Chicago Electric 40764 User's Manual
Contents
1. 10 11 12 Read all instructions before using this tool Observe work area conditions Do not use machines or power tools in damp or wet locations Don t expose to rain Keep work area well lighted Do not use electrically powered tools in the presence of flammable gases or liquids Keep children away Children must never be allowed in the work area Do not let them handle machines tools or extension cords Do not force tool It will do the job better and more safely at the rate for which it was intended Do not use inappropriate attachments in an attempt to exceed the tool capac ity Use the right tool for the job Do not attempt to force a small tool or attachment to do the work of a larger industrial tool Do not use a tool for a purpose for which it was not intended Do not use this item for aircraft purposes Do not exceed winch load weight capacity for your model see Specifications on page 2 Dress properly Do not wear loose clothing or jewelry as they can be caught in moving parts Protective electrically nonconductive clothes and nonskid footwear are recom mended when working Wear restrictive hair covering to contain long hair Use eye protection Always wear ANSI approved impact safety goggles Heavy duty work gloves need to be worn when handling the cable Do not overreach Keep proper footing and balance at all times Do not reach over or across running machines Do not cross over or under cable under load2. 6335 38 6243 64 o Aan 5 ft 15 38 64 95 00 Sku 93752 9 000 Ib capacity Performance of First Layer Line Pull and Cable Capacity by Layer Ib ft min Ib ft o J az 1 9 f 5 2000 78 10 f 2 zo 38 400 72 10 f 3 620 6 amp 4 6000 65 20 f 4 54 800 5 25 5 420 10 Sku 91905 10 000 Ib capacity Performance of First Layer Line Pull and Cable Capacity by Layer Line Pull Line Speed Amp Draw Cable Layer Rated Line Pull Cable Capacity Ib ft min Ib ft Or BR oOy hm o 8 1 10 000 2 000 8 110 oO _ 40000 72 10 3 eso 6 amp 600 65 20 4 589 5 800 5 J 20 5 51o 10 Note Performance of this winch may vary depending on variations of vehicle s battery power and other factors oy amp REV 06l SKUs eo A For technical questions please call 1 800 444 3353 Page 2 Save This Manual You will need the manual for the safety warnings and precautions assembly instructions operating and maintenance procedures parts list and diagram Keep your invoice with this manual Write the invoice number on the inside of the front cover Keep the manual and invoice in a safe and dry place for future reference Safety Warnings and Precautions WARNING When using tool basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment
3. Fairlead Assembly for Skus 93752 amp 91905 see Roller Fairlead parts list Screw M10x34 Description Cap Screw M6x12 Gear intermediate sun Gear input sun Thrust Washer oO 6 NutM10 y ode N Gear Housing Cover Spring o ooo y ode TieBar O2 Brake shaft assy Motor End Bearing Assy Bolt M8 x 30 4 K Solenoid Assy see parts list S Nut M8 Gear Ring Retainer 4 O1 RingGear J1 Cable Assy 03 8 x100 Gear Carrier Assy output Sewn e Shaft Bushing RorPn axo i NOTE Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Gear Carrier Assy intermediate Gear Carrier Assy input Solenoid Bracket Bracket Tie down Strap Spring Washer 5 NO ep ep U 7 glglolole alz pai nin al 3 2 x 7 i 015 n y lt 2 s O lt a z N HRPER PTR POLoOlLoloplvolvomloloaoslopfvolMmlslMO sl MPN TMT MIT_NM NM O COI NI O WLM O O LOINI OI a RI dITNM a fof of of oOo of Oo Of OT OT OT 3 M o lt Item 3 6 a 8 2 20 N PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR 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
