5,500 LB. WINCH WITH
ROLLER FAIRLEAD
91780
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
TO PREVENT SERIOUS INJURY,
READ AND UNDERSTAND ALL WARNINGS
AND INSTRUCTIONS BEFORE USE.
©
®
Copyright 2004 by Harbor FreightTools . 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.
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7.
8.
Do not overreach. Keep proper footing and balance at all times. Do not reach over or
across the Winch cable.
Maintain tools with care. Keep the Winch clean for better and safer performance. Fol-
low instructions for lubricating and changing accessories. Inspect cords and cables
periodically, and if damaged, have them repaired by an authorized technician.
9.
Stay alert. Watch what you are doing, use common sense. Do not operate the Winch
when you are tired.
10. Check for damaged parts. Before using the Winch, any part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
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 theWinch if any switch does not turn On and Off properly.
11. Replacement parts and accessories. When this unit is serviced by a qualified techni-
cian, only identical replacement parts should be used. Use of any other parts will void
the warranty.Only use accessories intended for use with this tool. Approved accessories
are available from Harbor Freight Tools.
12. Do not operate Winch if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgment or reflexes are im-
paired while taking drugs. If there is any doubt, do not operate the Winch.
13. Maintenance. For your safety, service and repairs should be performed regularly by a
qualified technician. This unit should receive regular maintenance.
14. Pacemaker safety warning. People with pacemakers should consult their physician(s)
before using this product. Electromagnetic fields in close proximity to a heart pace-
maker could cause interference to or failure of the pacemaker.
Note: Performance of this tool may vary depending on variations in battery power.
Specific Winch Warnings and Precautions
1.
2.
Keeps hands and body away from Fairlead (cable intake slot) and operating gears when
operating the Winch and when the Winch is supporting a load.
Secure vehicle in position with the emergency brake and wheel blocks before using
winch. Never keep the vehicle in Park or in gear while using the Winch.
3.
4.
Do not exceed winch Rated Line Pull Capacity (5,500 Lbs.).
Be certain winch is properly bolted to a structure (or vehicle) that can hold the Winch and
the load supported by the Winch.
5.
6.
7.
8.
Always use proper couplings when connecting winch cable hook to load.
Do not lift items vertically. The winch was designed for horizontal pulling use only.
Never leave the Winch unattended when it is under a load.
Do not use inappropriate attachments to extend the length of the winch cable.
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 3
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Winch Warnings and Precautions (continued)
9.
Never pull people or pull loads over people. Do not lift people or animals; as noted in
Specific Warning 6, this Winch should not be used for lifting whatsoever.
10. Never come in between the winch and the load when operating.
11. Examine Winch before using. Components may be affected by exposure to chemicals,
salts, and rust. Do not use the Winch if even minor structural cracks, bends, a frayed
cable, or any other condition that may affect safe operation are noted.
12. Do not apply winch to load when cable is fully extended. Never fully extend cable while
under load. Keep 4 complete turns of cable around the winch drum.
13. When loading a boat into a trailer without keel or side hull rollers, make sure the trailer is
submerged in the water (but not the Winch) when the boat is loaded by the winch.
Attempting to drag the boat on to the trailer while on land can cause winch failure and
possible injury.
14. Never operate winch if cable shows any signs of weakening, or is knotted or kinked.
15. Winch does not have a locking mechanism. After moving an item with the winch, secure
the item. Do not rely on the winch to hold it for an extended period.
16. Do not cross over or under cable under load.
17. Do not move vehicle with cable extended and attached to load to pull it.The cable could
snap.
18. Use leather gloves while handling cable. Always wear ANSI approved safety goggles
during setup, use, and maintenance.
19. Re-spool cable properly in a smooth pattern as shown in the photo on the next page.
20. Not to be used for aircraft purposes.
21. Make sure to read and understand all instructions and safety precautions as outlined in
the manufacturer’s manual for the object you will winch. Make sure you attach the Cable
Assembly (36) to the manufacturer’s recommended pulling point.
22. Make sure to read and understand all instructions and safety precautions as outlined in
the manufacturer’s manual for the vehicle/trailer to which the Winch will be attached.
