Manual For The 63770 12000 Lb. Off Road Vehicle Electric Winch With Automatic Load Holding Brake

User Manual: Manual for the 63770 12000 lb. Off-Road Vehicle Electric Winch with Automatic Load-Holding Brake 12000 lb. Off-Road Vehicle Electric Winch with Automatic Load-Holding Brake

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Owner’s Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly,

operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the
back of the manual near the assembly diagram (or month and year of purchase if product has no number).
Keep this manual and the receipt in a safe and dry place for future reference.

17j

Visit our website at: http://www.harborfreight.com
Email our technical support at: productsupport@harborfreight.com
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2017 by Harbor Freight Tools®. All rights reserved.
No portion of this manual or any artwork contained herein may be reproduced in
any shape or form without the express written consent of Harbor Freight Tools.
Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein.
Tools required for assembly and service may not be included.

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

Table of Contents
Specifications ............................................. 2
Safety ......................................................... 3
Setup .......................................................... 8
Operation ................................................... 10

Maintenance .............................................. 13
Parts List and Diagram .............................. 15
Warranty .................................................... 16

Specifications
Rated Single
Line Pull
Application

12,000 lb (5454 kg)

Motor
Power IN &
Power OUT
Duty Cycle Rating
Pendant Controller
Geartrain
Gear Ratio
Freespool
Brake
Drum (Dia. X L)
Clevis Hook
Fairlead
Overload Protection
Sound Rating

Wire Rope
Size / Type

Vehicle Recovery /
For Trucks and SUV’s
12VDC 6 HP Series Wound
Yes
5% (45 sec at Max Rated Load;
14 min, 15 sec Rest)
Wired, 12 ft (3.7m) long
3-Stage Planetary
265:1
Sliding Ring Gear
Auto. Load Holding
2.5" X 8.8" (64mm X 224mm)
3/8", Replaceable with
Spring-loaded Safety Latch
Roller with nylon bushings
In line Circuit Breaker
90 dB

Ø0.375" X 65' (Ø9.5mm X 19.8m)
Nominal strength=14,400 lb
7X19 Galvanized Steel
Aircraft Wire Rope
12VDC Minimum 650 CCA

Battery
Battery Cables
Mounting Bolt
Pattern
Mounting Hardware

Overall Dimensions
(L X D X H)
Weight
IP Rating
Winch Certification

Layer

Rated Line Pull

Page 2

Winch:
4x G8, M10-1.50 X 30mm
Fairlead:
2x G8, M12-1.75 X 25mm
Solenoid Box:
2x G8, ST-M5 X 14mm
21" X 6.4" X 10.125″
(533x162x211mm)
85.8 lb (39 kg)
IP 66 - Winch and Controls
(resistant to powerful water jets,
except remote control switch)
CE

Wire Rope Capacity

1

12000 lb (5443 kg)

16.3' (5m)

2

9517 lb (4317 kg)

37' (11m)

3

7885 lb (3577 kg)

60' (18.3m)

First Layer of Wire Rope Performance
Line Pull lb (kg)
1

Min. 2 AWG X 6'
10" x 4.5" (254mm x 114.3mm)

0
3000
6000
9000
12000

(0)
(1361)
(2722)
(4082)
(5443)

Line Speed fpm (mpm) Amp Draw (@ 12V)
15.5
9.5
7.4
5.7
4.4

(4.7)
(2.9)
(2.3)
(1.7)
(1.3)

For technical questions, please call 1-888-866-5797.

101
173
244
311
359

Item 63770

WARNING SyMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.

SAFETy

Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

Addresses practices not related to personal injury.

Symbol

Property or Statement

Wear heavy-duty, cut- and
abrasion-resistant leather gloves.

Do not use winch in
overwind orientation.
(Wire rope enters/exits at the top.)

Wear ANSI-approved safety glasses.

Use winch only in
underwind orientation.
(Wire rope enters/exits at the bottom.)

Roller entanglement hazard.

Hot surface burn hazard.

VDC
A
CCA
HP

Fire hazard.

