BOAT TRAILER WINCH
OWNER'S MANUAL
Models 712 & 912
Setup with double line pull (pulley block)
pw912101
12 Volt Powered Winch
Power-In/Free-Wheel Out Operation
P7033603r1 Printed in USA July, 2012
PROPRIETARY STATEMENT
The Powerwinch Trailer Winch is a product of Carefree of Colorado, located in
Broomfield, Colorado, USA. The information contained in or disclosed in this document
is considered proprietary to Carefree of Colorado. Every effort has been made to
ensure that the information presented in the document is accurate and complete.
However, Carefree of Colorado assumes no liability for errors or for any damages that
result from the use of this document.
The information contained in this manual pertains to th e current configuration of the
models listed on the title page. Earlier model configurations may differ from the
information given. Carefree of Colorado reserves the right to cancel, change, alter or
add any parts and assemblies, described in this manual, without prior notice.
Carefree of Colorado agrees to allow the reproduction of this document for use with
Carefree of Colorado products only. Any other reproduction or translation of this
document in whole or part is strictly prohibited without prior written approval from
Carefree of Colorado.
TABLE OF CONTENTS
Safety Information ................................................................................... 1
General Safety Information ........................................................................... 1
Specifications .......................................................................................... 2
Winch Specifications .............................................................................. 2
Approximate Rolling Load Capacities (values are in pounds) ................ 2
Winch & Boat Capacities (values are in pounds) ................................... 2
Mounting the Unit .................................................................................... 3
Mounting the Unit .......................................................................................... 3
Wiring the Unit ......................................................................................... 4
Pulley Block ............................................................................................. 5
Assembly Instructions: ........................................................................... 5
Double Lining the Winch ........................................................................ 5
Operating the Winch ............................................................................... 6
Unloading The Boat....................................................................................... 6
Loading the Boat ........................................................................................... 6
Emergency Hand Crank ................................................................................ 7
Maintenance ............................................................................................. 8
Lubrication ..................................................................................................... 8
Replacing the Cable ...................................................................................... 8
Troubleshooting Guide .................................................................................. 9
Replacement Parts List ........................................................................ 10
Warranty ................................................................................................. 12
Powerwinch 2145 W. 6th Avenue Broomfield, CO 80020
by Carefree of Colorado www.powerwinch.com
POWERWINCH 712 & 912 BOAT TRAILER WINCH
SAFETY INFORMATION
WARNING A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
THAT, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY AND/OR MAJOR
PROPERTY DAMAGE
.
CAUTION A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT
MAY CAUSE MINOR TO MODERATE PERSONAL INJURY AND
ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES
NOTE: A note indicates further information about a product, part, or step.
Tip: A tip provides helpful suggestions.
/OR PROPERTY DAMAGE. IT MAY
.
GENERAL SAFETY INFORMATION
The following Safety Precautions Must be followed at ALL Times
Failure to follow the warnings and cautions in this manual could result in
serious injury and/or property damage.
Thoroughly read the manuals furnished with this prod uct and be familiar with the
controls. Do not allow individuals to operate the winch without understanding th e
safe operation and procedures for the equipment.
WARNINGS
ALWAYS unplug the wiring harness before attempting to install, relocate,
service or perform maintenance on the unit.
NEVER use the winch to lift or move people or animals.
NEVER use the winch for overhead lifting.
NEVER attempt to pull a load greater than the rated load of the winch.
NEVER use the winch to exclusively hold, support or permanently secure the
load. Use separate straps to support the load.
ALWAYS stand away from the winch during operation. ALWAYS stand clear of
the area behind and between the load and the winch. Serious injur y could
occur if the cable breaks.
ALWAYS keep hands clear of the cable spool (drum area).
ALWAYS wear leather gloves when handling the cable.
NEVER wear loose fitting clothes, scarves, ties or jewelry when operating th e
winch. Loose clothing can become caught in moving parts.
ALWAYS use the recommended cable. Never substitute rope for cable.
ALWAYS block the vehicle wheels to help prevent the vehicle from moving
when pulling a load with the winch.
1
712 & 912 BOAT TRAILER WINCH POWERWINCH
SPECIFICATIONS
Various load conditions affect winch performance. The line pull required for a
specific application depends on the weight of the load, condition of the trailer
rollers, and the degree of the loading ramp incline. T he charts below are based
on a single line pull and provided as a guideline in calculating pulling capabilities.
