Harbor Freight Tools 1 Ton Capacity Hand Winch Product manual
Contents
1. Page 3 wn gt mn m j lt 12 13 14 15 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 unexpec2. 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 iaster 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
3. E the Shear Pin has broken to prevent an overweight load from causing Winch failure WARNING To prevent serious injury and death from catastrophic Winch failure only replace with Shear Pin replacement part 13 from Parts List on page 11 During normal operation the Worm Gear Worm Worm Gear Broken Worm Gear Shaft 16 and Shear Pin Gear Shaft Shear Pin rotate together by turning the Handle When the Shear Pin breaks the Worm Gear Shaft and middle section of the Shear Pin continue to rotate while the Worm Gear and broken Shear Pin pieces do not rotate The Winch will not operate unless the Shear Pin is replaced Pin Figure H Shear Pin Replacement 1 If possible shift the load to another winch Shine a light behind the Shear Pin before replacing the Shear Pin then slowly rotate the Handle until you can see the light indicating the broken 2 Locate the Shear Pin on the pieces of the Shear Pin are lined up bottom of the Worm Gear n Using a pin punch and hammer both sold Worm DOANE iA separately tap the end of the Shear Pin Gear to force the pieces out of the hole Shear _ Pin Insert a new Shear Pin into the hole and tap it in until centered Only replace with genuine replacement part Figure Haul Mviaster MAINTENANCE Item 5798 For technical questions please call 1 800 444 3353 Page 9 gt par m Z gt Z 2 m Maintenance and Servicing A Procedures n
4. 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 2000 LB CAPACITY Haul ITEM 5798 29 FT WIRE ROPE au aster D D Visit our website at http www harborfreight com REV 13i 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 1997 by Harbor Freight Tools All rights reserved 5 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 i 2 Maintenances scesu ontus 10 Specifications 0 00 eeeeeeeeeeeeeeeeeeeeeeeeeeneees 5 Parts List and Di
5. T 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 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
6. 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 Rug 10 Mounting 11 Surface Figure G Double Line Setup 12 c Loop the Wire Rope around the pulley and connect l to a separate anchor point Do not anchor the Wire Rope back to the Winch or winch mount 13 8 Do not operate the Winch at extreme angles Do not exceed the angles shown in Figure B e 15 E m Vertical 15 gt e lt I 15 Y 15 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 When it is safe to do so turn the Handle clockwise to reel in the Wire Rope When winching operation is finished secure the load Turn the Handle counterclockwise to release tension on the Wire Rope so that you can move the blanket or rug and unfasten the Hook from the load Turn the Handle clockwise and reel in the Wire Rope Refer to instructions for Preparing the Wire Rope on page Haul aster Page 8 For technical questions please call 1 800 444 3353 Item 5798 IF THE HANDLE SUDDENLY MOVES FREELY AND THE DRUM WILL NOT MOV
7. agram 11 SOUU Pies EAT fees eels E ET 6 Warranty iets denetivaciinianiedinneshaes 12 OPO RATION iio ods recetiessienteeneeatuadivie neeientesaeekee 7 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 5798 IMPORTANT SAFETY INFORMATION WARNING Read all instructions Failure to follow all instructions may result serious injury and or DEATH The warnings and precautions discu
8. igure C to keep the Wire Rope pull straight Figure C Pulley Anchoring Broken strands 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 5798 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 2 000 Ib O12 x 6 116 5 8 Clevis with Spring loaded Safety Latch 534 x 5 51 G5 3 8 bolts and lock nuts sold separately Ring Gear Shear Pin not shown Hook SS Figure D Item 5798 For technical questions please call 1 800 444 3353 Page 5 Assembly and Installation Instructions including all text under subheadings therein before set up or use of this product Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual Attaching the Handle Attach the Handle by securing with the N
9. o the Wire Rope itself This can damage the load being pulled and kink or fray the Wire Rope 5 Attachment point must be centered in loop of Hook and the Hook s safety clasp must be fully closed Do not attach load to point of Hook See Figure F Figure F Correct and Incorrect Hook Attachment 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 7 Place a heavy blanket or rug not included over the Wire Rope span 6 feet from the Hook to help absorb the force released if the Wire Rope breaks See Figure A a Figure A Whiplash Dampening Blanket or Rug Z O H lt aa Lu ou O 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 Item 5798 For technical questions please call 1 800 444 3353 Page 7 9 Double Line Rigging a Adouble 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 e 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
