POWERWINCH Sport Fishing 450 Windlass User manual

Printed in USA
OWNER'S MANUAL
Sport Fishing 450 Windlass
FREE FALL ROPE AND CHAIN ANCHOR WINCH
PW46101
12 Volt Powered Winch
Power-In / Freewheel-out operation
These instructions apply to all models listed. Details and procedures unique to a
specific model are labeled appropriately.

PROPRIETARY STATEMENT
The Powerwinch Anchor 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 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
Davit/Bow Roller............................................................................................ 2
Furnished Materials:...................................................................................... 2
Required Materials (not included with winch)................................................ 2
Rope and Chain Rodes................................................................................. 3
Rope Locker.................................................................................................. 3
Mounting the Unit....................................................................................4
Wiring the Unit.........................................................................................6
Testing the Unit............................................................................................. 8
Loading the Rope and Chain Rode............................................................... 8
Operating the Anchor Winch .................................................................9
Anchoring...................................................................................................... 9
Retrieving the Anchor.................................................................................... 9
Maintenance.................................................................................................. 9
Troubleshooting Guide................................................................................ 10
Replacement Parts List ........................................................................11
Warranty.................................................................................................13
Powerwinch
by Carefree of Colorado

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
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 cable spool (drum area).
ALWAYS wear leather gloves when handling the rope and chain.
NEVER wear loose fitting clothes, scarves, ties or jewelry when operating the
winch. Loose clothing can become caught in moving parts.
NEVER place foreign objects in the gypsy while retrieving or free falling the
anchor. Serious injury can occur.
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 and chain rode (a rode is a length of
rope and chain).

SPORT FISHING 450 ANCHOR WINCH 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 anchor winch 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.
FURNISHED MATERIALS:
qty Description qty Description
1 Anchor Winch 1 25A Circuit Breaker
3 5/16-18 x 3.5 Stud 1 Switch Plate
3 5/16 Lock Washer 4 #10 x 3/4 Screw
3 5/16 Flat Washer 1 Switch,DPDT
3 5/16-18 Nut 1 Mounting Template
REQUIRED MATERIALS (NOT INCLUDED WITH WINCH)
Marine grade plywood for under deck support (optional).
Loctite 242 thread locker or equivalent (optional).
Silicone sealant.
REQUIRED MATERIALS FOR ELECTRICAL INSTALLATION
The following items are required for the electrical installation Sport Fishing 450
winch. These items are furnished by the installer.
Qty Description
2 ft 12 awg RED Wire Class 105˚C
2 ft 12 awg BLACK Wire Class 105˚C
70 ft 6 awg RED Wire Class 105˚C 6 awg wire is the "run" wire from anchor to
switch and battery to switch. Length is
based on installation.
70 ft 6 awg BLACK Wire Class 105˚C
10 5/16" 6 awg ring terminals
4 5/16" 12 awg ring terminals
4 1/4" 12 awg insulated female
spade quick disconnects
6 1/4-20 x 1/2 Screws Screws and nuts should be stainless
steel to avoid rust and corrosion.
6 1/4-20 Nuts
Wire ties
2 ft 1" diameter heat shrink
2 ft 2" diameter heat shrink

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
3
ROPE AND CHAIN RODES
This product is designed to raise and lower anchors using spliced rope and chain
rodes (a rode is a length of rope and chain). It is very important that only sizes
and brands of spliced rope and chain rodes specified below are used. Use of
non-specified ropes and chains could cause reduced levels of performance or
serious personal injury and/or property damage.
Recommended Rope and Chain Rodes
WINCH MODEL REQUIRED ROPE REQUIRED CHAIN
36' Class 1/2" Diameter, 3 strand, medium
lay, premium nylon Powerwinch
rope or New England Rope
1/4" Acco G4 Hi-Test
chain.
CAUTION .Use only spliced rope and chain rodes. Shackles should never be
used to secure rope to chain. Shackles will damage winch and void warranty.
Failure to use the recommended rope and chain will void product warranty!
Rope and chain rodes are sold separately and not included with winch.
ROPE LOCKER
The anchor winch must be positioned
above a rope locker. The anchor line and
chain feed into the rope locker through a
deck insert (rode glide) mounted through
the deck. Minimum locker dimensions for
storage of lines are shown.
Line
Dimensions Locker Dimensions L x W x D
1/2" x 200' 15" x 17" x 12"
1/2" x 300' 15" x 24" x 12"