Caustic chemical (acid) hazard.

fpm

Volts Direct Current

Amperes

Cold Cranking Amperes

Horsepower

Feet Per Minute

Explosion hazard.

mpm

Meters Per Minute

Do not loop the wire rope around
object and hook onto itself.

RPM

Revolutions Per Minute

Do not place finger(s) through hook.
Fingers may be caught and get
pulled into fairlead or drum.
Pull hook using strap only.

Item 63770

IP
G8

OPERATION

Cut or sever hazard.

SETUP

Property or Statement

International Protection rating
Classifies the degrees of protection provided
against the intrusion of solid objects,
dust, accidental contact, and water.

Grade 8
A fastener strength rating.

For technical questions, please call 1-888-866-5797.

Page 3

MAINTENANCE

Symbol

IMPORTANT SAFETy INFORMATION

SAFETy

WARNING! Read all instructions. Failure to follow all instructions listed on pages 4 to 7 may
result in fire, serious injury and/or DEATH.
The warnings and precautions discussed in this manual cannot cover all possible conditions and
situations that may occur. It must be understood by the operator that common sense and caution
are factors which cannot be built into this product, but must be supplied by the operator.

Installation Precautions

SETUP

1. Do not wear loose clothing or jewelry,
as they can be caught in moving parts.
Non-skid footwear is recommended.
Wear restrictive hair covering to contain long hair.

7. Ventilate area well before and while working
on battery. Explosive invisible hydrogen gas
can accumulate and then explode when ignited
by a spark from the battery connection.

2. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during installation.

8. Only connect to a clean, corrosion free battery.

3. Before installation confirm that area is clear
of fuel lines, brake lines, electrical wires,
gas tanks or any other component which
could be damaged during drilling.

9. Do not lean over or come in contact with
battery while making connections.
10. Remove all metal jewelry before
working near battery.

4. Mounting location and hardware
must support winch and load.

11. Connect red wire to positive battery terminal
and black wire to negative battery terminal.

5. Use supplied power cords and wire rope listed
in manual only. Do not use thinner/longer
cables or link multiple cables together.

12. Insulate all exposed wiring and
terminals after installation.

OPERATION

6. Do not route electrical cables near sharp edges
or parts that will move or become hot.

13. Install winch and fairlead in underwind
orientation, so that the wire rope enters and
exits the winch at the bottom of the drum.

MAINTENANCE
Page 4

For technical questions, please call 1-888-866-5797.

Item 63770

2. Do not maintain power to the winch if the motor
stalls. Verify load is within rated capacity for
the wire rope layer, see Winch Specifications on
page 2.
Make sure the battery is fully charged.
Use double line rigging whenever possible,
see Double Line Rigging on page 11.

13. Use as intended only. Do not lift items
vertically or use for aircraft purposes.
14. Prevent entanglement. Do not wear loose clothing
or jewelry, as they can be caught in moving
parts. Non-skid footwear is recommended. Wear
restrictive hair covering to contain long hair.
15. Disconnect Pendant Controller before
working near the Wire Rope, drum, fairlead
or load, to prevent accidental starting.

5. Keep clear of fairlead when operating.
Do not try to guide wire rope.

16. Inspect before every use; do not use if damaged or
parts loose. Examine the winch for structural cracks,
bends, damage, frayed or kinked wire rope, and any
other conditions that may affect the safe operation
of the winch. Do not use the winch even if minor
damage appears. A kink permanently weakens the
wire rope, even after it is straightened out; kinked
wire rope can fail suddenly and must not be used.

6. Do not place finger(s) through hook. Fingers may
be caught and get pulled into fairlead or drum.
Use included strap to hold hook instead.

17. Keep wire rope straight to avoid kinking
the wire rope. The illustrations to the
right show how a kink forms.

4. Do not disengage clutch under load.
Engage clutch before starting.

7. Place heavy rag or carpet over wire
rope span 6 feet from hook to help absorb the force
released if the wire rope breaks. (See Figure A.)

a. This illustration shows a kink about
to form. At this point the winch
should be stopped and the wire
rope should be straightened out
to prevent kinking.

