POWERWINCH CAPSTAN 1000, CAPSTAN 300 Owner's Manual

OWNER'S MANUAL

Capstan Powered Lift Assist

This Manual Provides Installation and Operation Instructions for the following models:

CAPSTAN 1000
C

APSTAN 300

Q

UICK CATCH POT PULLER

pwcs101

 12 Volt Powered Winch
 Powered Lift Assist for anchors, pots and traps.

PROPRIETARY STATEMENT

The Powerwinch Capstan is a product of Carefree of Color ado, 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. Ho wever,
Carefree of Colorado assumes no liability for errors or for any d amag es that result from
the use of this document.

The information contained in this manual pertains to the 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, chan ge, 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

Furnished Materials: ...................................................................................... 3

Required Materials (not included with winch) ................................................ 3

Mounting the Unit .................................................................................... 4

Wiring the Unit ......................................................................................... 5

Testing the Unit ............................................................................................. 6

Operating the Winch ............................................................................... 7

Loading the Rope .......................................................................................... 7

Lowering the Load ......................................................................................... 7

Retrieving the Load ....................................................................................... 7

Maintenance .................................................................................................. 7

Replacement Parts List .......................................................................... 8

Warranty ................................................................................................. 10

POWERWINCH CAPSTAN POWERED LIFT ASSIST

1

SAFETY INFORMATION

WARNING A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,

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

/OR PROPERTY DAMAGE. IT MAY

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.

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 product 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 t he

load. Use separate straps to support the load.
ALWAYS stand away from the winch during o peration. ALWAYS stand clear of

the area behind and between the load or anchor point and the winch.

Serious injury could occur if the rope breaks.
ALWAYS keep hands clear of the drum area.
ALWAYS wear leather gloves when handling the rope.
NEVER wear loose fitting clothes, scarves, ties or jewelry when operating the

winch. Loose clothing can become caught in moving parts.
ALWAYS tie off the anchor to a secure mount (e.g. a deck cleat) for storage

and after lowering the anchor. N

EVER use the winch to tie off the anchor.

ALWAYS use the recommended rope.

CAPSTAN POWERED LIFT ASSIST POWERWINCH

2

SPECIFICATIONS

Davit/Bow Roller

This product requires the use of a close d loop davit or bow roller. Davit or bow roller
must be installed prior to installing inch to ensure proper performance.

CAUTION USE OF A DAVIT WITH AN OPEN LOOP IS NOT RECOMMENDED WITH THIS

PRODUCT

. USE A DAVIT WITH A CLOSED LOOP TO PREVENT SERIOUS PERSONAL INJURY

AND

/OR PROPERTY DAMAGE.

6 7/16"

7 1/8"

8 5/16"

10 5/8"

pwcs004

Model

Maximum

Pull Rope Size* Voltage

Circuit

Breaker

Unit

Weight

Capstan 1000 1000 lbs. 1/2-3/4" 12VDC 80 amps 23 lbs.

Capstan 300 300 lbs. 1/2-5/8" 12VDC 25 amps 20 lbs.

Quick Catch Pot Puller 200 lbs. Up to 5/8" 12VDC 80 amps 19 lbs.

* Recommended rope is three (3) strand, medium lay, premium nylon.

POWERWINCH CAPSTAN POWERED LIFT ASSIST

3

FURNISHED MATERIALS:

Capstan 1000 Capstan 300 Quick Catch Pot Puller

qty Description qty Description qty Description

1 Winch 1 Winch 1 Winch
3 5/16-18 x 3.5 Stud 3 5/16-18 x 3.5 Stud 3 5/16-18 x 3.5 Stud
3 5/16 Lock Washer 3 5/16 Lock Washer 3 5/16 Lock Washer
3 5/16 Flat Washer 3 5/16 Flat Washer 3 5/16 Flat Washer
3 5/16-18 Nut 3 5/16-18 Nut 3 5/16-18 Nut
1 80A Circuit Breaker 1 25A Circuit Breaker 1 80A Circuit Bre aker
1 Foot Switch 1 Foot Switch 1 Foot Switch
1 Mounting Template 1 Mounting Template 1 Mounting Template

REQUIRED MATERIALS (NOT INCLUDED WITH WINCH)

 Loctite 242 thread locker or e quivalent.
 Silicone sealant.

E

LECTRICAL INSTALLATION – CAPSTAN 1000 & QUICK CATCH POT PULLER

These items are furnished by the installer.

Qty Description

6 awg RED Wire Class 105˚C Wire is used for the "run" wire from winch to

switch, batte ry to swit ch and battery to winch.
Length is based on installation.

6 awg BLACK Wire Class 105˚C

7 5/16" 6 awg ring terminals
5 1/4-20 x 1/2 Screws Screws and nuts should be stainless

steel to avoid rust and corrosion.

5 1/4-20 Nuts

a/r Wire ties
2 ft 1" diameter heat shrink
2 ft 2" diameter heat shrink

E

LECTRICAL INSTALLATION – CAPSTAN 300

These items are furnished by the installer.

