Owner s Manual Boat Trailer Winch: 5:1 ratio model (500kg~700kg) F10204, F10205, F10214, F10215, F10216 Contents: Specifications and Features 1 Spare Parts Listing 2 Front and Side Elevation, Bolt Down Specifications 2 Safety Information 3 General Theory of Operation 3 Installing the Winch 4 Installing wire cable / fibre rope / webbing 4 Preparing for Operation 5 Attaching the Load 5 Moving the Load 6 Cleaning the Winch 6 Lubricating the Winch 6 Inspecting the Winch 6 Warranty 8 Rolling Capacity 9 advansa Advansa Pty Ltd 258 Halifax Street, Adelaide SA 5000 (T) +61 (0)8 8243 9100 (F) +61 (0)8 8243 9185 Email: sales@advansa.com.au Web: www.advansa.com.au Toll Free Sales: 1 300 135 935
5:1 ratio Boat Trailer Winch Owner s Manual 1 Boat Trailer Winch 5:1 ratio model (500 kg ~ 700kg*) Model: No Cover Cover Webbing F10204 F10204WC Fibre rope (Ø6mm) Winch only Cable (Ø4mm) Cable (Ø5mm) F10205 F10215 F10214 F10216 Gear Ratio 5:1 Application Pulling * Rated Capacity (using Ø5mm Cable / Webbing) 700kg (6860N) * Rated Capacity (using Ø6mm Fibre Rope) 700kg (6860N) * Rated Capacity (using Ø4mm Cable) 500kg (4900N) F10214 Mass (Winch only) Type of Ratchet Drum Diameter Flange Diameter Drum Width Maximum Cable capacity Maximum Fibre Rope capacity Maximum Webbing capacity Max. Effort on handle at Rated Load Breaking Strain Cable (Ø4mm / Ø5mm) Breaking Strain Fibre Rope (Ø6mm) Breaking Strain Webbing 4.1kg Lever Action 50mm 127mm 52mm 20m x Ø4mm / 15m x Ø5mm 12m x Ø6mm 9m 25kg 1269kg / 1855kg 2050g 2070kg Cable (Galv) / Webbing / Fibre Rope as supplied 6m x Ø4mm-Ø5mm / 6m / 6m x Ø6mm Fastening Device Snap Hook Note: These winches are not to be used for lifting Features include: Heavy duty 4mm winch body, Steel bushes, Machined gears, Spare parts available, Electroplated zinc cobalt, Powder coated finish These winches are recommended for boat (outboards and inboards) size up to 6 metres, aluminium or fibreglass hull boat, where trailer design is unknown or has no keel rollers or side wobbles. For fast slack cable retrieval, the dual ratio winch 5:1 / 1:1 (2 speed) is recommended, where the 1:1 ratio is used to retrieve slack cable then use the 5:1 to complete the retrieval of the boat. Please record the following: Date Purchased: Model No: Where Purchased: Serial No: This information (and receipt) is required should a warranty claim be necessary.