23. Use extreme caution when applying or releasing a load. Never allow the load to sud-
denly release. Carefully and slowly, apply and release the load.
24. This Winch is designed for mounting on square or rectangular surfaces. Never attempt
to mount theWinch on a round surface.
25. Do not replace the Steel Cable with ropes or fiberglass straps. This Winch is only de-
signed to work with the 1/4” Steel Cable provided. Replacement cables for this winch
should only be ordered through Harbor Freight Tools as parts for this item.
Warning:The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which cannot be
built into this product, but must be supplied by the operator.
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 4
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Unpacking
When unpacking, check to make sure that all of the parts listed on pages 9, 11, and 12, are
included. 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.
Cable Assembly (36)
FIGURE 1
Winch
Cables From
Solenoid (34w)
Solenoid Unit
Cam Ring (11w)
Switch Assy. (35)
Roller Fairlead
Assembly Hardware
BatteryWire Assembly (17 & 20)
Roller Fairlead
Mounting Plate (46)
and
Hardware (43,44, & 45)
REV 11/04; 0505
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 5
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Installation
Warning! Injury or death can occur if this Winch comes apart from its mounting location
when it is under load. Electrical damage or fire may occur if theWinch is wired improp-
erly. For these reasons, it should only be installed by a qualified technician.
1.
After matching up the mounting holes, attach the Roller
Fairlead (2w) to the Mounting Plate (46w) using the sup-
plied M12 Bolts (43w), Nuts (44w), and Washers (45w).
2.
Now mount the Roller Fairlead and Mounting Plate as-
sembly to the mounting channel (not included) or other
suitable mounting point using the included hardware
(M10, bolt, lock washer, and nut). It is recommended
that the Harbor Freight Universal Mounting Channel
(SKU 90476) be used.
NOTE: If recommended mounting channel is not used, a
mounting channel or mounting point of equal or greater
design, must be used.
3.
Now place the mounting channel in position on the ve-
hicle and mark on the vehicle’s frame where the holes
will need to be drilled for the winch’s mounting hardware. Remove the mounting chan-
nel from the vehicle and drill the holes for the mounting channel.
4.
Attach the Winch to the mounting channel (not included) using Bolts (3w), FlatWashers
(5w), Lock Washers (4w), and Nuts (6w). NOTE: Tighten bolts to at least 35 ft. lbs. of
torque.
5.
6.
Connect the short Solenoid Cables to the terminals on the Winch. The cables can be
connected to either terminal.
Mount the Solenoid (34w) to the mount-
ing channel (not included) using three
Lock Washers (4s) and three Nuts (3s).
The Solenoid may also be mounted to
the Winch motor using the included So-
lenoid mounting bracket (7s). Remove
both Bolts (12-1w) and Nuts (13w) from
the Motor End Bearing Ass’y (33w).Then
align the Solenoid Bracket (40w) with the
2 mounting holes. Attach the Solenoid
bracket to the Motor End Bearing Ass’y
(33w) by reattaching the Tie Bars (10w)
with the Bolts (12-1w) and Nuts (13w)
FIGURE 3
that were previously removed. Tighten. Secure the Solenoid Bracket (40w) to the Motor
End Bearing Ass’y (33w) by attaching the Bracket Tie Down Strap (41w) around both
the Solenoid Bracket and the Motor End Bearing Ass’y. Pull Strap until secure. Attach
the Solenoid to the bracket using the Lock Washers (4s) and Nuts (3s). See FIGURE 3.
7.
Place the mounting channel and Winch on the vehicle. Now align the holes previously
drilled in the vehicle frame with the holes in the mounting channel. Using four each of
REV 11/04; 05/05
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 6
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Installation (continued)
Bolt (3w), FlatWasher (5w), Lock Washer (4w) and Nut (6w), place through the mounting
channel and the vehicle frame and tighten to at least 35 ft. lbs.
NOTE: The winch should be mounted to flat part of the vehicle (frame) that is capable of sup-
porting and evenly distributing the Winch and its full load capacity. Remember, the Winch
is designed for horizontal pull, NOT vertical.
8.