OPERATION

3. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during operation.

SETUP

1. Do not exceed load capacity. Be aware of
dynamic loading! Sudden load movement may
briefly create excess load causing product failure.

SAFETy

Operation Precautions

b. This wire rope is
kinked. It is too
late to reverse the
damage at this point, the
wire rope must be discarded.
It is permanently damaged
and must not be used.

8. Stay out of the direct line that the wire
rope is pulling. In case it slips or breaks,
it will “whiplash” along this line.
9. Do not use for lifting or moving people.
10. Use a spotter to assist you in assuring that it is safe
to operate the winch. Make sure the spotter is out of
the way of the vehicle and the wire
rope before activating the winch.
11. Do not use the hand crank, if equipped,
to “assist” the winch.
12. Do not use vehicle to pull on the
Wire Rope and “assist” the winch.

Item 63770

c. This is a kinked wire rope that has been
straightened out. Even though it has been
pulled straight, some wires in the wire rope
are stretched, and others are severely bent,
if not broken. The unstretched wires will
take more load and can fail suddenly before
the rope reaches its capacity. This wire
rope must be discarded and not be used.
A kink permanently weakens the wire rope,
even after it is straightened out; kinked wire
rope can fail suddenly and must not be used.
18. Keep children and bystanders away while operating.
Distractions can cause you to lose control.

For technical questions, please call 1-888-866-5797.

Page 5

MAINTENANCE

Figure A: Whiplash Dampening Blanket or Rug

19. Stay alert, watch what you are doing and
use common sense when operating. Do not
use a winch while you are tired or under the
influence of drugs, alcohol or medication.
A moment of inattention while operating winches
may result in serious personal injury.

30. Do not operate the winch at extreme angles.
Do not exceed the angles shown in Figure B for
a roller fairlead. For a hawse fairlead, the angle
should be as close to straight as possible.

SAFETy

15°

20. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the winch in unexpected situations.

15°

21. Hook onto the object using a pulling point, tow
strap or chain. Do not wrap the wire rope around
the object and hook onto the wire rope itself.
This can cause damage to the object being
pulled, and kink or fray the wire rope.

45°

22. Do not use a Recovery Strap while
winching. They are designed to stretch
and can suddenly whip back towards the
operator during a winching operation.

45°

SETUP

23. Secure load after moving.
NO LOCKING MECHANISM.
24. Keep at least 5 full turns of wire rope on
drum. The wire rope’s connection to the
drum is not intended to sustain a load,
without the added support from the friction
of at least 5 full turns of wire rope.
25. Wrap wire rope under 500 lb. tension before use.
Otherwise, wire rope may bind during operation.

Figure B: Roller fairlead Maximum Winching Angles
31. If the object to be pulled must be pulled at an
angle in relation to the winch, use a pulley
(sold separately) and an anchor point directly
in front of the winch, as shown in Figure C,
to keep the Wire Rope pull straight.

Figure C: Pulley anchoring

OPERATION

26. Keep clear of wire rope, hook, and load while
winching. Do not step over wire rope.
Do not push sideways against wire rope
under tension; wire rope might break under
this load and recoil back, striking the
person pushing against it or a bystander.
27. If wire rope begins to get entangled, stop winch
immediately and release wire rope using switch.
28. Do not submerge winch in water.
If winch gets submerged accidentally, it needs
to be immediately disassembled, cleaned, dried
and re-lubricated by a qualified technician to
prevent permanent damage from corrosion.

MAINTENANCE

29. Only winch with the winching vehicle′s
transmission in neutral. Winching with a vehicle′s
transmission in gear or park may damage
the transmission. A vehicle′s transmission is
not designed to handle that type of load.