4. Nuts 22s Place the completed Electric Winch assembly at the location where it will be mounted Use the remaining holes in the Mounting Frame as a template to mark and drill holes for mounting ALWAYS check for electrical wires or cables in the drilling path before starting to drill If the provided hardware does not accommodate the installation use SAE grade 5 bolts or higher with torque to 35 ft lb It should be aligned and secured to a solid part of the vehicle front or rear where the full rated load will be evenly distributed Also remember that the Electric Winch is designed for horizontal pull not vertical Connect the Solenoid Assembly red positive Battery Cable 13s to the closest screw down positive terminal to the 12 volt battery The battery should be of at least 650 CCA capacity Caution Battery cables should not be drawn taut Leave slack for some cable move ment T Connect the black negative Battery Cable 16s from the Solenoid Assembly 34 to the closest screw down nega tive terminal to the 12 volt battery 8 Disengage the clutch by moving the Cam Ring 11 to the OUT position 9 Pull the Cable 36 through the Fairlead and connect the Hook and safety pin 10 Test Electric Winch for proper operation Refer to the Op eration section next page SKUs 40764 93752 For technical questions please call 1 800 444 3353 Page 6 amp 91905 Operation 1 Disengage the clutch by movi
5. 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 REPLACE MENT PARTS THERETO REV 07a SKUs o For technical questions please call 1 800 444 3353 Page 9 Winch Diagram 40764 87495 SKUs o For technical questions please call 1 800 444 3353 Page 10 Roller Fairlead Parts List IMPORTANT When ordering parts reference the appropriate number as follows Sku 40764 uses a single piece hawse fairlead instead don t order from this list Sku 93752 9 000 Ib 87478 Sku 91905 10 000 Ib 87496 Pan Description ty Part Description ay er Bushing e Ca fei S e Roller Fairlead Diagram SKUs o For technical questions please call 1 800 444 3353 Page 11 Solenoid Parts List IMPORTANT When ordering parts reference the appropriate number as follows Sku 40764 8 000 Ib 87495 Sku 93752 9 000 Ib 87478 Sku 91905 10 000 Ib 87496 Item Description Q ty Item Description Qty Battery Cable Red Battery Cable Black Output Cable Black Output Cable Red SKUs o For technical questions please call 1 800 444 3353 Page 12 LIMITED 90 DAY
6. possible injury 24 Never operate winch if cable shows any signs of weakening is knotted or kinked 25 Winch does not have a locking mechanism Secure load after moving Do not rely on the winch to hold it for an extended period 26 Re spool cable properly 2 Make certain that the hook s safety clasp is shut and the hooks is securely at tached to the item to be moved before use 28 People with pacemakers should consult their physician s before use Electro magnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure REV 07j 08h SKUs 40764 93752 For technical questions please call 1 800 444 3353 Page 4 amp 91905 29 The warnings cautions 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 Unpacking When unpacking check to make sure all parts are included Refer to the Assembly Diagrams and Parts Lists at the end of this manual If any parts are missing or broken please call Harbor Freight Tools at the number on the cover of this manual as soon as possible Installation 1 Mountthe Fairlead 2 to the Mounting Frame 1 using supplied bolts nuts and wash ers 2 Mount Electric Winch to the Mounting Frame 1 using Bolt 3 and
7. solenoid to loosen contacts Apply 12 volts to connections coil terminals directly A clicking indicates proper Solenoid malfunctioning activation Defective Switch Assy Replace Switch Assy Defective motor Check for voltage at armature port with Switch _ Water has entered motor pressed If voltage is present replace motor Allow to drain and dry Run in short bursts without load until completely dry Motor runs but Cam Ring clutch not engaged _ Move the Cam Ring to the In position If problem cable drum does persists a qualified technician needs to check and not turn repair Motor runs slowly 1 Insufficient current or voltage 1 Battery weak recharge Run winch with vehicle or without normal 2 Loose or corroded battery motor running power cable connections 2 Clean tighten or replace Motor overheating Winch running time too long Allow winch to cool down periodically Motor runs in one 1 Defective or stuck solenoid 1 Tap solenoid to loosen contacts Repair or direction only 2 Defective Switch Assy replace solenoid 2 Replace Switch Assy SKUs o For technical questions please call 1 800 444 3353 Page 8 Parts Lists and Diagrams Winch Parts List IMPORTANT When ordering parts reference the appropriate number as follows Sku 40764 8 000 Ib 87495 Sku 93752 9 000 Ib 87478 Sku 91905 10 000 Ib 87496 arty Mounting Frame Box B Fairlead Single Piece Hawse for Sku 40764 Roller 1