5:1 ratio Boat Trailer Winch Owner s Manual 2 5:1 ratio model Boat Trailer Winches Spare parts listing - F10204, F10205, F10214, F10215, F10216 Front and side elevation, and bolt-down specifications / dimensions (T) +61 (0)8 8243 9100 (F) +61 (0)8 8243 9185 Toll Free Sales: 1 300 135 935 Email: sales@advansa.com.au Web: www.advansa.com.au
5:1 ratio Boat Trailer Winch Owner s Manual 3 Important Safety Information DO the following: Read carefully and comply with the guidelines set forth in the Owner s Manual. Keep hands away from the drum, gears, wire cable / fibre rope, and other moving parts of the equipment. Keep all unnecessary personnel away from the winch while in operation. Keep out of the path of the winching operation should the wire cable break and snap back and cause injury. DO NOT do the following: Do not lift people, or objects over people. Do not walk or work under or in the line of force of any winching operation. Do not exceed the load rating of the winch or any other component in the system. To do so could result in failure of the equipment. Do not use more than one winch to move a boat that exceeds the load rating of a single winch. A shift in load weight could overload the equipment. Do not use damaged or malfunctioning equipment. To do so could result in failure of the equipment. Do not modify the equipment in any way. To do so could cause equipment failure. Do not winch a boat onto a trailer with the wire cable / webbing / fibre rope fully extended. Keep at least three full turns of cable / fibre rope (or one turn of webbing) on the drum. Do not wrap the wire cable / fibre rope around the load. This may damage the wire cable / fibre rope and could damage the boat. Use a sling, shackles or other approved devices. Do not operate the winch with covers removed or improperly installed. Do not divert your attention from the operation. Stay alert to the possibility of accidents, and try to prevent them from happening. Do not jerk or swing the boat. Avoid shock loads by starting and stopping the winching operation smoothly. Shock loads overload the equipment and may cause damage to both the winch and boat. Do not leave a suspended load unattended unless specific precautions have been undertaken and keep people away from the winch and out from under the load. Please note that all goods are supplied by the Advansa to the Customer for use only in applications and purposes for which they were originally designed. Advansa is not liable for any consequential loss whatsoever from improper or inappropriate use of the goods supplied, where the goods are used for purposes beyond or outside of the scope of application for which they were designed and which exceeds their designed performance limit. At all times please consult Advansa if unsure of the suitability of the goods for your intended application. General theory of operation Limit non-uniform winding by keeping tension on the wire cable. It is the operators responsibility to detect and account for different factors affecting the condition and performance of the equipment. The pull required to move the boat must not exceed the load rating of the winch. Consider the total force required to move the boat, not the weight of the boat. The winch can develop forces that will exceed the load rating. It is the responsibility of the winch operator to limit the size of the load. Inspect the winch regularly for damage according to the instructions contained in the Owner s Manual. Performance ratings of the winch are affected by the amount of wire cable, webbing or fibre rope wound onto the drum, the way in which it is wound, and the way the winch is used. Drum capacity depends on how tightly and evenly the wire cable or fibre rope is wound onto the drum. Actual drum capacities are usually 25-30% less than the values shown in performance tables, due to loose winding and overlapping. Load rating represents the maximum pull that can be placed on a new winch. Load ratings are assigned values for specific amounts of load travel or wire cable / fibre rope accumulation. The load rating decreases as layers of wire cable / fibre rope accumulate on the drum. Duty ratings refer to the type of use the winch is subject to. Consider the following when determining duty rating. Environment: harsh environments include hot, cold, dirty, wet or corrosive surroundings. Protect the winch against harsh environments when possible. Maintenance: poor maintenance, meaning poor cleaning, lubrication or inspection, leads to poor operation and possible damage of the winch. Minimise poor maintenance by carefully following the instructions contained in the Owner s Manual. Loading: severe loading includes shock loading and moving boats that exceed the load rating of the winch. Avoid shock loads, and do not exceed the load rating of the winch. Frequency of operation: frequent or lengthy operations increase wear and shorten the life span of gears, bushes, and other components. Increase maintenance of the winch if used in frequent operations.