32. Broken strands of wire rope will be sharp.
Wear heavy-duty work gloves when handling
the wire rope. Do not slide wire rope
through hands, even with gloves on.
33. Winch motor will be hot during and after use.
Keep clear.
34. Do not power the hook all the way
into the fairlead or winch.
35. To prevent accidental starting, unplug winch controls
and any RF receivers immediately after extending
or retracting. This is especially important before
rigging, installing, free spooling, or servicing.
36. People with pacemakers should consult their
physician(s) before use. Electromagnetic fields in
close proximity to heart pacemaker could cause
pacemaker interference or pacemaker failure.

Page 6

For technical questions, please call 1-888-866-5797.

Item 63770

1. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during service.
2. Disconnect power to winch and allow it
to cool completely before service.
3. Use supplied power cords/wire rope or cables
listed in manual only. Do not use thinner/
longer cables or link multiple cables together.

4. Have the winch serviced by a qualified repair person
using only identical replacement parts. This will
ensure that the safety of the winch is maintained.
5. Maintain labels and nameplates on the winch.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.

SAFETy

Service Precautions

MAINTENANCE

OPERATION

SETUP

SAVE THESE INSTRUCTIONS.

Item 63770

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Page 7

Installation and Setup
Read the ENTIRE IMPORTANT SAFETy INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.

1. The mounting plate must be rated to
at least the winch’s capacity.

8.58 in. / 218mm

SAFETy

Mounting the Winch

2. Align the winch perpendicular to center line of
the vehicle at the desired location, and mark the
locations of the winch base holes. Compare the
dimensions of the marked holes to Figure D.
3. Before drilling, verify that the installation
surface has no hidden components or
structural pieces that will be damaged.

4. Drill holes appropriate for the hardware
at the marked locations.

8.8 in. / 223.6mm

5.28 in. / 134mm

4*Ø0.43 in. / 11mm

6.3 in. / 160mm

10 in. / 254.6mm

4.49 in.
/ 114mm

SETUP

NOTE: This winch can generate extreme
forces. Select a location that can withstand the
rated capacity without damage or weakening.
Steel reinforcement plates may be needed or a
certified welder may need to weld on additional
bracing depending on the mounting location.

6.85 in. / 174mm

20.94 in. / 532mm

Figure D: Winch Dimensions

5. Install the winch using the hardware
specified on the specification chart.

Mounting the Solenoid Assembly
OPERATION

1. Place the Solenoid Box in a suitable
place near enough to the winch to allow
the cables to be routed properly.

3. Verify that the installation surface has no
hidden components or structural pieces
that will be damaged before drilling.

2. Mark the where the screw holes will be.

4. Drill pilot holes for the mounting screws.
5. Secure in place with mounting screws.

MAINTENANCE
Page 8

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Item 63770

Wiring

SAFETy

TO PREVENT SERIOUS INJURy FROM EXPLOSION
DUE TO SPARKING AT THE BATTERy CONNECTION:
Unplug the Pendant Connector and disconnect the Battery Cables
before making other wiring connections.
TO PREVENT SERIOUS INJURy FROM LEAKING BATTERy ACID:
Do not use a dirty, corroded or leaking battery.
Only use a 12V automotive (or equivalent) battery, in good condition.

2. If you drill through the bumper or any part
of the body to route the wires, be sure
to install a rubber grommet in the hole to
prevent fraying of the wires at that point.
3. Route the Cables from the Solenoid to the battery
and from the Solenoid to the Winch, following the
precautions discussed above. See Figure E.
Solenoid
Box

Black
Red

4. Attach the Red, Black and Yellow
Cables to the terminals on the Winch.
The Winch terminals are color-coded.
5. Attach the Circuit Breaker to the
Positive Terminal on the battery.

SETUP

6. Attach the red Battery Cable to the Circuit Breaker.
7. Attach the black Battery Cable directly to
the negative terminal of the battery.
8. Lift the Socket Cover exposing the
electrical switch connector. Insert the
Pendant connector into the Socket.
Note: The attachment of the Motor Cables determines
the direction of the Pendant Controller’s button.
After the unit is mounted and powered, check the
direction of the Power In and Power Out on the Pendant
Controller button. If you wish to change the direction on
the Pendant Controller, disconnect the Battery Cables
from the battery, switch the Motor Cable connections on
the Motor Assembly, then reconnect the Battery Cables.
9.

