Harbor Freight Tools 1/2 ton Capacity Hand Winch Product manual
Contents
1. 11 DOCU Pies EAT E A A ETA 6 Wanat soens n onn a a 12 Operati Nennn niia 8 WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol Itis used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DAN G ER Indicates a hazardous situation which if not avoided will result in death or serious injury AWARN NG Indicates a hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury CAUTION Symbol Property or Statement Symbol Property or Statement Wear heavy duty cut and Do not loop the wire rope around abrasion resistant leather gloves load and hook onto itself Addresses practices not related to personal injury Do not use winch in Wear ANSI approved safety glasses overwind orientation Wire rope enters exits at the top Use winch only in underwind orientation Cuborsever hazard Wire rope enters exits at the bottom Grade 5 Roller entanglement hazard A fastener strength rating Page 2 For technical questions please call 1 800 444 3353 Item 65688 IMPORTANT SAFETY INFORMATION WARNING Read all instructions Failure to follow all instructions may result serious injury and or DEATH The warnings and precautions discussed in this manual cannot cover all possible conditions and situations2. 16 17 Page 4 Keep Wire Rope straight to avoid kinking it The illustrations below show how a kink forms and how to prevent kinking 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 SSNS 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 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 Hook onto the load using a pulling point tow strap
3. a mounting location that can withstand the mark the locations of the mounting rated capacity without damage or weakening Steel holes that fit your application reinforcement plates may be needed or a certified i welder may need to weld on additional bracing 5 Before drilling verify that the mounting depending on the mounting location Mounting location surface has no hidden components or and hardware must support Winch and load structural pieces that will be damaged 1 When choosing mounting location make sure that 6 Drill holes appropriate for the proper hardware the Handle will be able to rotate 360 degrees freely sold separately described under Specifications on page 5 at the marked locations N Remove Hook from Pawl Bushing 7 Secure the Winch with the hardware w Put the Pawl in Reel Out position see Ratchet and Pawl on page 8 then turn Handle counterclockwise to reel out Hook far enough to expose mounting holes Page 6 For technical questions please call 1 800 444 3353 Item 65688 Preparing the Wire Rope Note The Wire Rope must be properly 2 Put the Pawl in Reel In position and turn the Handle wrapped on the Drum to be able to support a clockwise carefully wrapping the Wire Rope back load without damaging the Wire Rope onto the Drum Tightly pack the coils side by side so the next layers cannot slip down between the coils 1 Put the Pawl in Reel Out position then reel out the Wire Rope completel
4. breaks See Figure A a Figure A Whiplash Dampening Blanket or Rug Item 65688 4 5 oO N 10 For technical questions please call 1 800 444 3353 SAFETY Mounting location and hardware must support Winch and load Use supplied Wire Rope listed in manual only Do not use thinner longer wire ropes or link multiple wire ropes together Install Winch in underwind orientation so that the Wire Rope enters and exits the Winch at the bottom of the Drum Do not use for lifting or moving people 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 load and the Wire Rope before activating 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 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 Page 3 wn gt mn m j lt 12 13 14 15
5. loop of Hook and the Hook s safety clasp f must be fully closed See Figure F 2 Remove the Hook from the Bushing and make sure the Hook is routed correctly under the Pawl Bushing See Figure D on page 6 3 Put the Pawl in Reel Out position then reel out the Wire Rope by turning the Handle counterclockwise WARNING Leave at least four full turns of Wire Rope on the Drum e m S e zZ 4 Hook onto the load using a pulling point or chain Do not wrap the Wire Rope around the load and hook onto the s Wire Rope itself This can damage the load being pulled Figure F Correct and Incorrect Hook Attachment and kink or fray the Wire Rope 6 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 Page 8 For technical questions please call 1 800 444 3353 Item 65688 7 Place a heavy blanket or rug not included 8 over the Wire Rope span 6 feet from the Hook to help absorb the force released if the Wire Rope breaks See Figure A Figure A Whiplash Dampening Blanket or Rug 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 a load 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 Double Line Rigging a Adouble li
6. 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 1 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 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 Operation Precautions 1 Do not exceed load capacity Be aware of dynamic loading Sudden load movement may briefly create excess load causing product failure 2 Verify load is within rated capacity If any part of the Winch starts to bend deform or show any signs of damage STOP using the Winch immediately 3 Use double line rigging whenever possible See Double Line Rigging on page 9 4 Wear ANSI approved safety goggles and heavy duty leather work gloves during operation 5 Do not try to guide Wire Rope while winching 6 Stay out of the direct line that the Wire Rope is pulling If it slips or breaks it will whiplash along this line Place heavy blanket or rug not included over Wire Rope span 6 feet from Hook to help absorb the force released if the Wire Rope
7. ASE 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 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 fro
8. 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 1000 LB CAPACITY Haul ITEM 65688 32 FT WIRE ROPE au aster Visit our website at http www harborfreight com REV 13h Email our technical support at tech harborfreight com When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 800 444 3353 as soon as possible Copyright 2008 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 Safety einiaid a a a 2 Maintenances scesu ontus 10 Specifications aeeeeeeeeeenneeerrreeeeernrenens 5 Parts List and Diagram