WARNING THE CABLE FASTENERS ON THIS OR ANY WINCH ARE NOT
DESIGNED TO HOLD RATED LOADS INDEPENDENTLY. ALWAYS LEAVE A MINIMUM OF FIVE
WRAPS OF CABLE ON THE DRUM TO ACHIEVE THE RATED LOAD VALUES
Winch Specifications
.
Power In
Switch
Clutch Control
Knob
Power
Socket
8"
4 1/2"
8 3/4"
11 5/8"
PW912001
Circuit
Breaker Unit Weight
Model
9 5/8"
Line Speed
@ Capacity
(FPM) Gear Ratio Voltage
712 14 225:1 12VDC 60 amps 34 lbs.
912 8 450:1 12 60 amps 39 lbs.
Approximate Rolling Load Capacities (values are in pounds)
% Incline Level 5% 10% 20% 30% 50% 70% 100%
˚ Incline 0˚ 3˚ 6˚ 11˚ 17˚ 26˚ 35˚ 45˚
712 24000 13340 10040 6800 5220 3720 3060 2580
912 40000 23345 17570 11900 9135 6510 5355 4515
A 10% incline (6˚) is 1 foot rise in 10 feet.
To convert from pounds (lbs) to kilograms (kgs) divide by 2.2.
Capacity can be increased by using a pulley block.
Winch & Boat Capacities (values are in pounds)
Vertical Lift
Capacity Double Line Pull
Approximate
Boat Weight*
Approximate
Boat Size*
712 2400 4300 7500 17-23 Feet
912 4000 7500 11500 23-30 Feet
* Boat size and weight is approximate and varies depending on boat type.
When calculating boat weight, use the fully loaded weight that includes boat,
motor, fuel, water, gear etc.
2
POWERWINCH 712 & 912 BOAT TRAILER WINCH
MOUNTING THE UNIT
MOUNTING THE UNIT
The following instructions are for standard mounting of the winch. A quick mount
kit is available (p/n P7700000AJ). If installing with the quick mount k it, follow the
directions with the kit. Steps 3, 4 and 6 apply when using the kit.
The winch can be mounted on the trailer in the same position and location as an
existing hand winch.
1. Remove the existing hand winch.
2. Position the unit on the trailer mount stand.
3. Confirm th at the winch's cable hook and the bo w eye on the boat are 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.
If necessary to create equal height, raise or lo wer the winch stand. In most
cases, trailer manufacturers have adaptors available for use with a winch.
4. Confirm that there is a minimum of 12 inch es clearance between the winch
and the bow eye when the boat is in the fully loaded position. If necessary,
extend the bow stop to obtain the clearance.
5. Bolt the unit using a minimum of two (2) 3/8" grade 5 machine bolts and lock
nuts. If the existing mounting holes do not line up with the winch, use the
bottom of the winch as a template and drill two (2) 7/16" holes in the
mounting surface of the trailer stand.
6. If using a double line pull (using a pulley block), install a 3/8" eyebo lt on the stand
as close as possible to the base of the winch. See illustration on page 5.
3
712 & 912 BOAT TRAILER WINCH POWERWINCH
WIRING THE UNIT
WARNINGS
ALWAYS disconnect the battery before working on electrical equipment.
ALWAYS use the recomme nded wire size and rated circuit breakers. Failure
to use the furnished and recommended sizes can cause a fire hazard and
void warranty.
When routing the wiring, avoid sources of heat.
When routing the wiring, avoid sharp edges that can cut or fray the wire
insulation.
The following instructions are for permanently wiring the winch. Two additional wiring
kits are available and sold separately: A universal bumper wiring kit (p/n P 770 2101AJ)
and a quick connect wiring harness (p/n P7866000AJ) for temporary connections. If
installing one of the kits, follow the directions with the kit.
1. Attach the circuit breaker to the battery's
the starter solenoid.
2. Attach the ground wire (black) to the vehicle frame. Clean the metal frame with a
wire brush or equivalent then attach the ground lug using a 5/16" bolt an d lock nut
(bolt and nut not furnished).
3. Route the wire under the vehicle and along the frame. Avoid sharp edges and
moving parts. Secure the wire to the frame approximately every 18" using nylon
ties or equivalent.
Connect To Positive (+)
Post of Vehicle Battery
Secure Harness to Frame
Approximately Every 18”
12V Vehicle Battery
60 amp
Circuit Breaker
POSITIVE (+) post or positive (+) terminal of
Power Plug
Red Wire
Black Wire
to Winch
Attach Ground
to Vehicle Frame
pwRC007
4
POWERWINCH 712 & 912 BOAT TRAILER WINCH
PULLEY BLOCK
The pulley block can increase the pulling capacit y approximately 55%.