Disconnect the Pendant Controller when not in use.

Black
yellow Cap

Red

Circuit
Breaker

Black

OPERATION

1. Plan a route for the wiring from the point of the
vehicle where the winch will be mounted, or used,
to the battery. This route must be secure, out of the
way of moving parts, road debris, or any possibility
of being damaged by operation or maintenance
of the vehicle. For example, you may wish to
route the wires under the vehicle, attaching it to
the frame using suitable fasteners. Do not attach
the wires to the exhaust system, drive shaft,
emergency brake cable, fuel line, or any other
components which may create damage the wiring
through heat or motion, or create a fire hazard.

Winch

Figure E: Wiring Connections

1. The wire rope must be properly coiled under tension
to be able to support a load without damage.

MAINTENANCE

Preparing the Wire Rope
3. Recoil the wire rope back into the winch
under at least 500 lb. of tension.

2. Uncoil the wire rope, except for 5 full wraps.

Item 63770

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Page 9

Operation

SAFETy

Read the ENTIRE IMPORTANT SAFETy INFORMATION section at the beginning of this manual
including all text under subheadings therein before set up or use of this product.
The instructions that follow are basic guidelines only and cannot cover all situations encountered
during use. The operator and assistants must carefully plan usage to prevent accidents.
1. Examine the wire rope. Do not use the winch if
the wire rope is frayed, kinked or damaged.

7. Hook onto the object using a pulling point, tow
strap, tree strap, or chain. See Figure G.

2. Fully charge the vehicle’s battery.
3. Check the Winch’s electrical connections.
All connections must be tight and clean.
4. Put the vehicle’s transmission in Neutral.
5. If the vehicle where the winch is mounted
is not supposed to be moved, engage the
emergency brake and block the wheels
using wheel chocks (sold separately).

SETUP

6. To pull out the wire rope, move the Clutch Handle to
the Released position, shown in Figure F, slide the
loop of the Hook Strap over the hook, then pull on
the Hook Strap to pull out the wire rope.
WARNING! Leave at least five full
turns of wire rope on the drum.

Figure G: Using a strap anchor point
Do not wrap the wire rope around
the object and hook onto the
wire rope itself.
This can damage the object being
pulled, and kink or fray the wire rope.
8. Attachment point must be centered in
loop of hook and the hook’s safety clasp
must be fully closed. See Figure H.

OPERATION
Figure F: Clutch released

Figure H: Correct and incorrect hook attachment
9. Do not use a Recovery Strap while
winching. They are designed to stretch
and can suddenly whip back towards the
operator during a winching operation.

MAINTENANCE
Page 10

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Item 63770

a. A double line system should be used whenever
possible. It reduces the load on the winch,
allowing it to work longer with less heat buildup.
It reduces load on the winch in two ways:
• It utilizes the lower layers of wire rope
that have higher capacity, and
• It halves the load on the winch
through pulley action.

FIGURE A: WHIPLASH DAMPENING
BLANKET OR RUG
11. Re-engage the clutch by moving the Clutch Handle
to the Engaged position, shown in Figure I.

SAFETy

Double Line Rigging

b. Connect the wire rope for a double line
system as shown in Figure J below.
Use a pulley block (sold separately) properly
rated for the load to be pulled and designed
to be operated with this winch’s wire rope.

Stationary
Winching Vehicle
(Chock tires,
set parking brake,
and leave in neutral)

Carpet

Load

SETUP

10. Place a heavy rag or carpet (sold separately) over
the wire rope span, 6 feet from the hook to help
absorb the force released if the wire rope breaks.

Figure J: Double Line setup

WARNING! Do not allow anyone to stand near
the wire rope, or in line with the wire rope behind
the winch while it is under power. If the wire rope
should slip or break, it can suddenly whip back
towards the winch, causing a hazard for anyone in
the area. Stand well to the side while winching.