8. the Winch motor becomes very hot to the touch stop the Winch and let it cool down for several minutes Never pull for more than one minute at or near the rated load Do not maintain power to the Winch if the motor stalls REV 08h SKUs o For technical questions please call 1 800 444 3353 Page 7 Maintenance Lubrication 1 All moving parts within the Electric Winch have been lubricated using high temperature lithium grease at the factory No internal lubrication is required 2 Lubricate the cable portion of the Cable Assembly 36 periodically using a light penetrat ing oil Cable Assembly Replacement L Move Cam Ring 11 to the OUT position 2 Extend Cable Assembly 36 to its full length Note how the existing cable is connected to the inside of the drum 3 Remove old Cable Assembly and attach new one Caution Do not replace with inferior cable Always use the approved replace ment part from Harbor Freight Tools 4 Retract Cable Assembly onto cable drum being careful not to allow kinking 9 Cover the Cable Assembly and Electric Winch when not in use Troubleshooting This chart is included as a reference tool for qualified technicians only Only a qualified technician should attempt to repair this unit SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION Motor does not Switch Assy not connected Insert Switch Assy all the way into connector turn On properly Tighten nuts on all cable connections Loose battery cable 3 Tap
9. CHICAGO Jail Power Tools ELECTRIC WINCH 12 VOLT 40764 93752 Wheel 2 91905 ASSEMBLY AND OPERATION INSTRUCTIONS Model 91905 shown Due to continuing improvements actual product may differ slightly from the product described herein Distributed Exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 Visit our Web site at http www harborfreight com TO PREVENT SERIOUS INJURY READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE Copyright 2004 2006 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 For technical questions and replacement parts please call 1 800 444 3353 Manual revised 07k 08h Specifications 40764 93752 91905 Capacity 4 1 HP 8 000 Ib 4 5 HP 9 000 Ib 4 8 HP 10 000 Ib 100 L x de dia Galvanized Aircraft Type Automatic Load holding Type Mounting Pattern 10 x 4 5 Speraion Power In Power Out p Handheld Remote Control on 12 Cable Fairlead Type Roller parts list on page 12 Power Supply 12 VDC 650 CCA or more battery Weight 80 Ib 85 Ib 86 Ib Sku 40764 8 000 Ib capacity Performance of First Layer Line Pull and Cable Capacity by Layer Line Pull Line Speed Amp Draw Cable Layer Rated Line Pull Cable Capacity Ib ft min Ib o z 5 8000 15
10. Maintain tools with care Keep equipment clean for better and safer performance Follow instructions for lubricating and changing accessories Inspect cords periodically and if damaged have them repaired by an authorized technician The hook must be kept clean dry and free from oil and grease at all times Remove adjusting keys and wrenches Check that keys and adjusting wrenches are removed from the tool or machine work surface before operating Avoid unintentional starting Remove the Switch Ass y 35 when not in use Stay alert Watch what you are doing use common sense Do not operate any equip ment when you are tired Check for damaged parts Before using any tool any part that appears damaged should be carefully checked to determine that it will operate properly and perform its SKUs 40764 93752 For technical questions please call 1 800 444 3353 Page 3 amp 91905 intended function Check for alignment and binding of moving parts any broken parts or mounting fixtures and any other condition that may affect proper operation Any part that is damaged should be properly repaired or replaced by a qualified technician Do not use the tool if any switch does not turn On and Off properly Examine winch before using Components may be affected by exposure to chemicals salts and rust 13 Replacement parts and accessories When servicing use only identical replacement parts Use of any other parts will void the warranty Only
