POWERWINCH 915 Leitfaden

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.

ALWAYS 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.

ALWAYS STAND

CLEAR OF THE AREA 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 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.

General Safety (Continued)

THE CABLE FASTEN-

ERS 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.

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.

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 on a

single line pull and is a guideline to aid in calculating

pulling requirements.

OPERATION AND PARTS MANUAL

MODEL 915

BOAT TRAILER WINCH

P7040104AV 12/06

– 2 –

P7040104AV MODEL 915

Chart 3 Winch Specifications

Line Speed @ Gear Voltage Circuit Unit Weight

Model Capacity (FPM) Ratio (volts) Breaker (lbs) Depth Height Width

(amps)

915 10 450:1 12 60 40 10” 10” 8”

* Boat size and weight are approximate and varies depending on boat type. When calculating the boat

weight, be sure to use fully loaded weight including boat, motor, fuel ,etc.

Single Double Approximate* Approximate*

Model Line Pull Line Pull Boat Weight Boat Size

915 3,200 lbs 5,900 lbs 9,500 lbs 22-29 ft

Level

% incline Surface 5% 10% 20% 30% 50% 70% 100%

(° incline) 0° 3° 6° 11° 17° 26° 35° 45°

Boat Wt.

(in lbs.) 32,000 20,010 15,060 10,200 7,830 5,580 4,590 3,870

• A 10% incline (or 6°) is 1 ft rise in 10 feet.

• To convert pounds to kilos divide by 2.2.

• Capacity can be increased (almost doubled) by using a pulley block.

Chart 2 Winch and Boat Capacities

Chart 1 Approximate Rolling Load Capacities

– 3 –

P7040104AV MODEL 915

BATTERY

TERMINAL

5/16" BOLT

5/16"LOCK WASHER

AND NUT

12 VOLT CAR

OR TRUCK

BATTERY

VEHICLE

FRAME

* NOT SUPPLIED

Figure 1 Permanent Wiring Hookup

Installation

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

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.

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 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 the 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.

– 4 –

P7040104AV MODEL 915

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.

WINCH

CABLE

HOOK

Figure 2 Operation Components

1. Attach the winch cable hook to the bow eye on the

boat (See Figure 2).

Operation (continued)

CLEAR THE AREA AROUND AND BEHIND THE

BOAT OF PEOPLE, ANIMALS, AND OBSTRUCTING

OBJECTS BEFORE LOADING OR UNLOADING.

POSSIBLE INJURY COULD OCCUR.

2. Remove the boat tie downs.

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.

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.

ALWAY STAND

CLEAR OF THE AREA

BETWEEN THE LOAD

– 5 –

P7040104AV MODEL 915

CABLE

FASTENER

COUNTERBORE

CABLE DRUM

INSERT

NEW

CABLE

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 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.

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.

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).

Figure 3 Cable Replacement

Operation (continued) Maintenance (continued)

– 6 –

P7040104AV MODEL 915

INNER

JAM NUT

OUTER

JAM NUT

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 the

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 opera tion or repair of

this product, please call AU: 1800-059-899 or NZ: 0800-876-526

and have the following information available:

• Model number

• Serial number

• Part number and description

Address correspondence to:

Maintenance (continued)

Figure 4 Brake Adjustment

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

ush 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 cover

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 o. If the load creeps while

the power is o 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

with a load attached

to the winch. The load

could release and cause load damage or personal

injury.

Trail Com AU Limited

P O Box 7061

Dandenong, Melbourne

Victoria 3175

Trail Com Limited

P O Box 98-961

SAMC, Auckland

New Zealand

– 7 –

P7040104AV MODEL 915

1. Start checking the wiring at the battery. Bypass the

circuit breakers and test the winch. If the winch

operates, replace the circuit breakers.

2. Check the wiring insulation for worn or bare spots

that may be causing a short.

3. Check all connections for tightness.

1. 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.

2. 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.

1. 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.

1. Adjust the brake (See brake adjustment section in

this manual).

2. Replace gears or clutch lining.

1. Disconnected or bad wiring or

bad circuit breakers.

2. Bad plug.

3. Bad switch or motor.

1. Jam nuts too loose.

2. Worn gears or clutch lining

SYMPTOM POSSIBLE CAUSE (S) CORRECTIVE ACTION

Winch will not

operate.

Clutch does not

hold.

General Troubleshooting Guide

P7040104AV MODEL 915

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 Pow erwinch Prod uct (the “Product”) spec-

ied in this man ual. This Limited Warranty is not trans ferable to

any other party.

B. Responsibilities of the Company under this Limited Warranty:

1. Re pair or replace (at the discretion of the Company)

any part or parts of the Product found by the Compa-

ny to be defective within a two (2) year period from the

date of pur chase.

2. The Company will pay the transportation charge

for ship ment back to the Purchaser of any Product

received for legitimate War ranty repair.

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.

3. At the Option of the Company, return the Product to

the Company for inspection. Authoriza tion must be

given prior to any Prod uct re turn. Call the Company at

AU: 1800-059-899 / NZ: 0800 876-526 or write the

Company, for authorization and complete instructions

on how to return the Product directly to the Company.

4. Use reasonable care in maintenance, operation, use

and storage of the Product in accordance with the

right to alter specications on any product without notice.

instructions con tained in the Owner’s Manual.

5. Have Warranty work performed by a deal er or rep re-

sentative ap proved by the Company.

6. Except as noted in B.2., transportation charges are

the re sponsibility of the Purchas er.

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, Purchas er’s

abuse, neglect, modication, improper maintenance,

or failure to operate and use the Product in accor-

dance with the instruc tions 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 MER CHANT ABILITY AND

FIT NESS FOR A PAR TIC ULAR PUR POSE, ARE LIMITED TO

TWO (2) YEARS FROM DATE OF PUR CHASE. THIS IS THE

EXCLUSIVE REMEDY AND ANY LIABILITY FOR ANY AND

ALL IN CI DENTAL OR CONSE QUENTIAL DAMAGES OR

EXPENSES WHAT SO EVER IS EXCLUDED.

Some states do not allow limitations on how long an implied war-

ranty lasts, or do not allow exclusion or limitation of incidental or

conse quential dam ages, the above limitations may not apply to

you. This Limited Warranty gives you specic legal rights, and

you may also have other rights which vary from state to state.

Trail Com AU Limited

Unit 5, 25-27 South Link

Dandenong, Melbourne

Victoria 3175

Trail Com Limited

15 Oak Road,

Manukau, Auckland

New Zealand

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