SPORT FISHING 450 ANCHOR WINCH POWERWINCH
4
MOUNTING THE UNIT
Mounting Template
Centerline
of Davit/Bow Roller
Rode Glide
5/16" Mounting Stud (x3)
Flat Washer
Lock Washer
5/16" Nut
(x3)
Rope Locker
PW27001
Drill Holes as
Shown on Template
(5 total)
BOW OF BOAT
Center Of Rope
Anchor Winch To Davit
5/16”
[7.9mm]
2 5/16"
(58.7mm]
5 1/2”
[139.7mm]
6 7/8”
[174.6mm]
3 1/4”
[82.6mm]
STERN OF BOAT
5/8” [15.9mm] Hole Thru
Wire Harness
11/32” [8.7mm] Hole Thru
Winch Mounting Hole
(3 Plcs)
3 3/16”
[81mm]
2 1/2” [63.5mm] Hole Thru
P1053900AV Mounting Template

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
5
1. Place the mounting template on the deck in the desired location and secure
with tape.
a. The winch must be placed above the rope locker.
b. The centerline of the gypsy 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. Place a bead of silicone sealant around the base of the rode guide. Insert
the rode guide into the 2 1/2" hole. The half-moon cut out must face the
davit or bow roller.
5. Use a small amount of thread locker and thread the 5/16-18 x 3 1/2" studs
into the winch. Hand tighten until snug.
6. Align the winch over the rode glide and align the studs with the holes in the
deck. Insert the wires through the hole in the deck. Lower the winch to the
deck.
7. 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.

SPORT FISHING 450 ANCHOR WINCH POWERWINCH
6
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. Ensure that there
is adequate room behind the
mounting surface for the
switch and wiring.
2. Cut a 1" x 1 3/4" hole into the
surface.
3. Press the switch into the
switch plate until the locking
tabs click into place.
4. Cut two (2) each 12" long pieces of the RED and BLACK 12 awg wire.
5. Terminate one end of each wire with a 12awg 1/4" female disconnect.
Ensure that the crimp is solid and cannot pull off.
6. Terminate the other end of each wire with a 12awg 5/16" ring terminal.
7. Connect the wires to the switch using the female disconnects as shown in
the wiring diagram (see next page).
8. Set switch aside.
9. Route one RED and one BLACK 6 awg wire from the anchor 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.
10. At the winch position, terminate the wires from the winch and the ends of
the new wires with 5/16" 6 awg ring terminals.
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.
Powerwinch
Windlass
To release anchor hold
switch down for 5 seconds
1"
1 3/4"
#10 Pan Head Screw
(4 plcs)
PW46005
Switch Switch Plate
Locking
Tabs

