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