Assembly Instructions:
1. Place the two screws through one of the tear drop plates
and hold in place.
2. Slide a bushing over each screw.
3. Slide the pulley wheel and hook over the bushings as
shown. The components fit loosely on the bushings.
4. Wrap the cable around the pulley.
5. Place the second tear drop plate over the screws and
secure using the washers and nuts provided.
6. Mount an eyebolt next to the winch. The eyebolt should be mounted as
close to the winch as possible. Eyebolt is furnished by the installer.
12” minimum
Level
Bow
Eye
Pulley Block
Eye Bolt
PW912002
Double Lining the Winch
1. With the cabl e threaded through the block, hook the pulley block to the eye
on the bow.
2. Power out the cable and attach the cable hook to the eyebolt next to the winch.
3. Power in the cable.
pw915014
5
712 & 912 BOAT TRAILER WINCH POWERWINCH
OPERATING THE WINCH
WARNINGS
To avoid personal injury and property damage, clear the area ar ound and behind
the boat of people, animals and obstructions before loading or unloading the boat.
Never stand between the load or anchor point and the winch. Serious pers onal
injury could occur if the cable breaks.
ALWAYS wear leather gloves when handling the cable. Steel cable can cause
serious damage to hands.
NEVER use the winch alone to secure the boat to the trailer during trans it.
Use separate straps or equivalent to secure the boat to the trailer.
UNLOADING THE BOAT
1. Attach the cable hook to the bow eye on the boat.
2. Connect the power to the winch. The plug goes
into the socket on the right side of the winch.
3. Remove the tie down straps from the boat.
4. Slowly turn the clutch knob counterclockwise to
release the winch brake.
5. Allow the boat to slide off the trailer. If
necessary, the clutch knob can be tightened
to slow the speed of the boat.
6. When the boat is in the water, release the cable hook.
7. Tighten the clutch control knob clock wise until finger tight to set the brake.
8. While maintaining tens ion in the cable, press the switch on the winch. Roll
the cable up completely. D
to the cable and winch components could occur.
O NOT allow the cable to roll up loosely, damage
CAUTION Do not allow the cable hook to roll into the winch.
Damage to the level wind plate can occur.
9. Secure the cable hook to prevent any accidental injury or damage.
Power In Switch
Set
Release
PW912003
LOADING THE BOAT
1. Align the boat and trailer.
2. Loos en the clutch knob (turn counterclockwise) and free-wheel the cable to the
boat. Attach the hook to the eye on the bolt.
NOTE: If the winch cable is initially difficult to pull out, try engaging the
motor for a few seconds with the clutch fully released. This should free the
clutch allowing the cable to pull out.
3. Tighten the clutch control knob clockwise until finger tight to set the brake. DO NOT
over tighten the clutch knob; over tightening can cause damage to the clutch.
4. Step clear of the cable and boat.
5. Press and hold the swit c h. P o w er i n t h e c a b l e un t i l th e b o a t t o u c he s t h e b o w
stop. Release the button.
6. When fully loaded, secure the boat to the trailer.
6
POWERWINCH 712 & 912 BOAT TRAILER WINCH
EMERGENCY HAND CRANK
An emergency hand crank is available when there is no power (i.e. a dead battery).
WARNING NEVER USE THE HAND CRANK TO ASSIST A RUNNING MOTOR.
SERIOUS PERSONAL INJURY CAN OCCUR.
1. Disconnect the po wer cord from the
winch.
2. Tighten the clutch control knob
clockwise until finger tight to set the
brake. D
clutch knob; over tightening can
cause damage to the clutch.
3. Remove the jam nut from the shaft
on the right side of the winch.
4. Place the emergency handle onto
the shaft and secure to the shaft with
the nut removed previously. Tighten
the nut snugly against the handle.
5. Turn the crank handle to wind in the cable.
(Clockwise for 912, counterclockwise for 712.)
6. After the boat has been secured on the trail er, remove the handle from the
shaft. Replace the nut on the shaft.
7. Store the handle.
O NOT over tighten the
912
712
Jam Nut
Rotate Handle
to Retract Cable
PW912004
7
712 & 912 BOAT TRAILER WINCH POWERWINCH
MAINTENANCE
LUBRICATION
The following steps should be performed a minimum of once a year or when the
unit is placed in storage.
Cable: Lubricate the cable with Whitmore's Wire Rope Spray, WD40 or
equivalent. Spray the shaft and the cable as the cable is being wound.
Gears: Remove the covers and lubricate the gears with lithium base gre ase. Be
careful not to get grease on the clutch lining (refer to figure on page 10).