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
7
Anchor
Winch
Green
Black
Red 6awg
Black 6awg
Control
Switch
Black 6awg
PW46004
Ring Terminals
1/4-20 x 1/2
Screw & Nut
Tape or
Heat Shrink
= Mechanical Connection
Red
12awg
Black
12awg
Red 6awg
25A Circuit Breaker
Battery
Black
12awg
Red
12awg
(A) (B)
(C) (D)
11. Connect the motor GREEN wire to the new RED wire with a 1/4 -20 screw and nut.
Position the wrap and lightly heat until it shrinks around the terminals.
12. Connect the motor BLACK wire to the new BLACK wire with a 1/4 -20 screw and
nut. Position the wrap and lightly heat until it shrinks around the terminals.
13. At the switch position, terminate the ends of the new wires with 5/16" 6 awg
ring terminals.
14. Connect the switch RED wire to the winch RED wire with a 1/4 -20 screw and nut.
Position the wrap and lightly heat until it shrinks around the terminals.
15. Connect the switch BLACK wire to the winch BLACK wire with a 1/4 -20 screw and
nut. Position the wrap and lightly heat until it shrinks around the terminals.
16. Route 1 RED and 1 BLACK 6 awg 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.
17. At the switch position, terminate the ends of the new wires with 5/16" 6 awg
ring terminals.
18. Connect the switch RED wire to the battery RED wire with a 1/4 -20 screw and nut.
Position the wrap and lightly heat until it shrinks around the terminals.
19. Connect the switch BLACK wire to the battery BLACK wire with a 1/4 -20 screw and
nut. Position the wrap and lightly heat until it shrinks around the terminals.
20. Push the switch and wires into the switch mounting hole. Secure the switch plate
using 4 #10 screws.
21. At the battery location, terminate each wire with a 5/16" ring terminal.
22. Attach the BLACK wire to the negative (-) post of the battery.
23. Attach the RED wire to the post on the circuit breaker.
24. Attach the circuit breaker to the positive (+) post of the battery.

SPORT FISHING 450 ANCHOR WINCH POWERWINCH
8
TESTING THE UNIT
1. Ensure that all connections are secure and correct. For the 46' make sure that the
in-line fuse is installed in the Red wire between the switch and relay module.
2. Without rope or chain in gypsy, press and hold switch in upward position. If
wiring to switch terminals is correct, gypsy will spin counterclockwise.
If gypsy does not turn, but motor runs, switch is incorrectly wired. To
correct, switch the black and white wires on back of the switch.
LOADING THE ROPE AND CHAIN RODE
(Refer to the rope and chain requirements on page 3.)
1. Feed rope through davit or bow roller and pull toward anchor winch. Make sure
rope is not twisted or kinked and can freely run through bow roller or davit.
2. Lift finger and insert rope into rode glide and down into rope locker. Allow
enough slack so rope can be tied off in rope locker.
3. Release finger and make sure rope is firmly seated in the gypsy.
4. Go below to rope locker and tie rope off.
5. Press switch up and begin retrieving rope and chain into rope locker.

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
9
OPERATING THE ANCHOR WINCH
ANCHORING
1. Turn boat into wind and place boat motors in neutral.
2. After the boat has stopped all forward progress, drop anchor by pressing the
winch switch in the down position for approximately 5 seconds. After the
anchor has begun to free-fall it is safe to release the switch.
CAUTION NEVER REVERSE THE WINCH WHILE THE UNIT IS IN FREE-FALL MODE.
3. After the desired amount of rope has been release, retrieve 3'-5' of line by
pressing the switch in the up position.
4. Tie the rope off to a deck cleat. DO NOT use the winch to tie-off the anchor.
5. Place the boat's motors in neutral and allow the boat to drift back and set the
anchor in the sea bed.
RETRIEVING THE ANCHOR
1. Untie the rope from the deck cleat.
2. Align bow of boat with anchor rode.
3. Place the boat's motors in forward and move boat slowly toward the anchor
point. While moving press the winch switch in the UP position.
CAUTION DO NOT PULL THE BOAT TO THE ANCHOR POINT WITH THE ANCHOR
WINCH.THIS CAN CAUSE DAMAGE TO THE WINCH MOTOR AND GEAR TRAIN.ALWAYS USE
THE BOAT MOTOR TO MOVETOWARD THE ANCHOR POINT.
4. When the chain begins enter gypsy, the rode is almost retrieved. Do not
allow the anchor to pull up to quickly into the davit or bow roller.
5. When the anchor reaches the davit or bow roller, do not place too much
tension on the chain between the winch and anchor. This can cause
damage to the davit or winch gypsy.
6. Tie off the anchor for storage and travel.
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 gypsy, stripper, finger and deck insert for wear. Replace
any worn components.
Check electrical connections every 6 months for corrosion. Replace any
connection or wire which is damaged, corroded, frayed or worn.
Check rope periodically for abrasion or deep cuts. Never splice an old rope with
a new rope. If replacement is necessary, use only Powerwinch® rope
specifically designed for this product.
Check chain periodically for bent links and corrosion. Damaged links can
become jammed in gypsy or damage stripper and finger. Use of damaged chain
will void warranty.