5:1 ratio Boat Trailer Winch Owner s Manual 4 Installing the Winch Inspect the winch immediately following installation. This will give provide a record of the condition of the winch from which to compare future inspections. Warning Do not install the winch near corrosive chemicals, flammable materials or other elements that may damage the winch or injure the operator. Adequately protect the winch and operator from such elements. Position the winch so the operator can stand clear of the boat, and out of the path of possible broken wire that could snap back and cause injury. Attach the winch to a rigid and level / flat foundation base that will support the winch and the boat under all load / unload conditions, including shock loading. Locate the winch in an area clear of traffic and obstacles that could interfere with its operation. Make sure the winch is accessible for maintenance and operation. The winch should be positioned onto a solid / flat foundation base (able to support the winch and the load / unload operations under all conditions) in the front of and central to the trailer. This ensures a balanced winching operation whilst loading / unloading the boat. Fasten the winch securely to the boat trailer, utilising all four mounting holes to ensure maximum capacity. 4ea. M10 galvanised or G316 stainless steel bolts, flat and spring washers and nuts should be used to secure the winch to the boat trailer. Installing wire cable / fibre rope / webbing onto Jarrett winches Use wire cable and other rigging equipment rated for the capacity of the winch. Do not drag the wire cable through dirt or debris that could cause damage, or poor operation. Always wear protective clothing when handling wire cable. Install the wire cable securely to the winch drum. A poorly secured wire cable could come loose from its anchor and could release the load. Ensure the wire cable is wound correctly or the winch may not work properly and could release the load. Always ensure that a minimum of three full turns remain on the winch drum at all times. Where wire cable / fibre rope / webbing is not supplied or is to be replaced, purchase the proper wire cable / fibre rope / webbing for your application. Keep the following in mind when selecting. Contact a reputable supplier for assistance. Breaking strength of new wire cable / fibre rope / webbing should be at least 2 times greater than the rating of the winch. Wire cable lay must agree with the winding direction of the drum to insure proper winding. Secure the wire cable / fibre rope / webbing to the winch drum as per the securing instructions below. Test the wire cable / fibre rope / webbing installation by operating the winch. The pawl (ratchet) operates in one direction only. Make sure the pawl (ratchet) engages to resist the force of the load. Wind three full turns of wire cable onto the drum by operating the winch whilst holding the wire cable taut. These turns serve as an anchor wraps and must remain on the drum at all times. Dependant on Boat Trailer Winch model, two securing methods for cable are applicable: Instruction for securing a cable to a winch using a plate clamp fitting 1. Tape the cable end using 50mm 70mm of plastic tape. This is to stop the cable end from fraying and causing injury in use. 2. Fold the end of the cable (approximately 30mm) back on itself and permanently kink the end. 3. Feed the taped end of the cable through the round hole of the drum flange (disc) from inside the drum. 4. Place one of the cup head bolts into Hole 1 of the clamp fitting, with the head on the inside of the drum assembly, and pull the cable tight against the bolt. Attach the nut and tighten. 5. Align the second hole in the plate with Hole 2, and secure with the second bolt and nut.
5:1 ratio Boat Trailer Winch Owner s Manual 5 Instruction for securing a cable to a winch using a single bolt fitting 1. Place the cup headed bolt into the square hole with the head on the inside of the drum assembly. 2. Screw on the combination nut and washer only 2-3 threads. 3. Tape the cable end using 50mm 70mm of plastic tape. This is to stop the cable end from fraying and causing injury in use. 4. Feed the taped end of the cable through the round hole of the drum flange (disc) from inside the drum and double back to loop the cable under the bolt, behind the washer and back towards the round hole. 5. While holding the cable in place under the nut with the left hand, pull the cable tight with the right hand. 6. Using the thumb of the left hand hold the cable in place inside the drum and tighten the nut to secure the cable in place. Turn the handle to wind the wire cable onto the winch drum. Uniformly wind the wire cable onto the winch drum by holding the wire cable taut. View from outside the drum showing cable flow Instruction for securing fibre rope to winch Note: Fibre rope to be Ø7mm 1. Take the winch drum with the gear facing the assembler and the free end of the rope and wrap three turns around the hub of the drum in an anticlockwise direction. 