Connect the (two short Black) Solenoid Cables to both terminals on the Winch (see
FIGURE 1). Securely tighten nuts.
Caution:The Battery cables should not be drawn taut. Leave slack for some cable move-
ment. Do not route cables near moving engine parts, or heated areas that could melt the
cable insulation.
9.
Connect the Battery Wire Assy.Red (positive +) (17s) from the Solenoid Assembly (34w)
to the positive (+) terminal on the vehicle’s 12 volt battery.
10. Connect the Battery Wire Assy. Black (negative –) (20s) from the Solenoid Assembly
(34w) to the negative (–) terminal on the vehicle’s 12 volt battery.
11. To check for correct winch motor rotation, first disengage the winch clutch by moving the
Cam Ring (11w) to the “out” position.
12. Pull out 3-4ft.of the Cable Assy. and then reengage the winch clutch by moving the Cam
Ring (11w) to the “in” position.
13. Insert the Switch Assy. (35w) into the Connector (9s) on the side of the of the Solenoid
Assy.(34w).
14. Now momentarily press the “Red” button on the Switch Assy. (35w) and observe if the
cable is being wound back into the winch. If not, first disconnect the Red (+) battery
cable and then reverse the two short Black Solenoid cables attached to the end of the
winch motor (see Figure 1). Now reconnect the battery cable. Installation of the winch is
now complete.
Operation
1.
2.
Disengage the clutch of the Winch by moving the Cam Ring (11w) to the out position.
See FIGURE 1.
Pull the Cable Assy. (36w) out the to the desired length, then attach the Hook to the item
being pulled. Make sure the Hook’s spring-loaded latch is set.
Warning: Always leave at least four turns of cable on the drum. Review Winch Safety
Warnings and Precautions on pages 3 and 4 before continuing.
3.
Reengage the clutch by moving the Cam Ring (11w) to the in position.
See FIGURE 1.
4.
Open the Cover (Female Conn.) (12s) on the Solenoid (34w) unit. Insert the Switch Assembly
(35w) plug into the connector on the Solenoid (34w).
Note: The vehicle battery must be fully charged and the engine running before using
theWinch.
Caution: Avoid damaging the vehicle transmission. Do not have the transmission in
Park or in any gear. Set the Emergency Brake and place wheel chocks, then put in neu-
tral.
REV 11/04; 05/05
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 7
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5.
While standing aside of the tow path, press (and hold) the RED push-button on the Switch
Assy. (35w) to pull the load. If the load will not move, release pull switch and check for
obstacles blocking the load, or check to see if load is too heavy for Winch capacity.
Always wait until the motor has stopped before changing directions!
To reverse directions, press (and hold) the opposite push-button to release the load.
When the pulling is complete, secure the load so it cannot move in either direction.
6.
7.
Caution: The 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. Never pull for more than one minute at or near the rated
load. Do not maintain power to theWinch if the motor stalls as it can damage the motor
or gears.
Maintenance
Lubrication
1.
All moving parts within the Winch have been lubricated using high temperature lithium
grease at the factory. No internal lubrication is required.
2.
Lubricate cable periodically using a light penetrating oil.
Cable Assembly Replacement
(To be performed only by a qualified service technician.)
1.
2.
Move Cam Ring (11w) to the OUT position.
Extend Cable Assy. (36w) 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 replacement part
from Harbor Freight Tools.
4.
Retract Cable onto cable drum being careful not to allow kinking.
General
1.
2.
Keep vehicle battery in good condition.
Be sure that the Winch battery cables are not drawn tight against any surfaces which
could possibly damage them.
3.
4.
Periodically remove and clean cable connections to the battery fuse box and chassis
ground. Corrosion will reduce performance or may cause a short.
Cover the cables and Winch when not in use.
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 8
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Winch Parts List
Note: When ordering parts for the Winch unit, always include the suffix “w” after the part number.
Part
1w
Description
Qty.
Part
24w
25w
26w
27w
28w
29w
30w
31w
32w
33w
34w
35w
36w
37w
38w
39w
40w
41w
42w
43w
44w
45w
46w
Description
Qty.