10. ot 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 condition of the Winch Check for misalignment or binding of moving parts cracked or broken parts frayed kinked or damaged Wire Rope and any other condition that may affect its safe operation Wire Rope Replacement 1 Reel the old Wire Rope all the way out by 7 turning the Handle counterclockwise 2 STAY CLEAR the Wire Rope end is under tension and may suddenly whip out Carefully loosen the Nut and remove the old Wire Rope from underneath the Wire rope Clamp 3 Remove the old Wire Rope from underneath the Wire Rope Clamp 4 Remove the old Wire Rope WARNING To prevent serious injury and death do not replace with inferior Wire Rope Only use a Wire Rope rated to the same rating cited on the Specifications chart on page 5 or better 5 Route new Wire Rope end under Bushing and through the Hole to the outside of the Drum See Figure J 6 Install the Wire Rope under the Wire Rope Clamp 9 loose hardware 3 AFTER USE wipe external surfaces of the Winch with clean cloth PERIODICALLY lubricate the Wire Rope with a light oil Lubricate the Gea
11. pe onto the Drum Tightly pack the coils side by side so the next layers cannot slip down between the coils When finished attach the Hook to the Bushing Item 5798 Operation Instructions including all text under subheadings therein before set up or use of this product 1 Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual 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 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 Note This Winch is equipped with a Shear Pin which will break to prevent an overweight load from causing Winch failure Keep extra Shear Pins on hand in case it needs to be replaced Only replace with Shear Pin replacement part 13 from Parts List on page 11 See Shear Pin Replacement on page 9 1 Examine the Wire Rope Do not use the Winch if the Wire Rope is frayed kinked or damaged 2 Remove the Hook from the Bushing and route the Hook under the Bushing See Figure E on page 6 3 Turn Handle counterclockwise to let out the Wire Rope WARNING Leave at least five full turns of Wire Rope on the Drum 4 Hook onto the load using a pulling point or chain Do not wrap the Wire Rope around the load and hook ont
12. rs with gear grease Tighten the Nut securely Nut Clamp Drum Bushing O Frame Wire Rope Hole Figure J Wire Rope Replacement Reel new Wire Rope onto Drum by turning the Handle clockwise being careful not to allow kinking Refer to instructions for Preparing the Wire Rope on page 6 Test Winch for proper operation Page 10 For technical questions please call 1 800 444 3353 Item 5798 Parts List and Diagram Part __ Description Qty Part __ Description _ _ Worm Brackett 2 Frame DrumBolt 1 Drum Bushing CC Wire Rope Bolt 1 7 Wire Rope Clamp 1 Wire Rope Nut Cid 10 DrumNut 1 11 Bushing f1 12 _ Bushing Nut Za 13 Shear Pin Drum o a 4 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 5798 For technical questions please call 1 800 444 3353 Page 11 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS DOCUMENT 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 PRODUC
13. span 6 feet from Hook to help absorb the force released if the Wire Rope breaks See Figure A a Figure A Whiplash Dampening Blanket or Rug Item 5798 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
14. ssed in this manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Installation Precautions 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 5Use double line rigging whenever possible See Double Line Rigging on page 8 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
15. ted situations Hook onto the object using a pulling point tow strap 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 NO LOCKING MECHANISM 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 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 15 Vertical lL 15 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 F
16. ut Installing the Wire Rope 1 Route the Wire Rope end under Bushing and through the Hole to outside of Drum 2 Loosen the Nut then install the Wire Rope under the Wire Rope Clamp See Figure E 3 Tighten the Nut securely Mounting the Winch Note This Winch can generate extreme forces Select a mounting location that can withstand the rated capacity without damage or weakening Steel reinforcement plates may be needed ora certified welder may need to weld on additional bracing depending on the mounting location 1 When choosing mounting location make sure that the Handle will be able to rotate 360 degrees freely Preparing the Wire Rope Note The Wire Rope must be properly wrapped on the Drum to be able to support a load without damaging the Wire Rope Lubricating the Gears Lubricate the Ring and Worm Gears with gear grease Page 6 For technical questions please call 1 800 444 3353 Nut Clamp Drum Bushing Frame Wire Rope Hole Figure E Place Winch on mounting surface and mark the locations of the mounting holes that fit your application Before drilling verify that the mounting surface has no hidden components or structural pieces that will be damaged Drill holes appropriate for the proper hardware sold separately described under Specifications on page 5 at the marked locations Secure the Winch with the hardware Turn the Handle clockwise carefully wrapping the Wire Ro
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