9. ds of Wire Rope will be sharp Wear heavy duty leather work gloves when handling the Wire Rope Do not slide Wire Rope through hands even with gloves on Item 65688 Service Precautions 1 Wear ANSI approved safety goggles and 3 Have the Winch serviced by a qualified repair person a heavy duty leather work gloves during service using only identical replacement parts This will LLI ensure that the safety of the Winch is maintained LL 2 Use supplied Wire Rope listed in manual lt x only Do not use thinner longer Wire Ropes 4 Maintain labels and nameplates on the Winch N or link multiple Wire Ropes together These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement A SAVE THESE INSTRUCTIONS Specifications Rated Single Line Pull 1 000 Ib 1 2 Clevis with Spring loaded Safety Latch G5 7 16 bolts and lock nuts sold separately Item 65688 For technical questions please call 1 800 444 3353 Page 5 Drum ae gt _ e Fn f Wire Rope Pawl Bushing Figure D Assembly and Installation 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 A Attaching the Handle Attach the Handle by securing with Lock Nut Mounting the Winch Note This Winch can generate extreme forces 4 Place Winch on mounting surface and Select
10. e Rope Pawl Hole Bushing 4 Route new Wire Rope end over Bushing and through Ratchet the Hole to the outside of the Drum See Figure H Bushing 5 Install the Wire Rope under the Wire Rope Clamp Figure H Wire Rope Replacement 6 Tighten the Nut securely 7 Put Pawlin Reel In position then reel the new Wire Rope onto Drum by turning the WARNING Do not replace with inferior Wire Rope Handle clockwise being careful not to allow Only use a Wire Rope rated to the same rating cited kinking Refer to instructions for Preparing on the Specifications chart on page 5 or better the Wire Rope on page 7 8 Test Winch for proper operation Page 10 For technical questions please call 1 800 444 3353 Item 65688 Parts List and Diagram Part Description Qty Pawl Flat Washer 3 Wire RopeAnchor 1 Direction Switch 4 Bolt M6x14 J 1 Pulling Spring 5 DrumAssembly 1 Circlip 10 6 Drum Bushing 1 Sleeve 7 Gear Spinde _ 1 Flat Washer 8 8 IF Handle 9 Flat Washer 10 Nut M8 Lock Nut M12 22 Wire Rope with Hook not shown 19 20 21 Record Product s Serial Number Here MAINTENANCE 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 Item 65688 For technical questions please call 1 800 444 3353 Page 11 PLE
11. m 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 Haul Mviaster 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 www harborfreight com
12. ne system should be used whenever possible 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 Connect the Wire Rope for a double line system as shown in Figure G 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 Anchor Point Mounting Surface Figure G Double Line Setup Loop the Wire Rope around the pulley and connect to another part of the load s chassis or to a separate anchor point Do not anchor the Wire Rope back to the Winch or winch mount 13 10 When finished pulling the load secure it Turn the Handle counterclockwise to release tension When it is safe to do so push the Pawl to Reel In position then turn the Handle clockwise to reel in the Wire Rope Do not operate the Winch at extreme angles Do not exceed the angles shown in Figure B 4 i 4 Vertical Horizontal Figure B Maximum Winching Angles If the load 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 Z O H lt of Lu ou O on the Wire Rope so that you can move the blanket or rug and unfasten the Hook f
13. or chain Do not wrap the Wire Rope around the load and hook onto the Wire Rope itself This can cause damage to the load being pulled and kink or fray the Wire Rope 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 18 19 20 21 22 23 24 For technical questions please call 1 800 444 3353 Secure load after moving Keep at least 4 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 4 full turns of Wire Rope 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 If Wire Rope begins to get entangled stop Winch immediately and release tension on Wire Rope Do not operate the Winch at extreme angles Do not exceed the angles shown in Figure B Vertical 4 Ly 4 Horizontal 4 Figure B Maximum Winching Angles If the load 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 Broken stran
14. rom the load Turn the Handle clockwise and reel in the Wire Rope Refer to instructions for Preparing the Wire Rope on page 7 Haul yviaster Item 65688 For technical questions please call 1 800 444 3353 Page 9 gt par m Z gt Z 2 m Maintenance and Servicing Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING 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 2 AFTER USE wipe external surfaces condition of the Winch Check for of the Winch with clean cloth loose hardware 3 PERIODICALLY lubricate the Wire Rope with a e misalignment or binding of moving parts light oil Lubricate the Gear with gear grease cracked or broken parts frayed kinked or damaged Wire Rope and any other condition that may affect its safe operation Wire Rope Replacement WARNING Use extreme care when replacing Drum Wire Rope it is secured under tension by the Wire Rope Clamp and may spring back forcefully Nut 1 Put Pawl in Reel Out position Reel the old Wire Rope all the way out by turning Handle counterclockwise Wire Rope 2 Loosen the Nut and remove the old Wire Rope from underneath the Wire Rope Clamp 3 Remove the old Wir
15. y by 3 When finished attach the Hook to the Pawl Bushing turning the Handle counterclockwise SETUP Haul yiaster Item 65688 For technical questions please call 1 800 444 3353 Page 7 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 AWARNING BEFORE USE verify that the load is within rated capacity If any part of the Winch starts to bend deform or show any signs of damage STOP using the Winch immediately Do not attempt to stop a spinning Handle Stay clear until the Handle stops Ratchet and Pawl 1 The Winch is equipped with a Ratchet and Pawl Ratchet Pawl Reel Free locking mechanism The Pawl has three positions a Reel Out Pull Pawl all the way back to reel out by turning Handle counterclockwise b Reel In Push Pawl all the way forward to reel in by turning handle clockwise c Free Spool Put Pawl in center position to reel out or reel in without the locking mechanism WARNING Keep a firm grip on the Handle when using Free Spool Figure E Basic Operation 1 Examine the Wire Rope Do not use the Winch 5 Attachment point must be centered in if the Wire Rope is frayed kinked or damaged
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