Harbor Freight 2000 Lb Marine Electric Winch Product Manual

Harbor-Freight-61237-Owner-S-Manual harbor-freight-61237-owner-s-manual

Manual for the 61237 2000 lb. Marine Winch 61237 2000 lb. Marine Electric Winch

2015-05-27

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Page Count: 16

Page 2 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Table of Contents
Safety ......................................................... 2
Setup .......................................................... 6
Operation .................................................... 8
Maintenance .............................................. 12
Parts List and Diagram .............................. 14
Warranty .................................................... 16
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.
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.
Wear ANSI-approved safety glasses.
Cut or sever hazard.
Roller entanglement hazard.
Hot surface burn hazard.
Fire hazard.
Caustic chemical (acid) hazard.
Explosion hazard.
Do not loop the wire rope around
object and hook onto itself.
Symbol Property or Statement
Do not place finger(s) through hook.
Fingers may be caught and
get pulled into drum.
Pull hook using strap only.
Do not use winch in
underwind orientation. (Wire rope
enters/exits at the bottom.)
Use winch only in
overwind orientation. (Wire rope
enters/exits at the top.)
VDC Volts Direct Current
AAmperes
fpm Feet Per Minute
IP
International Protection rating.
Classifies the degrees of
protection provided against the
intrusion of solid objects, dust,
accidental contact, and water.
Page 3For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
IMPORTANT SAFETY INFORMATION
WARNING! Read all instructions.
Failure to follow all instructions listed on page 3 to page 5 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 Specific Safety Information
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.
2. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during installation.
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.
4. Mounting location and hardware
must support Winch and load.
5. Winch is not waterproof and is not intended
for use underwater. Do not mount in locations
that are subject to submersion in water.
6. Use supplied power cables and wire rope or
replacement cables listed in manual only. Do not
use thinner/longer cables or link multiple cables
together. Do not route electrical cables near sharp
edges or parts that will move or become hot.
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.
8. Only connect to a clean, corrosion free battery.
9. Do not lean over or come in contact with
battery while making connections.
10. Remove all metal jewelry before
working near battery.
11. Connect red wire to positive battery terminal
and black wire to negative battery terminal.
12. Insulate all exposed wiring and
terminals after installation.
13. Install Winch in overwind orientation,
so that the Wire Rope enters and exits
the Winch at the top of the drum.
14. For temporary Winch mounting, only use the
Adapter Plate (56) with a 2" hitch ball. Do not
use Adapter Plate to attach Winch to anything
other than hitch ball. Bolt Adapter Plate to
Winch Frame Assembly (31) before mounting
to hitch ball. Do not use a different plate to
install on hitch ball. Do not use hitch ball for
any other purpose while Winch is mounted.
Operation Specific Safety Information
1. Do not exceed load capacity. Be aware of
dynamic loading! Sudden load movement may
briefly create excess load causing product failure.
2. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during operation.
3. 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 6. Make sure the battery is fully charged.
Use double line rigging whenever possible;
see Double Line Rigging on page 11.
4. Do not disengage clutch under load.
Engage clutch before starting.
5. Keep clear of Wire Rope intake opening when
operating. Do not try to guide Wire Rope.
6. Do not place finger(s) through Hook.
Fingers may be caught and get pulled into drum.
Use a hook strap (not included) to hold hook instead.
Page 4 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
7. Stay out of the direct line that the Wire
Rope is pulling. If it slips or breaks, it
will “whiplash” along this line.
8. Place a heavy blanket or carpet (not included) over
Wire Rope span 6 feet from Hook to help absorb
the force released if the Wire Rope breaks.
9. Do not use for lifting or moving people.
10. Use a spotter to assist you in ensuring 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.
13. Use as intended only. Do not lift items
vertically or use for aircraft purposes.
14. At the start of winching when using temporary winch
mounting, take up slack slowly and make sure
Winch is securely and properly mounted to hitch ball.
15. 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.
16. Disconnect Battery Cable before working
near the Wire Rope, drum, or load,
to prevent accidental starting.
