Harbor Freight Tools 2 Ton Cable Winch Puller Product manual
Contents
1. 1 Do not leave a supported load unattended unless specific precautions have been instituted and are in place Exercise care when removing a sling from under a landed and blocked load Secure the load so it will not move before releasing the tension on the wire rope To release the wire rope tension a Swing the Handle away from the Anchor Hook to expose the Drive Pawl b Slide the Pawl Spring up to the disengaged position The Drive Pawl will be held clear of the Ratchet 7 Each time a load approaching rated capacity is handled check puller brake action by pulling the load just clear of supports and continuing only after verifying that the brake system is operating properly 8 WARNING Do not carry any load over any person 9 WARNING Do not carry personnel on the hook or the load 10 Pull the Handle toward the Anchor side of the Puller This will pull the Load 11 Swing the Handle back and forth until the load has been pulled to the desired position c Swing the handle to the Anchor Hook side and force the spring loaded STOP PAWL pin down then slowly raise the handle This action will allow the wire rope drum to back off by one cam step d Repeat this action as needed until the tension on the wire rope eases e Pull on the STOP PAWL TRIGGER to release it from the cam and gently pull back on the tool to get wire rope slack and free it from the load 5 To prevent entangling of the wire rope onto2. 866 5797 Item 61964 Parts List and Diagram Parts List Part Description __ Part Description 5 Ratchet 6 DrivePaw sid Stop Pawl Spring Load Hook Stop Pawl Trigger 8 Drive Pawl Spring 61964 Assembly Diagram 1 2 3 Z O Lu ou N Item 61964 For technical questions please call 1 888 866 5797 Page 11 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 setup 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 p
3. less than a year must be inspected before being used according to the Frequent Inspection requirements Maintenance 1 Repair or replacement of puller components must be performed only by a qualified technician using only identical replacement parts with the same rating Operating mechanisms pawls and brakes may require adjustment Note the following regarding specific components a Replace damaged or worn hooks Do not repair them by welding or reshaping b Replace excessively worn braking components such as friction disks ratchets pawls and pawl springs c Replace or repair all critical parts including load suspension components that are cracked broken bent excessively worn or missing Testing 1 Before use test repaired pullers and pullers that have not been used for a year or more Check all functions of the puller including retracting and extending with the puller unloaded first This puller may require a small load or pull on the load hook to test lowering extending A puller that has been idle for a period of a year or more must be inspected according to the Periodic Inspection requirements and then tested according to the procedure in the Testing section below before being used d Replace bent cracked or otherwise damaged levers e Replace missing or illegible warning labels Do not repair load sustaining members by welding Replace them as needed Lubricate all moving
4. lifting Do not lift people or lift loads over people Falling loads can injure or kill people Setup Specific Safety Information 1 The supporting structure the puller is mounted 2 to must be designed to withstand the loads and forces imposed by the puller for the rated load N SAFETY Do not operate puller with a lever extension Do not operate with rope not centered in its groove Do not remove or cover warning labels and or tags These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement 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 Install in location that allows the operator to move and stay clear of the load Inspect the puller as explained in Frequent Inspection on page 8 after setup but before use Inspection Testing and Maintenance Specific Safety Information 1 Perform a Frequent Inspection 3 at least monthly see page 8 2 Perform a Periodic Thorough Inspection 4 at least yearly see page 9 Operation Specific Safety Information 1 Wear ANSI approved safety goggles 3 ANSI approved hard hat and steel toed work boots during setup and use 2 This pr
5. the drum with the Load Hook still attached to the load push the spring into its Down position Hold the Anchor hook in one hand While gently pulling against the load swing the Handle back and forth to rewind the wire rope CAUTION Do not rewind the wire rope to its end Item 61964 For technical questions please call 1 888 866 5797 Page 7 Z O H lt aa Lu ou oO zZ U m O e zZ Inspection Testing and Maintenance Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY Remove any load before performing any inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM TOOL FAILURE Do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use Frequent Inspection Perform the procedures in this section BEFORE 4 Frequent Puller Rope Inspection INITIAL USE and AT LEAST MONTHLY Inspection All ropes should be visually inspected by the operator is needed more often for heavily used pullers or other designated person at the start of each shift These visual observations should be concerned with discovering gross damage such as listed below which may be an immediate hazard 1 Check operating mechanisms for proper operation proper adjustment and unusual sounds such as but not limited to binding noise of the wire rope and be
