2000 Lb. Electric Winch

Transcription

1 2000 Lb. Electric Winch Set up and Operating Instructions Visit our website at: Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright 1999 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. For technical questions or replacement parts, please call Cover Revised 07k, Manual revised 09h

2 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. Important SAFETY Information In this manual, on the labeling, and all other information provided with this product: 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. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if 1. not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. WARNING Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The warnings, precautions, and instructions discussed in this instruction 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. Set up precautions Mounting location and hardware must support winch and load. Wear ANSI-approved safety goggles during installation, operation and service. Use supplied power/pull cables or cables listed in manual only. Do not use thinner/longer cables or link multiple cables together. Page 2

3 Only connect Red to Red (Positive to Positive) and Black to the frame, making a ground connection, when using battery power from your vehicle. Do not use a dirty, corroded or leaking battery. You may suffer injury from acid burns. Verify that installation surface has no hidden components or structural pieces that will be damaged before drilling or driving screws. Operation precautions 1. Do not exceed load capacity. Be aware of dynamic loading! Sudden load movement may briefly create excess load causing product failure Wear ANSI-approved safety goggles and heavy-duty leather work gloves during operation. Do not disengage clutch under load. Engage clutch before starting. Keep clear of Fairlead when operating. Do not try to guide pull cable. Place rag or carpet over center of cable span to help absorb the force released if the cable breaks. Stay out of the direct line that the cable is pulling. In case it slips or breaks, it will whiplash along this line. Do not winch a boat or other object with anyone in or on it. 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 cable before activating the winch. Do not use the hand crank to assist the winch. Use as intended only. Do not lift items vertically or use for aircraft purposes. 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. Inspect before every use; do not use if damaged or parts loose. Examine the winch for structural cracks, bends, damage, frayed cable, and any other conditions that may affect the safe operation of the winch. Do not use the winch even if minor damage appears. Keep children and bystanders away while operating. Distractions can cause you to lose control. 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. Do not overreach. Keep proper footing and balance at all times. This enables better control of the winch in unexpected situations. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to heart pacemaker could Page 3

4 cause pacemaker interference or pacemaker failure. Service precautions Wear ANSI-approved safety goggles during installation, operation and service. Keep at least 5 full turns of pull cable on reel. Secure load after moving. No locking mechanism. If pull cable begins to get entangled, stop winch immediately and release pull cable with switch. Use supplied power/pull cables or cables listed in manual only. Do not use thinner/longer cables or link multiple cables together. Have your winch serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the winch is maintained. Maintain labels and nameplates on the winch. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 8. 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 , et seq.) Save these instructions. Page 4

5 Specifications 6000 Lb. Rolling, Capacity 5000 Lb. Marine, 2000 Lb. Single Line Pull Max Boat Size 18 Feet Max. Boat Weight 5000 lb. Line Speed 5 FPM Cable Length 30 Ft. Hook Size 3/4 Opening x 3-3/4 L Power Supply 12 V Power Cord 10 5 Both Leads Remote Switch 9 9 L Mounting Plate 8-3/4 x 4-15/16 x 3/16 Dimensions 9-1/2 x 7-1/2 x 10 Pull Cable 3/16 X 30 Galvanized Steel (7 X 19 Aircraft* type) * Aircraft refers to the cable type, not the function of the winch. 4. that can withstand this much force without damage or weakening. You may need to use steel reinforcement plates, or weld on additional bracing, depending on the mounting location. Align the winch with the desired location, and mark for drilling the locations of the 4 holes on the base of the winch. Drill these locations on your vehicle. Using hardened steel bolts at least 3/8 in diameter, install your winch to the location. Temporary Mounting Unpacking When unpacking, make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at as soon as possible. Instructions for putting into use 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. Mounting Permanent Mounting 1. Select a mounting site on the bumper of your vehicle, truck bed, boat trailer, or other suitable location. 1. Attach the (3) Plate Stud Bolts to the Adapter Plate, as shown, using the supplied Nuts. Tighten securely. Index the heads of the Plate Studs into the keyhole slots on the back of the winch. Attach the Winch/Adapter Plate assembly to your trailer hitch, by inserting the trailer hitch ball through the shaped hole in the Adapter Plate. Wiring To prevent serious injury from explosion due to sparking at the battery connection: Turn the Power Switch of the winch off and disconnect the power and control cables before making wiring connections. NOTE: This winch can generate 2,000 lb. pulling force. Select a location REV 99i, 00h Page 5

6 To prevent serious injury from Leaking battery acid: Do not use a dirty, corroded or leaking battery. Temporary Wiring 1. Lift the rubber seal, and plug the Power Cord (37a) into the Cord Plug (36) on the right side of the winch body. This plug is labeled Power. Route the Electric Cord from the winch to your battery, being careful to avoid tangling it in moving equipment, or causing a tripping hazard. Connect the Black Clamp Handle of the Power Cord (37a) to the frame of your vehicle, establishing a ground connection. Connect the Red Clamp Handle to the Positive (+ / Red ) terminal of your battery. Note: Be sure you are using a 12V automotive (or equivalent) battery, in good condition. Lift the rubber seal on the left side of the winch body. Taking the Remote Control Unit, insert the Socket (33) at the end of the cord into the Plug on the left side of the winch body labeled Remote Control. 4. Set the remote control aside in a safe place until ready for use 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. 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. Route the Power Cord (37a) from the point the winch will be used to the battery, following the precautions discussed above. Remove the Red Clamp handle, and attach the red wire to the Circuit Breaker (45), which is permanently mounted to the frame of the Winch. Only connect Red to Red (Positive to Positive) and Black to the frame, making a ground connection, when using battery power from your vehicle. Remove the Black Clamp handle, and attach the black wire to the frame of your vehicle, creating a secure electrical ground. Permanent wiring 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 REV 00h Page 6