17. 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.
18. Keep wire rope straight to avoid kinking the wire
rope. The illustrations below show how a
kink forms and how to prevent kinking.
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.
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.
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.
19. Keep children and bystanders away while operating.
Distractions can cause you to lose control.
20. 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.
21. Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the Winch in unexpected situations.
22. 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.
23. 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.
24. Secure load after moving.
NO LOCKING MECHANISM.
25. 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.
26. Wrap Wire Rope under 500 lb. tension before use.
Otherwise, Wire Rope may bind during operation.
Operation Specific Safety Information (continued)
Page 5For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
27. 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.
28. If Wire Rope begins to get entangled, stop Winch
immediately and release Wire Rope using switch.
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.
30. 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.
31. Do not operate the Winch at extreme angles.
Do not exceed the angles shown in Figure A.
45°
45°
15°
15°
Winch
Vertical
Horizontal
Figure A: Maximum Winching Angles
32. 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 B,
to keep the Wire Rope pull straight.
Load
Pulley
Anchor Point
Winch
Figure B: Pulley Anchoring
33. Winch motor will be hot during
and after use. Keep clear.
34. Do not power the hook all the way into the Winch.
35. 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.
Service Specific Safety Information
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 cables and wire rope
or replacement 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.
6. WARNING: Handling the cord on this product
will expose you to lead, a chemical known
to the State of California to cause cancer,
and birth defects or other reproductive harm.
Wash hands after handling. (California
Health & Safety Code § 25249.5, et seq.)
SAVE THESE INSTRUCTIONS.
Page 6 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Specifications
Power Supply 12VDC Battery
(not included)
Rated Capacity
Dead Pull: 2000 lb.
Marine Pull: 5000 lb.
Rolling Stock Pull: 6000 lb.
Maximum Boat Weight 5,000 lb. – (about 18 ft. Boat
Length)
Drum (Dia. x L) 1" x 3-1/8"
Overall Dimensions 9-1/2" L x 7-1/2" W x 10" H
Wire Rope Ø3/16" x 30'
Galvanized Steel
Hook Opening 11/16"
Line Pull Line Speed Amp Draw
lb. kg. fpm mpm
0 0 4.5 1.4 3.1
500 227 3.6 1.1 6
1000 454 2.9 2.3 11
1500 680 2.3 0.9 17
2000 907 1.7 0.5 21
Layer Rated Line Pull Cable Capacity
lb. kg. feet meters
1 2000 907 4.7 1.4
2 1520 689 10.8 3.3
3 1226 556 18.4 5.6
4 1027 466 27.5 8.4
5 884 401 38.0 11.6
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.
Note: For additional information regarding the parts listed in the
following pages, refer to Parts List and Diagram on page 14.
Temporary Winch Mounting
1. Use the Adapter Plate (56) to temporarily attach
the Winch to a 2" hitch ball on a vehicle.
2. The Adapter Plate has three pre-mounted Plate
Stud Bolt (55) / Nut (61) / Lock Washer (62) sets.
Push the Bolt heads into the keyhole slots on
the bottom of the Frame Assembly (31) and slide
them into the narrow section of the keyholes.
3. Bolt Adapter Plate to Winch Frame Assembly using
holes provided to lock components together.
4. Place teardrop-shaped hole in
Adapter Plate over hitch ball.
WARNING! At the start of winching when
using temporary winch mounting, take up
slack slowly and make sure Winch is securely
and properly mounted to hitch ball.
WARNING! Remove Winch after use. Do not
drive vehicle with Winch temporarily mounted.
Permanent Winch Mounting
1. Select a mounting site on the boat trailer, vehicle
bumper, truck bed, or other suitable location.
NOTE: This Winch is not waterproof and is not intended
for use underwater. Do not mount in locations that are
subject to submersion in water.
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.
2. If a mounting plate (not included) is used, it must
be flat and rated to at least the Winch’s capacity.
3. Align the Winch perpendicular to the center
line of the vehicle at the desired location. Use
mounting holes in the Winch Frame Assembly (31)
as a template to mark the spots where holes will
need to be drilled in the installation surface.