6. Owner s Manual amp 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 ITEM 61964 4000 LB CAPACITY Haul iaster 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 AWARNING please call 1 888 866 5797 as soon as possible Copyright 2013 by Harbor Freight Tools All rights reserved a No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included Table of Contents SAIGI wevteascsacevaabasgestvasaccacrasdnssahewsstancdeaessatie 3 INSPECHON einng enne enia 8 Specifications 0 02 eeeeceeeeeeeeeeeeeeeeeeee
7. age 4 For technical questions please call 1 888 866 5797 Item 61964 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 AWARNING TO PREVENT SERIOUS INJURY Operation of a puller involves more than pulling the lever The use of pullers 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 Puller 1 Familiarize yourself with all operating controls 4 Only a qualified technician should of the puller and with the operation s to be perform maintenance to the puller performed Instructions include the warnings f on the puller and the safety and operating 5 Do not use the wire rope as a ground for welding instructions portion of this manual Do not touch a welding electrode to the wire rope 2 AAWARNING TO PREVENT SERIOUS INJURY 6 Designate a work area that is clean and well lit FROM PULLER FAILURE The work area must not allow access by children Do not use damaged equipment or pets to prevent distraction and injury If adjustments or repairs are necessary 7 or any defects are known have the problem corrected before further use There must not be objects suc
8. aring squeal a distortion of the rope such as kinking crushing unstranding birdcaging 2 Frequent Braking System Inspection main strand displacement or core protrusion a The braking system must automatically stop and b general corrosion hold up to the rated load if the lever is released c broken or cut strands 3 Frequent Hook Inspection d number distribution and type Check hooks for the following problems of visible broken wires a distortion such as bending twisting 1 in running ropes or increased throat opening 12 randomly distributed broken wires in one lay or four broken wires in one strand in one lay b wear on erackeatieks or goud s 2 one outer wire broken at the contact point i i Or gouges with the core of the rope which has worked its d latch engagement if equipped way out of the rope structure and protrudes e damaged or malfunctioning latch if equipped or loops out from the rope structure f hook attachment and securing means If such damage is discovered either remove the rope from service or arrange for a qualified technician to give it a periodic thorough inspection 5 Check wire rope reeving 6 Check puller lever for bends cracks or other damage 7 Check for damage to the support for the puller AAWARNING TO PREVENT SERIOUS INJURY FROM PULLER FAILURE Do not use damaged equipment If any defect or damage is noted have the problem corrected before further use Page 8 Fo
9. d cracked bent worn or improperly applied end connections 5 Check load sprockets idler sprockets drums and pulleys for evidence of damage and wear Inspect with special care the following sections of rapid deterioration 6 Check the brake mechanism for evidence of 1 sections in contact with saddles worn glazed or oil contaminated friction disks equalizer pulleys or other pulleys worn pawls cams or ratchets where rope travel is limited And Eo treded sieched or broken Pail springs 2 sections of the rope at or near terminal ends 7 Check supporting structure or trolley where corroded or broken wires may protrude if used for evidence of damage 3 sections subject to reverse bends 8 Check warning label for legibility and replacement 4 sections of rope which are normally hidden during visual inspection such 9 Check end connections of wire ropes for evidence as parts passing over pulleys of wear corrosion cracks damage and distortion 11 Check the puller and puller mounting for evidence of missing parts AAWARNING TO PREVENT SERIOUS INJURY FROM PULLER FAILURE Do not use damaged equipment If any defect or damage is noted have the problem corrected before further use Z O O Lu ou e Item 61964 For technical questions please call 1 888 866 5797 Page 9 zZ 2 m O e zZ Storage Inspection 1 A puller that has been idle for a period of a month or more but
10. h as utility lines nearby that will present a hazard while working 8 Inspect the puller as explained in Frequent Inspection 3 Do not operate a puller with an out of order sign on page 8 after setup but before use Operating Controls Lever Z O H lt aa Lu ou O Pawl Spring Drive Ratchet Pawl Stop Pawl Trigger hidden Guard Figure B Item 61964 For technical questions please call 1 888 866 5797 Page 5 e m S zZ Applying the Load 1 Swing the Handle away from the Anchor Hook to expose the Drive Pawl Ratchet Drive Pawl Ee f Te o engaged Figure D Drive Pawl Operation 2 Slide the Pawl Spring up to the disengaged position The Drive Pawl will be held clear of the Ratchet Anchor Hook Ratchet Load Hook Stop Pawl Trigger Figure E Releasing the Stop Pawl 3 Squeeze the Stop Pawl Trigger as shown above Page 6 N Oo OW SF 13 For technical questions please call 1 888 866 5797 Pull the wire rope out to reach the load Release the Stop Pawl Trigger Do not wrap the puller wire rope around the load Attach the load to the load hook securely by properly rated suitable means such as chains shackles hooks lifting slings etc Load must be attached to prevent accidental disconnection Figure F Correct and incorrect load hook attachment Properly seat the sling or other device in the base bowl or saddle of the hoo