2. Take the free end and pass it between the three turns and the drum hub and then pass the free end over the three turns on the drum and under the last turn. 3. Pass free end of the rope under the last bite and through the cable hole in the flange. Pull firmly so that the turns on the drum lie reasonably flat. The length protruding needs to be about 150mm. 4. Insert from inside the drum flange (centre hole) the M6 square neck cup head bolt and screw the M6 flanged serrated hexagon nut onto the bolt. 5. Wrap the rope around the M6 bolt inside the flanged serrated hexagon nut. Secure the fibre rope by tightening the nut using an M6 spanner. When securing, ensure that the rope fibres do not catch on the bolt threads and that the rope stays inside the flanged section. Trim any excess rope. 6. The turns around the drum will have become loose. Work the turns so that the rope lays flat against the hub and there is no slack. Instruction for installing / replacing webbing To install the webbing, perform the following steps bar #3. To replace the webbing, perform all the following 7 steps. 1. gently knock out the roll pin that secures the winch drum to the shaft - a round punch or screwdriver will suffice - providing that they are smaller in diameter than the roll pin. Light / 'firm' taps with a small hammer should remove the roll pin. 2. gently knock out the shaft to a point where it releases the webbing - be careful not to burr over the shaft corner/edge or damage the bushing 3. remove old webbing 4. ensure loop of new "Jarrett" brand webbing is flexible/loose 5. locate webbing 'loop' into slot of the winch drum and secure with shaft (which goes through the loop) 6. gently relocate shaft into bushing - a drop of general purpose oil on the bushing would not go astray 7. align pin hole on winch drum and shaft and gently tap in roll pin till it is flush Preparing for Operation When determining whether the boat will exceed the load rating, consider the total force required to move the boat. Consider the operation. Do not begin until you are sure you can perform the entire operation without hazard. Inspect all components of the system. Inspect the winch and other equipment in accordance with Inspection instruction. Operators should be in good health, alert and suitably clothed (i.e. no loose clothing) The boat must be clear of objects and free to move. Ensure the boat will not tip, spin, roll away, or in any way move uncontrollably. Know your boat and make sure you do not exceed the load rating of the winch or any other equipment in your system. Attaching the Boat Warning Do not wrap the wire cable / fibre rope around the boat winch connection. This damages the wire cable / fibre rope and could damage the boat. If necessary, use a sling or other approved device. Clear objects from the path of the boat so you can move it freely and observe it at all times during the operation. Attach the boat using a nylon sling, shackle or other approved rigging device. Seat the sling / shackle in the saddle of the snap hook with the hook latch completely closed. If an S-Hook is used, the sling / shackle is positioned in the S-hook, and the winch drum operated slowly to retrieve the slack cable / webbing / fibre rope. When the cable / webbing / fibre rope is taut, check to ensure the sling is correctly positioned in the S-hook / snap hook prior to moving the boat. Centre the load on the hook so the boat will remain balanced and not tip or rotate to one side.
5:1 ratio Boat Trailer Winch Owner s Manual 6 Moving the Boat Obey a stop signal from anyone. Maintain tension on the wire cable to keep it tightly and evenly wound on the drum. If the winch and boat are not visible during the entire operation, get help from another person. Appoint a supervisor if more than one person is involved in the operation. This will reduce confusion and increase safety. Where possible, remove the handle when the winch is not in use, to help avoid unauthorised use. Move the boat slowly and smoothly, only a small distance at first. Make sure the boat is balanced and securely attached before continuing. Engage the pawl (ratchet) when winding the boat towards the winch, disengage the pawl (ratchet) when releasing the boat. Do not engage the pawl (ratchet) while the winch gears are turning. Stop the winch before engaging the Pawl. Ensure the handle is securely positioned on the shaft. Grip the handle tightly at all times during operation. When required, disengage the Pawl by moving the load slightly to remove pressure from the Pawl, then pull out and turn the Pawl lever 90 degrees. Do not try to stop a spinning handle, step clear until the spinning stops. Observe the wire cable as it winds onto the drum. If it becomes loose, uneven, or overlapped, stop the operation and rewind before continuing. Continued operation with overlapped or uneven wire cable can damage and shorten its life. Cleaning the Winch Increase the frequency of maintenance procedures if the winch is: Operated for long periods. Used to pull heavy loads. Operated in wet, dirty, hot or cold surroundings. Clean the winch to remove dirt and help prevent rust and corrosion. Clean the winch every three months or whenever it is dirty. Wipe all components to remove dirt and grease. Leave a light film of oil on all surfaces to protect them