SPORT FISHING 450 ANCHOR WINCH POWERWINCH
10
TROUBLESHOOTING GUIDE
WINCH DOES NOT OPERATE
A. Confirm power to winch
1. Check battery is fully charged
2. Confirm connections are tight & clean.
3. Check wires if worn or bare that may cause
shorts
Correct as required.
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.
YES If winch runs, circuit
breaker is bad, replace.
NOReconnect circuit breaker
and go to step C.
ROPE SLIPS OR JAMS WHEN RETRIEVING
A. 1. Wrong rope size. Replace rope. Refer to page 3 for
recommended rope.
2. Rope is frayed and worn.
3. Rope is too stiff.
CHAIN SLIPS OR JAMS
A. 1. Wrong chain size. Replace chain. Refer to page 3 for
recommended chain.
2. Links are bent or corroded.
3. Chain is kinked Unkink chain
A
NCHOR LINE WILL NOT FREE-FALL
A 1. Rope tangled in rope locker Untangle rope, Be sure rope is not
kinked or twisted before anchoring
2. Chain is kinked Unkink chain.
3. Anchor is wedged in bow roller Free anchor

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
11
REPLACEMENT PARTS LIST
Powerwinch
Windlass
To release anchor hold
switch down for 5 seconds
DETAIL A
A
1
4
2
2
5
6
8
14
13
8
7,8
7,8
7,8
9
11
10
10
11
12
12 12
12
3
PW27501

SPORT FISHING 450 ANCHOR WINCH POWERWINCH
12
Item Description Description Notes
1 R001430 FingerKit
2 R001431 GypsyKit
3 P10341 GypsyShaft Kit
4 R001432 StripperKit
5 P10343 Bearing Kit
6 R001434 MotorKit
7 R001435 Shock Absorber Kit
8 R001436 Spin Off Gear Kit 1
9 R001437 Locking Gear Kit
10 R001438 GearKit
11 R001440 MotorPlate
12 R001439 Fastener Kit
13 R001441 SwitchKit
14 P1027600AJ Circuit Breaker, 25A
Notes: 1. Spin Off Gear Kit (item 8) includes shock absorber kit (item 7).
The following rope and chain rodes are available from Powerwinch.
Part Number Chain Rope Model Use
P10293 1/4 in. x 10 ft. 1/2 in. x 150 ft. 36'
P10294 1/4 in. x 15 ft. 1/2 in. x 200 ft. 36'
P10295 1/4 in. x 15 ft. 1/2 in. x 300 ft. 36'
P10296 1/4 in. x 20 ft. 1/2 in. x 300 ft. 36'

POWERWINCH SPORT FISHING 450 ANCHOR WINCH
13
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. THIS WARRANTY IS NOT TRANSFERABLE.
1. DURATION
a) 2 years 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.
2. WHAT IS COVERED UNDER THIS WARRANTY
Defects in the manufacturer’s material and workmanship of product under normal use, and
which occur within the duration of the warranty period.
3. WHAT IS NOT COVERED UNDER THIS WARRANTY
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.
4. RESPONSIBILITIES OF THE PURCHASER
IN ORDER FOR THE WARRANTY TO BE HONORED,THE PURCHASER MUST HAVE PROOF OF
PURCHASE.FAILURE TO PROVIDE THE REQUIRED DOCUMENTATION MAY DELAY OR VOID ANY
WARRANTY CLAIM.
a) Retain dated proof of purchase for the product, and provide it as requested.
b) Perform
“Periodic Maintenance” as specified in Owners 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.
THIS WARRANTY GIVES THE OWNER SPECIFIC LEGAL RIGHTS.THE LAWS OF CERTAIN JURISDICTIONS MAY
GRANT THE OWNER ADDITIONAL RIGHTS AND PRIVILEGES.Except as set forth above; Carefree makes
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 which has been shipped
or in service.