REPLACING THE CABLE
WARNING ALWAYS USE THE EXACT POWERWINCH REPLACEMENT CABLE
(P/N P7188800AJ). WINCH RATING AND CABLE STRENGTH ARE MATCHED FOR SAFE
AND OPTIMUM PERFORMANCE
CAUTION ALWAYS wear leather gloves when handling the cable. Steel
cable can cause serious damage to hands.
1. Disconnect the power cable.
2. Loosen the clutch knob (turn counterclockwise) and free-wheel the cable
completely out.
3. Cut the old cable off appr oximately
2" from the cable drum.
4. Slide the collar a way from the cable
then push the old cable out of the
drum shaft.
5. Insert the new cable through the
shaft. The cable must be inserted
through the side opposite the
counter bore.
6. Insert the stop sleev e over the end
of the cable until the cable is flush
with the end of the stop. Solder or
crimp the stop onto the cable.
7. Pull the cable back through the shaft
until the stop is seated in the counter
bore of hole.
8. Slide the collar around the cable. The notch on the collar fits around the cable.
9. Tighten the clutch control knob clockwise until finger tight to set the brake. D
over tighten the clutch knob; over tightening can cause damage to the clutch.
10. Reco nnect the power harness t o the unit. Po wer-in the ca ble, keeping tension on
the cable as it is winding. The cable must wind from the top of the cable spool.
CAUTION If the cable is not wound correctly, it may cause loss of
power and risk damage to the level wind plate. If the cable is not correct (too
loose or wound on one side), unw ind the cable then rewind while keeping
tension on the cable.
. NEVER REPLACE THE CABLE WITH ROPE.
Stop Sleeve
Drum Flange
Drum Collar
Completed Installation
Crimp or Solder
Over End of Cable
Counterbore
Stranded Cable
pwRC013
O NOT
8
POWERWINCH 712 & 912 BOAT TRAILER WINCH
TROUBLESHOOTING GUIDE
WINCH DOES NOT OPERATE
A. Confirm power to winch
1. Check that vehicle battery is fully charged.
2. Confirm connections are for tight & clean.
3. Check wires that are worn or bare that may
cause shorts.
B. Check circuit breaker at battery
Bypass circuit breaker and test winch.
Does the winch run?
CAUTION Do not operate the winch
without the circuit breaker. Removing the CB
from the circuit is
ONLY for testing.
LOAD SLIPS
A. Load s lip s during r etrie val Thrust washers and thrust bearings
B. Load slips back after boat is retrieved Clutch bearing inside the 120 gear
C. Check clutch lining
The clutch lining is located on the 120
tooth gear under the LH (clutch side) of
the case. Ensure that the clutch is clean
free of grease.
CABLE DIFFICULT TO PULL OUT
A. If the winch cable is initially d ifficult to pull out, try engaging the motor for a
few seconds with the clutch fully released. This should free the clutch
allowing the cable to pull out.
Correct as required.
YES If winch runs, circuit
breaker is bad, replace.
NO Reconnect circuit breaker.
Contact your authorized
service center.
are worn or deformed. Replace
has failed. Replace gear assembly
Clean as required. If clutch lining is
worn or damaged, replace the 120
tooth gear assy.
9
712 & 912 BOAT TRAILER WINCH POWERWINCH
REPLACEMENT PARTS LIST
11
7
2
1
9
6
10
8
3
2
16
13
14
14
17
15
18
17
Parts marked with * are not used on 712 Model.
10
16
17
12
18
16
4
5
16
pw912501
POWERWINCH 712 & 912 BOAT TRAILER WINCH
Item 712 912 Description Notes
1
P7188800AJ P7188800AJ Cable Assy, 7/32" x 40'
2
R001284 R001292 Cover Kit 1
3
P5594700AJ P5594700AJ Emergency Hand Crank
4
P7904300AJ P7904300AJ Pulley Block Kit
5
P7700000AJ P7700000AJ Quick Mount Kit
6
R001287 R001295 Motor Assy
7
P7811700AJ P7811700AJ Switch
8
P7810300AJ P7810300AJ Socket, Power 1
9
P7830201AJ P7830201AJ Wire Harness w/ items 6 & 7
10
P7810500AJ P7810500AJ Plug, Wire Harness
11
P7837300AJ P7837300AJ Circuit Breaker, 60amp
12
R001275 R001275 Level Wind Plate
13
R001314 R001314 Clutch Knob
14
P7160901AJ P7160901AJ Clutch Spr ing and Washer Kit
15
R001283 R001291 120T Gear Kit
16
R001282 R001290 Gear Kit
17
R001285 R001293 Shaft Kit
18
R001281 R001289 Bearing Kit
19
R001286 R001294 Fastener Kit
The following repair kits are also available
20
P91007 P91007 Drum Shaft and Gear Kit 3
21
n/a P91008 Intermediate Shaft and Gear Kit 3
22
P91010 P91009 Rear Shaft and Gear Kit 3
Notes 1. Fasteners are included with kit.