against rust and corrosion. Wipe off excess amounts of oil to avoid accumulation of dirt. Remove all unnecessary objects from the area surrounding the winch. Lubricating the Winch Make sure the lubricant has a temperature rating appropriate for the ambient temperatures of the operation. Lubricate the winch properly to help protect it from wear and rust. Lubricate the winch at least every three months, by applying a light grade oil to the drum shaft and bushes. Rotate the drum several times to allow oil to penetrate, and wipe off excess oil to avoid dirt accumulation. Inspecting the Winch and other associated equipment Keep written records of inspection. This allows comparison with comments from previous inspections so you can see changes in condition or performance Warning Do not use damaged or malfunctioning equipment. Seek immediate repair. Inspect the winch to detect signs of damage or poor operation before they become hazardous. Instructions Frequent Inspection Perform frequent inspections: Before each operation. Whenever you notice signs of damage or poor operation
5:1 ratio Boat Trailer Winch Owner s Manual 7 Visually inspect the entire winch and all other associated equipment involved in the operation. Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage. Check gears, pinions and pawl for wear, and other damage. Make sure the wire cable / fibre rope is installed correctly and anchored securely to the drum Make sure the winch is properly lubricated. Where applicable, make sure the handle is securely held in place. Make sure the mounting fasteners are tightened securely Make sure the foundation is in good condition, and capable of supporting the winch and the boat under all load / unload conditions. Test winch performance by moving a test load equal to 10% of the rated capacity. Listen for unusual noises, and look for signs of damage as you operate the winch. Make sure the winch cable / fibre rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing. Make sure the handle moves freely in both directions. Make sure the Pawl (ratchet) engages and disengages completely. Completely correct all problems before continuing. Use the Troubleshooting Chart (at end of this Section) to help determine the cause of certain problems. Instructions Periodic Inspection Perform periodic inspections: Every three months. Whenever you return the winch to service from storage. Whenever you notice damage or poor operation in a frequent inspection. Whenever you have, or think you may have, overloaded or shock loaded the winch. Visually inspect the entire winch and all other associated equipment involved in the operation. Check the finish for wear, flaking, or other damage. Check all equipment for cracks, dents, bending, rust, wear corrosion and other damage. If the equipment was overloaded, or if you notice cracks and other signs of overloading and damage, promptly remove the equipment from use and have it repaired or replaced. Do not continue to use the damaged or overloaded equipment. Check all fasteners for stripped threads, wear, bending, and other damage. Check gears, pinions and pawl for wear, and other damage. Check the foundation for cracks, corrosion, and other damage. Make sure the winch is properly lubricated. Make sure all labels and plates are readable, firmly attached, free from damage and clean. A1 - If your winch is installed with webbing or fibre rope: Unwind the webbing completely. Inspect the length on both sides for kinks, fraying, and other damage. Unwind the fibre rope completely. Inspect the entire length of fibre rope for excessive wear, chafing, dirt and grit, and other damage. THEN Make sure the snap hook is securely attached to the webbing. Check the throat opening, thickness, and twist of the snap hook. Replace the hook if it shows signs of damage. See figure 2. Make sure the hook latch opens without binding and closes when released. Check the anchor holes in the drum flange, clamp fittings and bolts for signs of wear or distortion. A2 - If your winch is installed with wire cable: Remove the wire cable entirely from the drum. Always wear protective clothing when handling wire cable. Check the entire length of wire cable for bent wires, crushed areas, broken or cut wires, corrosion, and other damage. Carefully inspect areas that pass over sheaves or through roller guides. Note the location and concentration of broken wires. Replace the wire cable if more than 6 wires are broken in one lay, or more than 3 wires are broken in one strand in one lay. See figure 1. Make sure the snap hook is securely attached to the wire cable, and the wire cable where it is attached is not frayed, corroded, broken, or otherwise damaged. Check the throat opening, thickness, and twist of the snap hook. Replace the hook if it shows signs of damage. See figure 2. Make sure the hook latch opens without binding and closes when released. Check the anchor holes in the drum flange, clamp fittings and bolts for signs of wear or distortion. Measure the diameter of the wire cable, especially in areas where wear is noticeable. Replace the wire cable if the diameter measures below the minimum diameter at any point. See figure 3.
