5,500 LB. CAPACITY 12 VOLT
WINCH WITH ROLLER FAIRLEAD
Model 91780
SET UP AND OPERATING INSTRUCTIONS
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
©
®
Copyright 2004 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. Diagrams within this manual may not be drawn proportionally. Due to continuing
improvements, actual product may differ slightly from the product described herein. Tools required for
assembly and service may not be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Manual Revised 10c
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6. Verify that the installation surface has no 10. Use as intended only. Do not lift items
hidden components or structural pieces
that will be damaged before drilling.
vertically or use for aircraft purposes.
11. 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.
OPERATION PRECAUTIONS
1. Do not exceed load capacity. Be aware
of dynamic loading! Sudden load
movement may briefly create excess
load causing product failure.
12. Inspect before every use; do not use if
damaged or if parts are loose. Examine
the winch for structural cracks, bends,
damage, frayed wire rope, and any
2. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during
operation.
other condition that may affect the safe
operation of the winch. Do not use the
winch even if minor damage appears.
3. Do not disengage clutch under load.
Engage clutch before starting.
13. Keep children and bystanders away
while operating. Distractions can cause
you to lose control.
4. Keep clear of Fairlead when operating.
Do not try to guide wire rope.
5. Place heavy rag or carpet
(not included) over wire
rope span 6 feet from
hook to help absorb
14. 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.
the force released if
the wire rope breaks.
15. Do not overreach. Keep proper footing
and balance at all times. This enables
better control of the winch in unexpected
situations.
6. Stay out of the direct line that the wire
rope is pulling. In case it slips or breaks,
it will “whiplash” along this line.
16. People with pacemakers should
consult their physician(s) before use.
Electromagnetic fields in close proximity
to heart pacemaker could cause
pacemaker interference or pacemaker
failure.
7. Do not winch a boat or other object with
anyone in or on it.
8. Use a spotter to assist you in assuring
that it is safe to operate the winch.
Make sure the spotter is out of the way
of the vehicle and the wire rope before
activating the winch.
17. Do not power the hook all the way into
the fairlead or winch.
9. Do not use the hand crank, if equipped,
to “assist” the winch.
SKU 91780
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thinner/longer cables or link multiple
cables together.
18.
Hook onto the object using
a pulling point, tow strap or
chain. Do not wrap the
wire rope around the
object and hook onto the
3. Have the winch serviced by a qualified
repair person using only identical
replacement parts. This will ensure that
the safety of the winch is maintained.
wire rope itself. This can cause damage
to the object being pulled, and kink or
fray the wire rope.
4. Maintain labels and nameplates on the
winch. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
19. Secure load after moving.
NO LOCKING MECHANISM.
20. 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.
5. WARNING: Handling the cord on this
product will expose you to lead, a
chemical known to the State of California
to cause cancer, and birth defects or
other reproductive harm. Wash hands
after handling. (California Health &
Safety Code § 25249.5, et seq.)
21. Keep at least 5 full turns of wire rope on
drum.
22. If wire rope begins to get entangled, stop
winch immediately and release wire rope
using switch.
SAVE THESE
INSTRUCTIONS.
15°
15°
45°
45°
23. Do not operate the winch at extreme
angles - do not exceed the angles shown
above.
SERVICE PRECAUTIONS
1. Wear ANSI-approved safety goggles
during installation, operation and service.
2. Use supplied power cords/wire rope or
cables listed in manual only. Do not use
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Schematics
SPECIFICATIONS
Capacity
Motor
5,500 lb. Single Line Pull on Layer 1
Permanent Magnet
3.4 HP
12 VDC
650 CCA or larger battery
Power Supply
Automatic Load
Holding Brake
Yes
3-Stage Planetary
294:1 Ratio
Gear Train
- 17.24” L x 6.3” W x 6.30” H without
Solenoid over motor
Overall
Dimensions
- 18.1” L x 6.30” W x 10.63” H with
Solenoid over motor
Drum Size
Ø2-1/2” Dia. x 5-1/2” W
Hook Opening 1/4”
Mounting Plate 6.54” x 4.5”
Mounting
6 Bolts (3w) M10 x 35 and Nuts M10
Hardware
Power Cords
60”, 5 Gauge (AWG)
Remote Cable 12’ cord
1/4” x 80’ Galvanized Steel
UNPACKING
Wire Rope
7,000 lb. Nominal Strength
(7 x 19 Aircraft* type)
When unpacking, make sure that the
item is intact and undamaged. If any parts
are missing or broken, please call Harbor
Freight Tools at 1-800-444-3353 as soon as
possible.
* “Aircraft” refers to the wire rope type, not the function
of the winch.