4. Before drilling, verify that the installation
surface has no hidden components or
structural pieces that will be damaged.
5. Drill 3/8" holes at the marked locations.
6. Bolt the Winch to the installation surface using
3/8" galvanized/zinc plated bolts, nuts and washers
(not included) of SAE Grade 5 or higher.
Page 7For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
Wiring
TO PREVENT SERIOUS INJURY FROM EXPLOSION DUE TO SPARKING AT
THE BATTERY CONNECTION:
Disconnect the Battery Cable 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.
Depending on your level of electrical wiring knowledge, you may have
these procedures performed by a qualified technician.
Note: Use of a circuit breaker is highly recommended to protect the vehicle and battery from
damage from winch failure/overload. A 50-amp circuit breaker (not included) should be installed
in a safe location as close to the vehicle’s battery as possible. The circuit breaker will be
installed in line with the Winch’s Battery Cable (8) and the vehicle battery. Use two solderless,
insulated, 12-10 AWG ring tongue terminals (not included) to install the circuit breaker.
Temporary Wiring
1. Remove the protective cover on the right side
of the Winch body and insert the female Battery
Cable Plug (7) at the end of the Battery Cable (8)
into the male socket on the Winch. The plug fits
into the socket only one way for correct polarity.
2. Route the Battery Cable from the Winch to the
battery, being careful to avoid tangling it in moving
equipment, or causing a tripping hazard.
3. Connect the Black Battery Clamp of the Battery
Cable to the frame of the vehicle, establishing a
ground connection. Connect the Red Battery Clamp
to the Positive (+/Red) terminal of the battery.
4. Insert the male Remote Control Cable
Plug (66) at the end of the Remote Control
Cable (67) into the female socket on the right
side of the Winch body. The plug fits into the
socket only one way for correct polarity.
Permanent Wiring
1. Plan a route for the wiring, from the point of the
vehicle where the Winch will be mounted, to the
battery. This route must be secure, out of the
way of moving parts or road debris, and free of
any possibility of being damaged by operation
or maintenance of the vehicle. For example,
route the wires under the vehicle, attaching them
to the frame using suitable fasteners. Do not
attach wires to the exhaust system, drive shaft,
emergency brake cable, fuel line, or any other
components which may create damage to the wiring
through heat or motion, or create a fire hazard.
2. If holes are drilled through the bumper or
any part of the vehicle body to route the
wires, install rubber grommets in the holes to
prevent fraying of the wires at that point.
3. Following the precautions discussed above,
route the Battery Cable (8) from the point where
the Winch will be mounted, to the battery.
4. Remove the Red Battery Clamp from the
red wire and attach the wire to the Positive
(+/Red) terminal of the battery.
5. Remove the Black Battery Clamp from the black
wire and attach the wire to the frame of the
vehicle, creating a secure electrical ground.
6. Follow the steps in Temporary Wiring to
attach the Battery Cable Plug and the
Remote Control Cable Plug to the Winch.
Preparing the Wire Rope
1. The Wire Rope must be properly coiled under
tension to be able to support a load without damage.
2. Uncoil the Wire Rope, except for 5 full wraps.
3. Recoil the Wire Rope back into the Winch
under at least 500 lb. of tension.
Page 8 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Attaching the Hand Crank
1. Attach the Hand Crank (21) only
when manually rewinding.
CAUTION! Do not operate the Winch electrically when
the Hand Crank is installed. Do not use the Hank Crank
to assist the Winch when it is electrically powered. This
will damage the Winch and may cause personal injury.
2. To attach the Hand Crank, tighten the clutch first
by turning the Clutch Knob (22) clockwise until
hand tight. Remove the outer Lock Nut and
slide the Hand Crank over the threaded shaft up
against the inner Lock Nut. Secure Hand Crank
in place with the outer Lock Nut. See Figure C.
Hand Crank
Clutch Knob
Outer Lock Nut
Inner Lock Nut
Figure C: Hand Crank Attachment
Operation Instructions
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.