12. Attach the Pendant Controller to the Socket
on the Solenoid Assembly, see Figure K.

MAINTENANCE

Figure I: Clutch Engaged

Note: If anchoring the winching vehicle, only attach
the anchor line to the front of the vehicle.
If the anchor line is attached to the rear of the vehicle,
the vehicle's frame may be damaged by
the forces exerted by winching.

Figure K: Pendant connection

Item 63770

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OPERATION

c. Loop the wire rope around the pulley and connect
to another part of the vehicle’s chassis or to
a separate anchor point. Do not anchor the
Wire Rope back to the winch or winch mount.

Page 11

13. Operate the Pendant controls briefly to ensure
they work properly, see Figure L. If operation is
reversed, the power cables may be connected
backwards. Correct any such issue before use.

FIGURE B: ROLLER FAIRLEAD
MAXIMUM WINCHING ANGLES

SAFETy

16. If the object to be pulled must be pulled at an
angle in relation to the winch, use a pulley
(sold separately) and an anchor point directly
in front of the winch, as shown in Figure C,
to keep the Wire Rope pull straight.

FIGURE C: PULLEy ANCHORING

SETUP

17. WARNING! Stop the winch and release
tension on the wire rope before moving
the rag or carpet placed on it.
Figure L: Pendant controls
14. When it is safe to do so, use the power switch on
the Pendant Controller to retract the wire rope, and
winch the as desired. Do not power the hook all
the way into the fairlead to prevent damage.

OPERATION

15. Do not operate the winch at extreme angles.
Do not exceed the angles shown in Figure B for
a roller fairlead. For a hawse fairlead, the angle
should be as close to straight as possible.
15°
15°

45°

45°

MAINTENANCE
Page 12

18. Do not continue use of the winch until
the battery is completely run down.
19. You may wish to keep the engine running while
using this winch, to continually recharge the battery.
However, exercise extreme caution when
working around a running vehicle and ONLY
operate a vehicle in an outdoor area.
CAUTION! Do not use the winch in a
constant duty application, it is designed for
INTERMITTENT USE ONLy. Keep the duration
of the pulling job as short as possible. If the
motor becomes very hot to the touch, stop and
let it cool down for several minutes. Do not pull
for more than one minute at or near the rated
load. Do not maintain power to the Winch if
the motor stalls. Double Line Rigging will help
prevent overloading and should be used whenever
practical, see Double Line Rigging on page 11.
20. When finished pulling the load, reverse the direction
of the winch just enough to release tension on
the Wire Rope so that you can unfasten the
Hook from the load and reel in the Wire Rope.

For technical questions, please call 1-888-866-5797.

Item 63770

45 seconds winching
at least
14 minutes,
15 seconds
of rest

Avoid damage to the Winch by not winching
for more than the prescribed duty cycle time.
The Duty Cycle defines the amount of time, within
a 15 minute period, during which a Winch can
operate at its maximum capacity without overheating.
For example, this Winch with a 5% duty cycle at its
maximum load must be allowed to rest for at least
14 minutes, 15 seconds after every 45 seconds of
continuous operation. Failure to carefully observe
duty cycle limitations can easily over-stress a
Winch contributing to premature Winch failure.

SAFETy

Duty Cycle (Duration of Use)

Maintenance and Servicing

SETUP

Procedures not specifically explained
in this manual must be performed
only by a qualified technician.

TO PREVENT SERIOUS INJURy FROM ACCIDENTAL OPERATION:
Unplug the Pendant connector and disconnect the Battery Cables before performing any
inspection, maintenance, or cleaning procedures.

Cleaning, Maintenance, and Lubrication
1. BEFORE EACH USE, inspect the general
condition of the winch. Check for loose hardware,
misalignment or binding of moving parts, cracked
or broken parts, damaged electrical wiring,
corroded or loose terminals, and any other
condition that may affect its safe operation.
Examine the wire rope. Do not use the winch if
the wire rope is frayed, kinked or damaged.