Qty Description

8 awg RED Wire Class 105˚C wire is used for the "run" wire from winch to

switch, batte ry to swit ch and battery to winch.
Length is based on installation.

8 awg BLACK Wire Class 105˚C

7 5/16" 8 awg ring terminals
5 1/4-20 x 1/2 Screws Screws and nuts should be stainless

steel to avoid rust and corrosion.

5 1/4-20 Nuts

a/r Wire ties
2 ft 1" diameter heat shrink
2 ft 2" diameter heat shrink

CAPSTAN POWERED LIFT ASSIST POWERWINCH

4

MOUNTING THE UNIT

Mounting Template

Centerline

of Davit/Bow Roller

5/16" Mounting Stud
(x3)

Flat Washer

Lock Washer

5/16" Nut

(x3)

pwcs001

Drill Holes as
Shown on Template
(4 total)

BOW OF BOAT

Center Of Rope

Anchor Winch To Davit

5/16"

[7.9mm]

3 1/2"

(88.9mm]

5 1/2"

[139.7mm]

6 7/8"

[174.6mm]

3 1/4"

[82.6mm]

STERN OF BOAT

1/2" Hole Thru

Wire Harness

3/8" Hole Thru

Winch Mounting Hole
(3 Plcs)

P1053700AV Mounting Template

Drill 5/8" Hole for Foot Switch
(see text for location suggestions)

1. Place the mo

unting template on the deck in the desired

location and secure

with tape.
a. The centerline of the capstan must line up with the centerline of the

davit or bow roller.

2. Drill the holes as marked on the template.

3. Remove the template.

4. Use a small a mount of thread locker on t he end of the studs then thread the
5/16-18 x 3 1/2" studs into the winch. Hand tighten until snug.

5. Align the winch and the studs with the holes in the deck. Insert the wires
through the hole in the deck. Lower the winch to the deck.

6. Under the deck, secure the winch to the deck use one (1) each 5/16 flat
washer, 5/16 lock washer and 5/16 nut on each of the studs. Tighten the
nuts to secure the winch to the deck.

POWERWINCH CAPSTAN POWERED LIFT ASSIST

5

WIRING THE UNIT

WARNINGS

ALWAYS disconnect the battery before working on el ectrical equipment.
ALWAYS use the recommended wire size and rated circuit break ers. Failure

to use the furnished and recommended size s 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.

1. Locate a suitable loc ation for the switch.
 Location should be easily accessible when handling the rope from the

capstan.

 Locate the switch outside the normal traffic patterns. This is to avoid

the switch being accidently stepped on or tripped over.

2. Drill a 5/8" hole through the mounting surface.

3. If attached, unscrew the rubber cap from the top of

the switch and install the switch from the underside of
the deck.

4. Fully thread the cap back onto the switch. Tighten the

jam nut from below deck to secure the switch.

5. Connect the two (2) red wires to the switch.

6. At the winch, terminate the wires from the winch with 5/16" ring terminals.

7. Route one B

LACK wire from the winch to the battery location. Be sure to

allow adequate wiring to make connections, allow the wire to have some
slack when routing. Secure the wires with wire ties.

Tip: Before making the mechanical connection, slide a 2 1/2" piece of the
shrink tubing over one wire. Make the connection then slide the wrap over
the connection. Lightly heat the wrap until it shrinks around the terminals.

8. At the winch, terminate the B LACK wire with a 5/16" ring terminal. Attach the

new wire to the motor B

LACK wire with a 1/4 -20 screw and nut and shrink wrap.

9. At the battery, terminate the B

LACK wire with a 3/8" ring terminal. Attach the

new wire to the

NEGATIVE (-) terminal of the battery.

10. Route one R

ED wire from the winch to the switch location. Be sure to allow

adequate wiring to make connections, allow the wire to have some slack
when routing. Secure the wir e s with wir e ti e s .

11. Terminate each end of the RED wire with 5/16" ring terminals.

12. Connect the motor G

REEN wire to the RED wire with a 1/4 -20 screw and nut and

shrink wrap.

13. At the switch position, connect the R

ED wire to one of the short wires from switch

with a 1/4 -20 screw and nut and shrink wrap.

Switch

Jam Nut

Switch Cap

5/8" Hole

pwcs006

CAPSTAN POWERED LIFT ASSIST POWERWINCH

6

14. Route one RED wire from the battery to the switch location. Be sure to

allow adequate wiring to make connections, allow the wire to have some
slack when routing. Secure the wires with wire ties.

15. At the switch terminate the new wire with a 5/16 ring terminal and attach to

the second sho rt wire from t he switch with a 1/4 -20 screw and nut and shrink
wrap.

16. At the battery terminate the R

ED wire with a #10 ring terminal. Attach the wire to

the "AUX" post of the circuit breaker.

17. Attach the circuit breaker to the

POSITIVE (+) terminal of the battery.