5:1 ratio Boat Trailer Winch Owner s Manual 8 After A1 or A2 - Remove the winch from the foundation. Check fasteners for stripped threads, wear, bending, and other damage. Check the frame (winch body) for bending, distortion, cracks, and other damage. A bent frame is caused by overloading, and is a sign that your application may require a winch with a larger load rating. Move the drum with your hands. Check for excessive movement indicating worn or loose gears, bushings, or shafts. Disassemble the winch if necessary. Inspect gears, pins, springs and shafts for wear, corrosion, distortion, and other damage Fasten the winch securely to the foundation. Install the wire cable / webbing / fibre rope. Test winch performance by operating the winch with a test load equal to the load rating. Listen for unusual noises, and look for signs of damage as you operate the winch. Make sure the winch cable winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing. Make sure the handle moves freely in both directions. Make sure the Pawl (ratchet) engages and disengages completely. Completely correct all problems before continuing. Use the Troubleshooting Chart (below) to help determine the cause of certain problems. Troubleshooting Chart problem cause correction handle turns, drum doesn t turn loose or broken pins inspect winch, repair as necessary loose, stripped or broken gears or pinions inspect gears / pinions and repair as necessary handle turns hard or not at all pawl (ratchet) on winch engaged disengage winch pawl (ratchet) load too heavy lighten load pins loose or broken on winch inspect winch, repair as necessary drum shaft broken or seized inspect, repair or replace as necessary overheating operated too long without rest allow to cool load too heavy lighten load poor lubrication inspect and lubricate as necessary bushings seized up inspect and replace as necessary unusual noises high pitched squeak poor lubrication inspect and lubricate as necessary grinding noise contaminated lubrication clean and relubricate winch rattling noise loose bolts, set screws or other fasteners tighten all bolts and other fasteners Warranty Please note that all goods are supplied by Advansa Pty Ltd to the Purchaser for use only in applications and purposes for which they were originally designed. Advansa Pty Ltd is not liable for any consequential loss whatsoever from improper or inappropriate use of the goods supplied, where the goods are used for purposes beyond or outside of the scope of application for which they were designed and which exceeds their designed performance limit. At all times please consult Advansa Pty Ltd if unsure of the suitability of the goods for your intended application. Advansa Pty Ltd Winch Warranty Policy: The Warranty is for the period of twelve months on Jarrett winches / cranes providing it is used for the purpose that it was designed for. Any modifications or misuse of the winches / cranes will void the warranty. Winches / cranes will be repaired under warranty providing proof of purchase is supplied. No credits or replacements will be issued except with approval from Advansa Pty Ltd.
5:1 ratio Boat Trailer Winch Owner s Manual 9 Rolling Load Capacity of a Winch Max. rated Rolling Load Capacity Multiply incline % incline Degrees winch capacity by To calculate the rolling load capacity of a winch - the amount of load that can be pulled up an incline - multiply the winch capacity by the factor shown in the chart below. The multiplication factor shown includes a 10% rolling friction factor. 10:10 100 45 0 00 ' 1.29 Note: 5% incline is 1/2 metre rise in 10 metres. 9:10 90 42 0 00 ' 8:10 80 38 0 40' 7:10 70 35 0 00' 1.53 6:10 60 30 0 58' 5:10 50 26 0 34' 1.86 4:10 40 21 0 48' 3:10 30 16 0 42' 2.61 2:10 20 11 0 19' 3.40 1:10 10 5 0 43' 5.02 0.5:10 5 2 0 55' 6.67 0:00 0 = level 10.00 Angle / incline - not to scale A commonly used ratio of boat size to winch capacity is 2 to 1. However, the ratio can be stretched to 3 to 1 using a trailer in excellent condition. A guide to the rolling load (pulling) capacity of a winch (in excellent condition) pulling a boat onto a trailer equipped with fitted keel rollers and side wobbles (in good condition) is as per the following table. For example, a 300kg winch can pull a 900kg boat onto a trailer (equipped with fitted keel rollers and side wobbles) with a 10 degree incline (i.e. 20% incline). The ratio should be reduced to 1 to 1 on trailers with wooden bunks and no self-alignment capabilities. Rated capacity of the winch % incline of trailer 200kg 300kg 500kg 700kg 800kg 1000kg 0 2000 3000 5000 7000 8000 10000 5 1300 2000 3300 4600 5300 6600 10 1000 1500 2500 3500 4000 5000 20 650 1000 1700 2350 2700 3300 30 500 750 1250 1750 1900 2500 50 350 550 900 1300 1450 1850 70 300 450 750 1000 1200 1500 100 250 350 600 850 1000 1250 Max. Rolling Load (Pulling) capacity of winch (kg) with a trailer in excellent condition