Performance of First Layer
Line Pull
Line Speed
Amp
Draw
40
104
122
147
192
COMPONENTS
(lb.)
0
2,000
3,000
4,000
5,500
(ft./min)
Winch
9.74
(Cable Assembly (36w))
Motor
Cables
(17s & 24s)
9.55
8.56
7.58
6.56
Cam Ring (11)
Motor
Solenoid
(34w)
Line Pull and Wire Rope Capacity by
Layer
Fairlead
(2w)
Hook
Wire Rope
Rated Line
Wire Rope
Layer
Pull (lb.)
Capacity (ft.)
1
2
3
4
5
5500
15
31.5
50
Switch
Assembly
(35w)
4650
4000
3550
3180
Battery Cables
(13s & 16s)
Mounting Hardware
70
78.7
Fairlead Mounting
Plate (45w)
Note: If a winch is to be used to pull a
vehicle, it should optimally be rated to a
single line pull at least twice the vehicle’s
weight.
Hook
Strap
(46w)
Figure 1
REV 10c
SKU 91780
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Mounting using the Mounting Frame
(Sold separately - SKU 90476):
INSTALLATION AND SETUP
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.
Mounting Frame
(Sold Separately - SKU 90476)
Bolt (47w)
Nut (6w)
Washer
(5w)
Mounting the Winch
1. Select a mounting site on the vehicle
bumper, truck bed, boat trailer, or other
suitable location, where the winch will
be perpendicular to the center line of the
vehicle.
Flanged Nut
(44w)
Flanged Bolt
(43w)
Fairlead (2w)
Fairlead Mounting
Plate (45w)
Figure 2
1. Mount the Fairlead (2w) to the Fairlead
Mounting Plate (45w) using two Flanged
Bolts (43w) and Nuts (44w).
NOTE: This winch can generate extreme
forces. Select a location that can
withstand the rated capacity without
damage or weakening. You may need to
use steel reinforcement plates, or weld
on additional bracing, depending on the
mounting location.
2. Mount the Fairlead/Mounting Plate
assembly to the Mounting Frame (sold
separately - SKU 90476) using two Bolts
(47w), Washers (5w) and Nuts (6w).
2. If the suggested mounting frame (SKU
90476 - sold separately) is not used, any
replacement mounting frame must be flat
and rated to at least the winch’s capacity.
Mounting Frame
(Sold Separately
SKU 90476)
Winch
Hardware Identification:
Use to
attach
Fairlead
(2w)
to
Plate
(45w)
Use to
attach
Plate
Fairlead (2w)
Figure 3
3. Mount the Winch to the Mounting Frame
using four Flanged Bolts (3w) and Nuts
(6w).
(45w) to
Frame
(SKU
90476)
Use to attach Winch to
Frame (SKU 90476)
4. Mount the Solenoid Assembly (34w)
according to one of the options in the
REV 10c
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Solenoid Assembly Mounting instructions
in the following section.
Mounting the Solenoid Assembly
Mounting Components
5. Place the Electric Winch assembly at
the location where it will be mounted.
Use the remaining holes in the Mounting
Frame as a template to mark holes for
mounting.
Solenoid Bracket (14s)
Solenoid
Assembly
Motor
(34w)
6. Verify that the installation surface has no
hidden components or structural pieces
that will be damaged before drilling.
Motor Cables
(17s & 24s)
7. Drill holes at the marked locations.
8. If the provided hardware does not
accommodate the installation, use
SAE grade 5 (Class 8.8) bolts (sold
separately), or higher, and torque to 35
ft-lb.
Battery Cables
(13s & 16s)
Figure 4
Mounting Option 1: Mounting the Solenoid
to the Mounting Frame
9. Attach the Hook to the loop at the end of
the Cable Assembly (36w).
In this configuration, the Solenoid
Assembly (34w) is connected to the
Mounting Frame (sold separately), in line
with the Motor.
Mounting using a different mounting plate:
1. The plate must be rated to at least the
winch’s capacity.
Solenoid Assembly
(34w)
Motor Terminals
2. Place the winch on the vehicle at the
desired location, and mark the mounting
holes. Decide how the Solenoid and
Fairlead will be mounted and mount
them in place.
Motor
Cables
(17s & 24s)
3. Before drilling, verify that the installation
surface has no hidden components or
structural pieces that will be damaged or
that could cause structural weakening.
Figure 5
4. Install the winch using the hardware
1. Line up the Solenoid Assembly with the
end of the Motor. Unthread one nut and
washer from each Motor Terminal and
attach the two Motor Cables (17s and
24s), securing in place with the nuts and
washers.
specified on the Specification chart.