Black

Green

Black

*awg

Red *

awg

Ring Terminals

1/4-20 x 1/2
Screw & Nut

Tape or

Heat Shrink

= Mechanical Connection

Red

*awg

Circuit Breaker

Battery

pwcs005

Foot Switch

25A Circuit Breaker

(used w/ Capstan 300)

80A Circuit Breaker

(used w/ Capstan 1000 &

Quick Catch Pot Puller)

To Battery
(+12VDC)

Red

Wire

Ring

Terminal

Red

Wire

Ring

Terminal

To Battery (+12VDC)

* Use 8awg wire for Capstan 300

Use 6awg wire for Capstan 1000
Use 6awg wire for Quick Catch Pot Puller

TESTING THE UNIT

1. Ensure that all connections are secure and correct.

2. With no rope on capstan, press do wn the switch. If the motor runs but the
capstan does not turn, motor wires are reversed. Reverse the red and black
wires at the motor leads.

POWERWINCH CAPSTAN POWERED LIFT ASSIST

7

OPERATING THE WINCH

The Capstan can be used to retrieve anc hors, traps or pots; these are referred t o
as the "load" in the directions below.

LOADING THE ROPE

1. Thread the rope throug h the davit or bow roller and pull back to the winch.

2. Wrap the rope counterclockwise 4-5 wraps around the capstan.

CAUTION ALWAYS SECURE THE ROPE TO A DECK CLEAT OR SIMILAR DEVICE. DO

NOT USE THE WINCH TO TIE OFF THE LOAD.

CAUTION ALWAYS USE THE RECOMMENDED ROPE (SEE PAGE 2). USE OF

DIFFERENT ROPE CAN CAUSE PROPERTY DAMAGE AND PERSONAL INJURY

.

LOWERING THE LOAD

1. Turn boat into wind and place boat motors in neutral.

2. After the boat has stopped all forward progress, release the rope from the
deck cleat. Allow the load to free fall to the sea bed.

CAUTION NEVER USE THE WINCH TO LOWER THE LOAD OR TO BRAKE THE LOAD

DURING FREE FALL

. THIS CAN RESULT IN SERIOUS DAMAGE TO THE GEAR TRAIN.

3. After the desired amount of rope has been released, tie the rope off to a
deck cleat. D

O NOT use the winch to tie-off the anchor.

4. For anchors, place the boat's motors in neutral and allow the boat to drift
back and set the anchor in the sea bed.

RETRIEVING THE LOAD

1. Untie the rope from the deck cleat.

2. Align bow of boat with load.

3. Place the boat's motors in forward and
move boat slowly toward the anchor
point.

4. Press the winch switch and pull the
rope hand over hand.

NOTE: The rope must be kept under
tension for the winch to work properly.

5. After the load is secured, tie the
rope off to a deck cleat. D

O NOT

use the winch to tie-off the load.

MAINTENANCE

Following each boat outing, flush exterior of winch with fresh water. Use only
mild detergents to clean exterior. Use of solvents can cause damage to the
finishes and seals, as well as void product warranty

Every 6 months inspect capstan for wear. Replace any worn components.
Check rope periodically for abrasion or deep cut s . Never splice an old rope with a new

rope. If replacement is necessary, use only Powerwinch recommended rope.
Check electrical connections every 6 months for corrosion. Replace any

connection or wire which is damaged, corroded, frayed or worn.

pwcs002

Pull Rope Hand over
Hand While Pressing
the Foot Switch

Wrap Rope
4-5 Times
Counterclockwise

Foot Switch

CAPSTAN POWERED LIFT ASSIST POWERWINCH

8

REPLACEMENT PARTS LIST

1

1

1

1

2

3

5

6

7

7

7

7

8

8

9

9

9

9

10

10

11

12

12

13

13

11

CAPSTAN 1000

CAPSTAN 300 &

QUICK CATCH POT PULLER

12,13

POWERWINCH CAPSTAN POWERED LIFT ASSIST

9

Item Description Capstan

1000

Capstan

300

Quick Catch

Pot Puller

Notes

1

Se a l & G a s k e t K i t P10346 P10346 P10346

2

Mounting Kit P10349 P10349 P10349

3

Capstan Kit R001461 R001461 R001461 1

4

Fo o t Switch P7817600AJ P7817600AJ P7817600AJ

5

Ci r c u i t B r e a k e r , 2 5A -- P1027600AJ --

6

Ci r c u i t B r e a k e r , 8 0 A P1066800AJ -- P1066800AJ

7

Bearing Kit P10725 P10343 P10343

8

Motor Kit R001462 R001451 R001463

9

Capstan Shaft R001456 R001456 R001456

10

Locking Gear Kit P10731 -- --

11

Locking Gear Kit -- R001453 R001453

12

Intermediate Shaft P10723

13

Intermediate Shaft -- R001446 R001446

Notes: 1. Capstan kit (item 3) includes seal and nut.

Discover other anchors & docking on our website.