2. AFTER USE, wipe external surfaces
of the winch with clean cloth.
3. Lubricate the wire rope occasionally with a light oil.

OPERATION

TO PREVENT SERIOUS INJURy FROM WINCH FAILURE:
Do not use damaged equipment. If abnormal noise or vibration
occurs, have the problem corrected before further use.

4. The winch’s internal mechanism is permanently
lubricated. Do not open the housing.
However, if the winch is submerged, it should be
opened, dried, and re-lubricated by a qualified
technician as soon as possible to prevent corrosion.

1. Move Clutch Handle to the Released position.
2. Extend the Wire Rope to its full length,
noting how the existing Wire Rope is
connected to the inside of the drum.
3. Remove old Wire Rope and attach new assembly.

CAUTION! Do not replace with inferior Wire Rope.
Only use a wire rope rated to the same rating
cited on the specification chart or better.
4. Retract Wire Rope onto Wire Rope
drum being careful not to allow kinking.
Refer to instructions for tensioning the wire rope
under ″Preparing the Wire Rope on page 9.
5. Test Electric Winch for proper operation.

Item 63770

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Page 13

MAINTENANCE

Wire Rope Replacement

Troubleshooting
Problem

Possible Causes

SAFETy

Motor overheats. 1.
2.
Motor does
1.
not turn on.
2.
3.
4.

Incorrect power cords.
Winch running time too long.
Switch Assembly not
connected properly.
Loose battery cable connections.
Vehicle battery needs charging.
Solenoid malfunctioning.

5. Defective Switch Assembly.
6. Defective motor.
7. Water has entered motor.

SETUP

8. Internal damage or wear.
Motor runs but
Clutch not engaged.
Wire Rope drum
does not turn.
Motor runs
1. Insufficient current or voltage.
slowly or without
normal power.
2. Loose or corroded battery
cable connections.
3. Incorrect power cords.
Motor runs in one 1. Defective or stuck solenoid.
direction only.
2. Defective Switch Assembly.

Likely Solutions
1. Use only supplied power cords.
2. Allow winch to cool down periodically.
1. Insert Switch Assembly all the way into connector.
2. Tighten nuts on all cable connections.
3. Fully charge battery.
4. Tap solenoid to loosen contacts. Apply 12 volts to coil
terminals directly. A clicking indicates proper activation.
5. Replace Switch Assembly.
6. Check for voltage at armature port with Switch
pressed. If voltage is present, replace motor.
7. Allow to drain and dry. Run in short bursts
without load until completely dry.
8. Have technician service winch.
Move the Clutch Handle to the Engaged position.
If problem persists, a qualified technician
needs to check and repair.
1. Battery weak, recharge.
Run winch with vehicle motor running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
1. Tap solenoid to loosen contacts.
Repair or replace solenoid.
2. Replace Switch Assembly.

OPERATION

Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.

PLEASE READ THE FOLLOWING CAREFULLy
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR
MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS
QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY
STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

MAINTENANCE

Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.

Page 14

For technical questions, please call 1-888-866-5797.

Item 63770

Parts List and Diagram
Description

Qty

Part

Description

Qty

SETUP

SAFETy

Part

30

29

27

28

26

25

24

23

22

21

20

19

18

16

17

15

13

14

31

12
33

11

10

9

3

1

2

OPERATION

4

7

8

34

32

6

5

38

36
35

41

37

42
40

Item 63770

For technical questions, please call 1-888-866-5797.

Page 15

MAINTENANCE

39

Limited 90 Day Warranty
Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and workmanship for the
period of 90 days from the date of purchase. This warranty does not apply to damage due directly or indirectly,
to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper
installation, normal wear and tear, or to lack of maintenance. We shall in no event be liable for death, injuries
to persons or property, or for incidental, contingent, special or consequential damages arising from the use of
our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
To take advantage of this warranty, the product or part must be returned to us with transportation charges
prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise.
If our inspection verifies the defect, we will either repair or replace the product at our election or we may
elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will
return repaired products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning the product.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797



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