11. k see the left side diagram on Figure F Do not allow the hook hitch to support any part of the load Do not apply the load to the point of the hook shown in Figure F on the right side diagram Before moving the load make sure wire rope is not kinked or twisted or that multiple part wire ropes are not twisted around each other Do not operate the puller unless wire rope is seated properly on the drum pulleys or sprockets Do not pick up a load in excess of the rated load appearing on the puller or load block except during properly authorized tests Do not use a puller overload limiting device to measure the maximum load to be pulled Give specific attention to load balancing and hitching or slinging to prevent load slipping Item 61964 Moving the Load 1 Slide the Pawl Spring down to the engaged position as shown in Figure D The Drive Pawl will be pressed against the Ratchet Do not engage in any activity which will divert the operator s attention while operating the puller Respond to signals from a designated person only However always obey a stop signal no matter who gives it Do not move a load with the puller until the operator and all other personnel are clear of the load Make sure the load and puller will clear all obstacles before moving or rotating the load Do not move a load more than a few inches until it is well balanced in the sling or pulling device Parking the Load
12. neeees 4 Parts List and Diagram c cccceeeee 11 SOLUS EE E EAE E A 4 Wanay enen ES 12 Operationen n 5 wn gt TI m lt Haul iaster 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 A DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury AWARN N G Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided ACAUTION could result in minor or moderate injury NOTICE CAUTION Addresses practices not related to personal injury Page 2 For technical questions please call 1 888 866 5797 Item 61964 IMPORTANT SAFETY INFORMATION AWARNING TO PREVENT SERIOUS INJURY AND DEATH Basic Safety Information 1 Do not pull more than rated load Be aware of 6 dynamic loading Sudden load movement may briefly create excess load causing product failure 2 Do not operate while puller restricted from forming a straight line with loading direction 8 3 Do not operate puller with twisted kinked or damaged wire rope Inspect wire rope carefully before every use 4 Do not operate a damaged or malfunctioning puller Inspect puller carefully and test operation before every use 5 Do not use for vertical
13. oduct is not a toy Do not allow children to play with or near this item 4 More frequent inspections are needed for pullers that are used heavily Raise test loads only to the minimum extent needed and stay well clear of load at all times during testing Use as intended only Do not use to handle molten material Do not use for aircraft purposes e Do not use to link towed vehicles Keep hands clear of moving parts A SAVE THESE INSTRUCTIONS Item 61964 For technical questions please call 1 888 866 5797 Page 3 Specifications Rated Capacity 4 000 Ib Setup 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 Note For additional information regarding the parts listed in the following pages refer to Parts List and Diagram on page 11 1 The supporting structure the puller is mounted to 2 Properly seat the anchor hook on the supporting including trolley monorail or crane structure at its intended load bearing point must be designed to withstand the loads and see the left side diagram of Figure A forces imposed by the puller for the rated load Do not allow the hook hitch to support any part of the load Do not apply the load to the point of the hook shown in Figure A on the right side diagram Figure A Correct and incorrect anchor hook attachment P
14. parts regularly using grease After maintenance work is completed and before restoring the puller to normal operation a reinstall guards b reactivate safety devices c remove replaced parts and loose material d remove maintenance equipment After testing in the unloaded state attach a 200 Ib load and retest to check proper load control and to check brake operation 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 BUYERASSUMES 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 SETUP OF REPLACEMENT PARTS THERETO 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 10 For technical questions please call 1 888
15. r technical questions please call 1 888 866 5797 Item 61964 Periodic Thorough Inspection A qualified technician should perform the procedures 10 Periodic Thorough Puller Rope Inspection in this section AT LEAST YEARLY Inspection is Check entire length of rope puller rope as follows needed more often for heavily used pullers Inspect the individual outer wires in the strands Remove or open access covers to allow of the rope Keep a record of any deterioration inspection of components resulting in appreciable loss of original strength such as described below and have a qualified technician determine whether further use of the rope would constitute a hazard 2 Check fasteners for evidence of loosening a Check points listed in Frequent Puller Rope Inspection on page 8 1 First follow all Frequent Inspection procedures Additionally 3 Check load blocks suspension housings levers clevises yokes suspension bolts b Check for reduction of rope diameter shafts gears bearings pins rollers and below nominal diameter due to loss of locking and clamping devices for evidence of core support internal or external corrosion wear corrosion cracks and distortion or wear of outside wires c Check for severely corroded or broken 4 Check hook retaining nuts or collars and pins f wires at end connections welds or rivets used to secure the retaining members for evidence of damage d Check for severely corrode
16. repaid 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 Haul miaster 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 1 888 866 5797
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