1
-unused-
Gear (Input)
Thrust Disc
2w
Fairlead
1
6
6
6
6
1
1
1
2
1
2
2
4
1
1
2
6
1
1
1
1
1
1
1
3w
Bolt M10x35
Thrust Washer
3
4w
Lock Washer M10
Flat Washer M10
Nut M10
Bushing-Drum
2
5w
Gasket
1
6w
Cover Gear Housing
Screw M4x12
1
7w
End Bearing
Spring
6
8w
Drum
1
9w
Locking Ring
Tie Bar
Break/Shaft Assy.
Motor End Bearing Assy.
Solenoid Assembly
Switch Assembly
Cable Assy. 80’, 1/4” Dia.
Gear Carrier Assy. - Output
Gear Carrier Assy. - Inter.
Gear Carrier Assy. - Input
Solenoid Bracket
Binding Strap
1
10w
11w
1
Cam Ring
1
12-1w Bolt M6x27
12-2w Bolt M6x25
1
1
13w
14w
15w
16w
17w
18w
19w
20w
21w
22w
23w
Nut M6
1
Gear, Ring
1
Retainer Ring Gear
Half Ring
1
1
Bolt M6x19
1
Gear - Output
Bushing - Shaft
Roll Pin (3x9)
Cable Anchor
Bolt
Spring Washer 5mm
Bolt M12 x 25
6
2
Nut M12
2
Washer M12
2
Fairlead Mounting Plate
1
Gear (Intermediate)
NOTE:Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE 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 RE-
PLACE ANY PARTS OFTHE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EX-
PRESSLY STATESTHAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY
CERTIFIED AND LICENSEDTECHNICIANS AND NOT BYTHE BUYER.THE BUYER ASSUMES ALL RISK
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRSTO THE ORIGINAL PRODUCT OR REPLACE-
MENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS
THERETO.
REV 11/04; 05/05
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 9
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Winch Assembly Drawing
Note: When ordering parts for the Winch unit, always include the suffix “w” after the part number.
NOTE:Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
REV 05/05
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 10
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Solenoid Parts List and Assembly Drawing
Part No.
1s
Description
Screw
Cable Bracket
Nut M6
Lock Washer D6
Spacer
Qty. Part No. Description
Qty.
6
4
2
1
1
1
1
1
2
1
2
1
7
3
6
3
3
3
1
2
1
1
2
1
4
14s
15s
16s
17s
18s
19s
20s
21s
22s
23s
24s
25s
Nut
Washer
Solenoid (12V)
2s
3s
4s
5s
6s
7s
8s
9s
10s
11s
12s
13s
Battery Wire Assy. - Red, 60”
Battery Wire Assy. - Blk., 6 Ga.x 3-1/2” L
Copper Strap
Wire Assy. - Battery Black 60”
Washer 5/16 Shake-proof External Teeth
Copper Strap
Wire Assy. - Blk., 16 Ga.x 1-1/2” L
Wire Assy. - Blk., 10 Ga.x 6” L
Wire Assy. - Blk., 6 Ga.x 3” L
Bolt
Bracket
Screw
Connector (Female)
Solenoid Cover
Lock Washer
Cover (Female Conn.)
Terminal Tab
Note: When ordering parts for the Solenoid unit, always include the suffix “s” after the part number.
NOTE:Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
SKU 91780
For technical questions, please call 1-800-444-3353.
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Roller Fairlead Specifications, Parts List, and Assembly Drawing
Parts List
Description
Specifications
1
Cable Opening
~4 / " x 0.7"
Part
1f Nut
Qty.
8
8
11
3
3
Overall Dimensions ~8 / " x 5 / " x 3 / "
32
16
16
2f Lock Washer
3f Short Shaft
8
Weight
7.14 Lbs.
2
4f Nylon Bushing
2
3
3
5f Short Roller (~3 / " x 1 / " Diameter)
2
8
8
6f Long Shaft
7f Long Roller (~4 / " x 1 / " Diameter)
2
3
3
2
4
8
8f Base
1
Note:When ordering parts for the Fairlead unit, always include the suffix“f”after the part number.
Assembly Drawing
NOTE:Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
REV 05/05
SKU 91780
For technical questions, please call 1-800-444-3353.
Page 12
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