circuit breaker to the positive battery post or to the positive battery side of the starter solenoid See Figure 1 Never attach the cir cuit breaker to the A CAUTION battery ground termi nal 2 Run the wire under the vehicle to the battery attach ing 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 Front Mounted Winch 1 Attach the circuit breaker to the positive battery post or to the positive battery side of the starter solenoid See Figure 1 2 Cut the harness at the circuit breaker end to the required length BATTERY amp TERMINAL 12 VOLT CAR lt OR TRUCK BATTERY NOT SUPPLIED lt _ 5 16 BOLT VEHICLE lt
9. ep hands clear of cable spool drum area 5 Do not wear loose fitting clothing scarves or neck ties Loose clothing may become caught in mov ing 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 Copyright 2006 Carefree of Colorado General Safety Continued THE CABLE FASTEN VNE Y N Ce 5 SERS 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 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 14 Always wear leather gloves when handling the cable Steel cable can cause hand injuries A CAUTION After using the winch always dis
10. he A CAU T l ON inner nut Overtighten ing the inner nut short ens the motor life 3 Tighten the outer nut against the inner nut to secure STORAGE The winch cable must be lubricated before storing Lubricate the cable with Whitmore s Wire Rope Spray WD40 or a similar product Spray the drum and the cable as the cable is being wound Technical Service and Replacement Parts Information For information regarding the operation or repair of this product please call AU 1800 059 899 or NZ 0800 876 526 and have the following information available Model number e Serial number Part number and description Address correspondence to Trail Com AU Limited Trail Com Limited P O Box 7061 r P O Box 98 961 Dandenong Melbourne SAMC Auckland Victoria 3175 New Zealand g Figure 4 Brake Adjustment 6 P7040104AV MODEL 915 General Troubleshooting Guide SYMPTOM POSSIBLE CAUSE S CORRECTIVE ACTION Winch will not 1 Disconnected or bad wiring or 1 Start checking the wiring at the battery Bypass the operate bad circuit breakers circuit breakers and test the winch If the winch operates replace the circuit breakers Check the wiring insulation for worn or bare spots that may be causing a short Check all connections for tightness 2 Bad plug Check the male connection at the end of the wir ing kit by using probe light across the two prongs inside the plug If the light illuminates the wiring is correct
11. mpany D This Limited Warranty covers any part or parts of the Product found by the Compa 1 Defects in workmanship or materials ny to be defective within a two 2 year period from the 2 Any part or parts of the Product sold or manufactured date of pur chase by the Company 2 The Company will pay the transportation charge pier for ship ment back to the Purchaser of any Product E This Limited Warranty does not cover received for legitimate War ranty re pair 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 accor dance with the instructions provided in the Owner s Manual sup plied with the Prod uct F THERE IS NO OTHER EXPRESS WARRANTY IMPLIED WAR RAN TIES INCLUDING THOSE OF MERCHANT ABILITY AND C Responsibilities of the Purchaser under this Limited War ranty 1 Complete fully and accurately and return to the Com pany the Warranty card included in the box Oth erwise 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 Com pany of any claim hereunder FIT NESS FOR A PAR TIC ULAR PUR POSE ARE LIMITED TO 3 At the Option of the Company return the Product to E A ANOINT Pee EA ae the Company for inspection Authorization must be ALL INC
12. ncluding boat motor fuel etc Chart 3 Winch Specifications Line Speed Gear Voltage Circuit Unit Weight Model Capacity FPM Ratio volts BST Ibs Depth Height Width amps 915 10 450 1 12 60 40 10 10 8 P7040104AV MODEL 915 Installation MOUNTING The winch can be mounted on the trailer in the same position and location as a present winch After remov ing 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 P7700000AJ 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 man ufacturer will have an adapter available for use with a inch A CAUTION Minimum of 12 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 clear ance 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 th
13. ver 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 When powering in the cable the motor will continue to run for a few seconds after releasing the toggle switch on the remote control device especially without a load Be sure to allow for this Do not let the cable hook go into the winch and bend the level wind plate When winding the cable onto the drum with no load keep the cable taut tight going into the drum BRAKE ADJUSTMENT The winch is equipped with a friction brake which holds the load when the power is off If the load creeps while the power is off or if the brake slips while powering the load in or out the brake needs adjustment To adjust the brake follow the outlined procedures and refer to Figure 4 Do not adjust the brake A CAUTION with a ead attached to the winch The load could release and cause load damage or personal injury INNER JAM NUT JAM NUT Oz OUTER 86 f 1 Make sure a load is not attached to the winch Locate the jam nuts on the rear shaft on the left side of the winch while facing the cable opening 2 Loosen the outer jam nut and tighten the inner nut Turn the inner nut clockwise to increase the load capacity or turn counterclockwise to decrease the load capacity The inner nut should be tight enough to keep the load from slipping or creeping Do not overtighten t
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