11. Nut 6 See illustration to the right 3 Connect the Solenoid Output Power Lines short black 17s 24s to either terminal of the Electric Winch as shown below left Securely tighten nuts 4 There are two options for mounting the so lenoid gi Mounting C es AY Mounting Option 1 Mounting the Solenoid to the Mounting Frame 1 Mount the Solenoid Assembly 34 to the Mounting Frame 1 using the three Flat Washers 20s three Spring Washers 21s and three Nuts 22s as shown below right Securely tighten nuts otor Terminal Solenoid Cable SKUs 40764 93752 For technical questions please call 1 800 444 3353 Page 5 amp 91905 Mounting Option 2 Mounting the Solenoid to the Solenoid Bracket 40 Remove both Bolts 12 and Nuts 13 from the Motor End Bearing Ass y 33 Then align Solenoid the Solenoid Bracket 40 with the 2 mounting holes Attach the Solenoid bracket to the Motor Solenoid End Bearing Ass y 33 by reattaching the Tie Bracket Bars 10 with the Bolts 12 and Nuts 13 that were previously removed Tighten Secure the Solenoid Bracket 40 to the Motor End Bearing Nut Ass y 33 by attaching the Bracket Tie Down Strap 41 around both the Solenoid Bracket Bracket and the Motor End Bearing Ass y Pull Strap Tie Down until secure Attach the Solenoid to the bracket Strap using the Flat Washers 20s Spring Washers 21s and
12. 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 in juries 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 det
13. ermine 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 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353 SKUs o For technical questions please call 1 800 444 3353 Page 13
14. ng the Cam Ring 11 to the OUT position 2 Grab the Cable Assembly 36 hook and pull the cable to the desired length then attach to item being pulled Make certain that the hooks safety clasp is fully closed WARNINGI You MUST leave at least five full turns of cable on the drum at all times Review Winch Safety Warnings and Precautions starting on page 3 before continuing STOP THE WINCH IMMEDIATELY and release cable with the switch if the cable begins to get entangled on the drum Reengage the clutch by moving the Cam Ring to the IN position Lift the Socket Cover 2s exposing the electrical switch connector Insert the Switch Ass y 35 connector into the Socket 6s oa amp While standing aside of the pull path press and hold the Red switch on the Switch Ass y 35 forward Press and hold the switch backward to reverse directions Wait until the motor stops before reversing directions The power out function will puts stress on the winch s automatic braking system IMPORTANT Do not use the power out function of the winch for more than 10 seconds at a time it may cause damage to the winch s brake system 7 When the pulling is complete remove the Switch Assembly from the Socket 6s and replace the Socket Cover 2s 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
15. use accessories intended for use with this tool Approved accessories are available from Harbor Freight Tools 14 Donot operate tool if under the influence of alcohol or drugs Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs If there is any doubt do not operate the tool 15 Risk of entanglement Keep hands and body away from Fairlead cable intake slot when operating 16 Secure vehicle in position before using winch Block the vehicle s tires prior to use Do not move vehicle with cable attached to a load to pull the load the cable could snap 17 Be certain winch is properly bolted to a structure or vehicle that can hold the winch load 18 Always use proper couplings when connecting winch cable hook to load Do not use inappropriate attachments to extend the length of the winch cable 19 Do not lift items vertically The winch was designed for horizontal use only 20 Never lift people or hoist loads over people 21 Never come in between the winch and the load when operating 22 Never fully extend cable while under load Do not apply load to winch when cable is fully extended Keep at least 5 full turns of cable on the drum 23 When loading a boat into a trailer without keel or side hull rollers make sure the trailer is submerged in the water when the boat is loaded by the winch Attempt ing to drag the boat on to the trailer while on land can cause winch failure and
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