TO PREVENT SERIOUS INJURY: Operation of a winch involves more than depressing
the power switch. The use of winches is subject to certain hazards that cannot be met
by mechanical means, but only by the exercise of intelligence, care, common sense, and
experience in anticipating the motions that will occur as a result of operating the controls.
Do not use this tool for vertical lifting.
Before Operating Winch
1. Familiarize yourself with all operating controls of the
Winch and with the operation(s) to be performed.
Instructions include the warnings on the Winch
and the safety and operating instructions
portion of this manual.
2. WARNING! TO PREVENT SERIOUS INJURY
FROM WINCH FAILURE:
Do not use damaged equipment.
If adjustments or repairs are necessary,
or any defects are known, have the
problem corrected before further use.
Page 9For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
Components and Controls
Wire Rope
and Hook
Handle
Hand Crank
Clutch Knob
Adapter Plate
Remote Control Battery Cable
Battery
Clamps
Battery
Cable Plug
Remote
Control Cable
Remote Control
Cable Plug
Page 10 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Basic Operation
1. Examine the Wire Rope. Do not use the Winch
if the Wire Rope is frayed, kinked or damaged.
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).
6. To pull out the Wire Rope, disengage the clutch
by loosening two Lock Nuts and turning the Clutch
Knob (22) counterclockwise to loosen it. Slide the
loop of a hook strap (not included) over the Hook,
then pull on the hook strap to pull out the Wire Rope.
WARNING! Leave at least five turns
of the Wire Rope on the drum.
7. Hook onto the object using a pulling point,
tow strap, tree strap, or chain. See Figure D.
Figure D: 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 left side diagram of Figure E.
9. Do not apply the load to the point of the
Hook. See right side diagram of Figure E.
Figure E: Correct and Incorrect Hook Attachment
10. 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.
11. Place a heavy blanket or carpet (not included)
over the Wire Rope span 6 feet from hook to help
absorb the force released if the Wire Rope breaks.
12. Re-engage the clutch by turning the
Clutch Knob (22) clockwise until hand
tight. Do not force it or overtighten.
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.
13. Operate the Remote Control briefly
to ensure it is working properly.
Page 11For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
Double Line Rigging
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.
b. 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.
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.
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.
14. When it is safe to do so, use the power switch on
the Remote Control to retract the Wire Rope, and
winch the item as desired. Do not power the hook
all the way into the Winch to prevent damage.
15. To rewind the Winch manually, attach the Hand
Crank (21) as described in Attaching the Hand
Crank on page 8. Turn the Hand Crank clockwise
to retract the Wire Rope and move the load.
CAUTION! Do not operate the Winch electrically
when the Hand Crank is installed. DO NOT USE the
Hank Crank to assist an operating Winch. This will
damage the Winch and may cause personal injury.
16. Do not operate the Winch at extreme angles.
Do not exceed the angles shown in Figure A.
45°
45°
15°
15°
Winch
Vertical
Horizontal
Figure A: Maximum Winching Angles
17. 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 B,
to keep the Wire Rope pull straight.
Load
Pulley
Anchor Point
Winch
Figure B: Pulley Anchoring
18. WARNING! Stop the Winch and release
tension on the Wire Rope before moving
the blanket or carpet placed on it.
19. Do not continue use of the Winch until
the battery is completely run down.
20. When possible, keep the engine running while using
this Winch, to continually recharge the battery and
prevent the battery from being drained so much that
the vehicle cannot start. 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.
21. When finished pulling the load, release
tension on the Wire Rope, unfasten the Hook
from the load and reel in the Wire Rope.
22. To prevent accidents, disconnect the power
supply and Remote Control after use. Clean,
then secure and cover the Winch when not
in use. If the Wire Rope gets wet, dry it
and then apply light oil right after use.
Page 12 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION:
Remove any load, release the operating controls, disconnect the Battery Cable before
performing any inspection, maintenance, or cleaning procedures.
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.