2. Fasteners and washers not index on illustration are part of the
fastener kit (item 19).
3. The shaft and gear kits (items 20,21,22) contain the respective
shaft, gears, bearings and associated hardware
11
712 & 912 BOAT TRAILER WINCH POWERWINCH
WARRANTY
Carefree of Colorado (hereafter referred to as Carefree) warrants to the FIRST retail Purchaser that
the Powerwinch Product described in this manual is free of defects in material and workmanship
within the terms and conditions as set forth below. Carefree’s obligation under this warranty is
limited to the repair or replacement, at Carefree’s option, of any defective component within the
stated warranty period. T
1. D
URATION
a) 1 year on parts and labor.
b) Carefree will pay the transportation charges for return shipment to the purchaser of any
product received for legitimate warranty repair.
Warranty duration is not extended by the length of time the product is not in use or the time
that the purchaser is deprived the use of the product. The duration of coverage is determined
by the date of the original product purchase, not the date of repairs.
HAT IS COVERED UNDER THIS WARRANTY
2. W
Defects in the manufacturer’s material and workmanship of product under normal use, and
which occur within the duration of the warranty period.
HAT IS NOT COVERED UNDER THIS WARRANTY
3. W
a) Improper installation and/or any consequent damage or failure that results from improper
installation of the product.
b) Normal wear.
c) Conditions that are not related to the material or workmanship of the product: including
any failure that results from an accident, wind, rain, or other acts of God.
d) Purchaser’s abuse, including but not limited to neglect; failure to operate, use or maintain
the product in accordance with the instructions provided with the product.
e) Any component not sold or manufactured by Carefree.
f) Any failure that results from the use of another manufacturer’s product with a Carefree
product that is not specifically approved by Carefree.
g) Any incidental, indirect, or consequential loss, damage or expense that may result from
any defect, failure or malfunction of the product.
h) The removal or alteration of any product component or device. In the event of such
removal or alteration, this warranty is void.
i) Any expense related to delivery or pick-up of product to/from the service dealer.
ESPONSIBILITIES OF THE PURCHASER
4. R
N ORDER FOR THE WARRANTY TO BE HONORED, THE PURCHASER MUST HAVE PROOF OF
I
PURCHASE
WARRANTY CLAIM
. FAILURE TO PROVIDE THE REQUIRED DOCUMENTATION MAY DELAY OR VOID ANY
a) Retain dated proof of purchase for the product, and provide it as requested.
b) Perform “Periodic Maintenance” as specified in Owner's Manual.
c) Use reasonable care in maintenance, operation, use and storage of the product in
accordance with the instructions contained in the owner’s manual.
HIS WARRANTY GIVES THE OWNER SPECIFIC LEGAL RIGHTS. THE LAWS OF CERTAIN JURISDICTIONS MAY
T
GRANT THE OWNER ADDITIONAL RIGHTS AND PRIVILEGES
no warranty, whether statutory or otherwise, including without limitation, any warranty of
merchantability or fitness for a particular purpose. Carefree shall have no liability except to repair,
replace or adjust defective products and parts. Carefree specifically excludes any liability, whether
in contract, tort or otherwise, for personal injury, property damage, economic or consequential
losses. Carefree has not authorized any person or company to alter the terms of this warranty.
It is Carefree of Colorado’s policy and practice to continuously improve the company’s products and
services. Therefore, Carefree reserves the right to make changes in design and components,
without notice, whenever it is believed the quality of the product will be improved, but without
incurring any obligation to incorporate such improvements in any product that has been shipped or
in service.
HIS WARRANTY IS NOT TRANSFERABLE.
.
. Except as set forth above; Carefree makes
12
POWERWINCH 712 & 912 BOAT TRAILER WINCH
FOR YOUR RECORDS:
DEALER/INSTALLER
PURCHASE DATE:
PART NUMBER:
SERIAL NUMBER:
PRODUCT NAME
OR DESCRIPTION:
AME:
N
A
DDRESS:
PHONE:
Retain your original proof of purchase.
It is requi
RED for all warranty repairs and returns.
NOTES:
13
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