7 Operation 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. Put your vehicle in Neutral. (Do not winch with your vehicle in Gear or in Park, since this could damage your vehicle s transmission.) Put your emergency brake On. Block the wheels from rolling, using suitable chocks. Keep hands, clothing, hair, and jewelry clear of the drum area and cable when winching. To pull out the cable, turn the Clutch Knob (19) counterclockwise to loosen it, then pull out the cable you need. Leave at least five full turns of cable on the spool to prevent pulling the cable out of the winch. Examine the cable. Do not use the winch if the cable is frayed, kinked or damaged. Hook onto the object using a pulling point, tow strap or chain. Do not wrap the cable around the object and hook onto the cable itself. This can cause damage to the object being pulled, and kink or fray the cable. Place rag or carpet over center of cable span to help absorb the force released if the cable breaks. Re-tighten the clutch knob. Do not allow anyone to stand near the cable, or in line with the cable behind the winch while it is under power. If the cable 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. When it is safe to do so, use the power switch in the remote control to retract the cable, and winch the item as desired. Do not power the hook all the way into the fairlead to prevent damage. Do not continue use of the winch until the battery is completely run down. You may wish to keep your engine running while using this winch, to continually recharge the engine. However, exercise extreme caution when working around a running vehicle. CAUTION! The Electric Winch is designed for intermittent use only, and should not be used in a constant duty application. The duration of the pulling job should be kept as short as possible. If the Winch motor becomes very hot to the touch, stop the Winch 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. 1 To prevent accidents, turn off the winch and disconnect its power supply after use. Clean, then store the winch indoors out of children s reach. Page 7

8 1. Pulling Capacity This winch has a capacity of 2,000 lb. Applying this measurement to practical applications, you can use this winch to move the following. a. Move a load from a dead stop of up to 2,000 lb. on level ground. Place the end of the hand crank over the flattened end of threaded shaft on the left side of the winch. Rotate the hand crank clockwise to tighten the cable. Continue to turn until the cable has been completely retracted. b. Move a water bourne craft of up to 5,000 lb. c. Maintain movement of a wheeled vehicle of up to 6,000 lb. Pulling Capacity is reduced as incline increases. For example, rolling capacity is reduced from 6,000 lb on flat ground to 1,100 lb. on a 45 incline. Please refer to the chart above for estimated pulling capacity (rolling weight) on various inclines. Using the Emergency Hand Crank Warning! Do not use the crank to assist an operating winch. This will damage the winch and may cause personal injury. 1. Turn the clutch knob clockwise until hand tight. Do not force it or overtighten. Page 8

9 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: Turn the Power Switch of the winch off and disconnect the power and control cables 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, and any other condition that may affect its safe operation. After Use, wipe external surfaces of the winch with clean cloth. 4. Lubricate the cable occasionally with a light oil. Grease the gears every 6 months. To do this, remove the clutch knob and separate the left and right housing. Use any good quality waterproof grease. Troubleshooting Problem Possible Causes Likely Solutions Winch will not start. 1. Winch s thermal reset breaker 1. Turn off winch and allow to cool. Press tripped (if equipped). reset button on winch. Winch operates slowly or overheats. Internal damage or wear. Incorrect power cords. Have technician service winch. Use only supplied power cables. Follow all safety precautions whenever diagnosing or servicing the winch. Disconnect power supply before service. Page 9

10 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 Part Description 1 Claw lock 2 R-clip 3 Bearing 4 Friction Plate 5 Clamp 6 Clamp Nuts 7 Plate 9 Plate 10 Shaft 11 Screw 12a Shaft lock 13a Spring 14 Cable Ring 15 Cable Assembly 16 Pressure Plate 17 Clutch Gear 17a Small Gear 17b Big Gear 18 Dual Gear 19 Clutch Knob 20 Shaft Assembly 21 Shaft Assembly 22 Lock Washer 22a Lock Washer 23 Adapter Plate 24 Frame 25 Right shell 26 Left shell 27 Lock Washer 28 Screw 29a Left control shell Part Description 29b Right control shell 30a Remote control connector 33a Socket (for Electrical Cord) 34 Plastic Nut 36 Power Plug 37a Power Cord 40 Hand Crank 41 Switch 43a Motor 45 Circuit Breaker 46 Relay 48 Lock Washer 49 Lock Spring 50 Lock Washer 51 Lock Washer 52 Lock Spring 53 Nut M8 54 Nut M10 55 Nut M12 55a Nut SM12 57 Screw 58 Screw 59 Self-tapping Screw 59a Screw 60 Roll pin 62 Handle (Not Shown) 63 Nut 64 Bushing 65 Support Bracket 66 Bracket Retaining Ring 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. REV 01a, 02l, 09h Page 10

11 Note: #62 Handle (not shown) ASSEMBLY DIAGRAM b a A 17 22a a 59 43a A a 3 13a 12a 55a 30a a a a b22a 3 55a a REV 02l, 09h Page 11

12 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 Mission Oaks Blvd. PO Box 6009 Camarillo, CA (800) Page 12