POWERWINCH CAPSTAN 1000 User manual

OWNER'S MANUAL
Capstan Powered Lift Assist
This Manual Provides Installation and Operation Instructions for the following models:
CAPSTAN 1000
CAPSTAN 300
QUICK 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 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 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, 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
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 AWARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH,
IF NOT AVOIDED,COULD RESULT IN DEATH OR SERIOUS INJURY AND/OR MAJOR PROPERTY
DAMAGE.
CAUTION ACAUTION 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 the
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 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. NEVER 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 closed 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 Breaker
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 equivalent.
Silicone sealant.
ELECTRICAL 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, battery to switch 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
ELECTRICAL 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, battery to switch 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 mounting 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 amount of thread locker on the 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 electrical equipment.
ALWAYS use the recommended 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.
1. Locate a suitable location 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 BLACK 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 BLACK wire with a 5/16" ring terminal. Attach the
new wire to the motor BLACK wire with a 1/4 -20 screw and nut and shrink wrap.
9. At the battery, terminate the BLACK wire with a 3/8" ring terminal. Attach the
new wire to the NEGATIVE (-) terminal of the battery.
10. Route one RED 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 wires with wire ties.
11. Terminate each end of the RED wire with 5/16" ring terminals.
12. Connect the motor GREEN wire to the RED wire with a 1/4 -20 screw and nut and
shrink wrap.
13. At the switch position, connect the RED 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 short wire from the switch with a 1/4 -20 screw and nut and shrink
wrap.
16. At the battery terminate the RED 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 down 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 anchors, traps or pots; these are referred to
as the "load" in the directions below.
LOADING THE ROPE
1. Thread the rope through 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
NOTUSE 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. DO 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. DO 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 cuts. 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 Seal &GasketKit P10346 P10346 P10346
2 Mounting Kit P10349 P10349 P10349
3 CapstanKit R001461 R001461 R001461 1
4 FootSwitch P7817600AJ P7817600AJ P7817600AJ
5 Circuit Breaker, 25A -- P1027600AJ --
6 Circuit Breaker, 80A P1066800AJ -- P1066800AJ
7 Bearing Kit P10725 P10343 P10343
8 MotorKit R001462 R001451 R001463
9 CapstanShaft 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.