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
• frayed, kinked or damaged wire rope
• any other condition that may
affect its safe operation.
2. AFTER USE, wipe external surfaces
of the Winch with clean cloth.
3. Lubricate the Wire Rope occasionally with a light oil.
4. Every six months, remove two Lock Nuts and
the Clutch Knob (22) and separate the Left and
Right Shells (2, 5) to grease the Gears. Use
any good quality, waterproof gear grease.
5. If the Winch becomes wet during use,
remove the Clutch Knob, separate the Left
and Right Shells, dry all parts, then grease
and lubricate as in steps 3 and 4 above.
6. If the Winch is exposed to salt water, rinse
with fresh water and allow to drain thoroughly,
then dry completely as in step 5 and grease
and lubricate as in steps 3 and 4 above.
7. Do not pull battery wires against any
surfaces which could damage them.
8. If the Winch is permanently mounted,
periodically remove and clean wire
connections to the battery. Corrosion will
reduce performance or may cause a short.
9. Secure and cover the Winch when not in use.
Wire Rope Replacement
1. Disengage the clutch by turning the
Clutch Knob (22) counterclockwise.
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 7.
5. Test Winch for proper operation.
Page 13For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
Troubleshooting
Problem Possible Causes Likely Solutions
Motor overheats. 1. Incorrect power cords.
2. Winch running time too long.
1. Use only supplied power cords.
2. Allow Winch to cool down periodically.
Motor does
not turn on.
1. Switch not connected properly.
2. Loose battery cable connections.
3. Vehicle battery needs charging.
4. Defective Switch.
5. Defective motor.
6. Water has entered motor.
7. Internal damage or wear.
1. Connect Switch properly.
2. Tighten nuts on all cable connections.
3. Fully charge battery.
4. Replace Switch.
5. Check for voltage at armature port
with Switch pressed. If voltage
is present, replace motor.
6. Allow to drain and dry. Run in short
bursts without load until completely dry.
7. Have technician service Winch.
Motor runs
slowly or without
normal power.
1. Insufficient current or voltage.
2. Loose or corroded battery
cable connections.
3. Incorrect power cords.
1. Battery weak, recharge.
Run Winch with vehicle motor running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
Page 14 For technical questions, please call 1-800-444-3353. Item 61237
SAFETY OPERATION MAINTENANCESETUP
Part Description
1 Screw
2 Left Shell
3 Handle
4 Nut
5 Right Shell
6 Socket
7 Battery Cable Plug
8 Battery Cable
9 Battery Clamp
10 Remote Control Switch
11 Front Remote Control Housing
12 Rear Remote Control Housing
13 Self-Tapping Screw
14 Spring Lock
15 Hexagon Shaft
16 Lock Washer
17 Large Gear Assembly 1
18 Screw
19 Small Gear Assembly 1
20 Shaft Assembly
21 Hand Crank
22 Clutch Knob
23 Friction Plate
24 Large Gear Assembly 2
25 Plate
26 Lock Washer
27 Bearing
28 Circuit Breaker
29 Lock Washer
30 Nut
31 Frame Assembly
32 Motor
33 Lock Washer
34 Screw
Part Description
35 Clamp
36 Screw
37 Clamp
38 Relay
39 Lock Washer
40 Lock Spring
41 Screw
42 Shaft
43 Small Gear Assembly 2
44 Lock Washer
45 Nut
46 Shaft
47 Lock Washer
48 Claw Lock
49 Shaft Lock
50 Nut
51 Lock Washer
52 Spring
53 Large Gear Assembly 3
54 Lock Washer
55 Plate Stud Bolt
56 Adapter Plate
57 Plate
58 Shaft
59 Plate
60 Wire Rope
61 Nut
62 Lock Washer
63 Hook
64 Cable Sleeve
65 Bearing
66 Remote Control Cable Plug
67 Remote Control Cable
Parts List and Diagram
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.
Parts List
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 15For technical questions, please call 1-800-444-3353.Item 61237
SAFETYOPERATIONMAINTENANCE SETUP
Assembly Diagram
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
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.

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