5. Attach the Hook to the loop at the end of
the Cable Assembly (36w).
SKU 91780
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Solenoid
Assembly
(34w)
Battery Cables
(13s & 16s)
Solenoid Assembly
(34w)
Motor
Bracket
Mounting
Holes
Solenoid
Bracket
(40w)
Motor Cables
(17s & 24s)
Bracket Tie-down
Strap (41w)
Mounting Frame
(Sold Separately -
SKU 90476)
Figure 7
Figure 6
1. To attach the Solenoid Assembly (34w)
to the Solenoid Bracket (40w):
2. Unthread the nuts, spring washers and
washers from the four bolts on the base
of the Solenoid. Insert the bolts on the
base of the Solenoid Assembly (34w)
through the holes in the Mounting Frame
and secure in place by replacing the
washers, spring washers and nuts.
a. Unthread the nuts, spring washers and
washers from the four bolts on the base
of the Solenoid Assembly.
b. Position the Solenoid Bracket so the
Bracket Mounting Holes face away
from the Motor Assembly and the Motor
Cables (17s & 24s) on the Solenoid
Assembly face the Motor Assembly.
Mounting Option 2: Mounting the Solenoid
to the Solenoid Bracket (40w)
c. Route the Cables through the openings
in the Solenoid Bracket, then slide the
Bolts on the Solenoid Assembly through
the holes in the bottom of the Solenoid
Bracket and secure the Solenoid
Assembly to the Solenoid Bracket by
replacing the washers, spring washers
and nuts.
In this configuration, the Solenoid is
rotated so that the two short cables
attached to the Motor Terminals are
crossed and Solenoid Assembly
(34w) and Solenoid Bracket (40w) are
positioned over, and attached to, the
Motor.
d. Line up the Solenoid Assembly with the
end of the Motor Assembly and attach
the two Motor Cables (24s) to the motor
terminals.
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Turn the Power Switch of the
winch off and disconnect the
power and control cables before
making wiring connections.
Bracket mounted to
Tie Bar (10w) ends
Solenoid
Assembly (34w)
TO PREVENT
SERIOUS INJURY
FROM LEAKING BATTERY ACID:
Do not use a dirty, corroded or
leaking battery. Only use a 12V
automotive (or equivalent)
battery, in good condition.
Motor Cables
(17s & 24s)
1. Plan a route for the wiring from the
point of the vehicle where the winch
will be mounted or used to the battery.
This route must be secure, out of the
way of moving parts, road debris, or
any possibility of being damaged by
operation or maintenance of the vehicle.
For example, you may wish to route
the wires under the vehicle, attaching
it to the frame using suitable fasteners.
Do not attach the wires to the exhaust
system, drive shaft, emergency brake
cable, fuel line, or any other components
which may damage wiring through heat
or motion, or create a fire hazard.
Motor
Bracket
Tie-down
Strap (41w)
Figure 8
2. To attach the Solenoid Assembly/Bracket
to the Motor Assembly:
a. Slide the Bracket Tie-down Strap (41w)
over the hook in the center of the
Solenoid Bracket (40w).
b. Unthread the two Bolts (12-1w) and
Nuts (13w) from the motor end of the
Tie Bars (10w).
c. Rotate the Solenoid Assembly/Bracket
so that the holes on the side of the
Bracket line up with the end of the Tie
Bars (10w).
2. If you drill through the bumper or any
part of the body to route the wires, be
sure to install a rubber grommet in the
hole to prevent fraying of the wires at
that point.
d. Re-insert and tighten the Bolts (12-1w)
and Nuts (13w), securing the Solenoid
Bracket to the Tie Bar.
e. Secure the Solenoid Bracket to the
Motor by tightening the Bracket Tie
Down Strap (41w) around both the
Solenoid Bracket hook and the Motor
Assembly. Pull the Strap until secure.
3. Route the Battery Cables (13s & 16s)
from the point the winch will be used to
the battery, following the precautions
discussed above.
4. Attach the red Battery Cable (13s) to the
positive terminal on the battery.
Wiring
5. Attach the black Battery Cable (16s) to
the negative terminal of the battery.
TO PREVENT
SERIOUS INJURY
FROM EXPLOSION DUE TO
SPARKING AT THE BATTERY
CONNECTION:
SKU 91780
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Solenoid Assembly (34w)
Socket (6s)
OPERATION
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.
Switch
Assembly
(35w)
Socket Cover (2s)
Figure 9
6. Lift the Socket Cover (2s) on the
Solenoid Assembly (34w) and insert the
Switch Assembly (35w) connector into
the Socket (6s). Disconnect the Switch
Assembly when not in use.
1. Examine the wire rope. Do not use the
winch if the wire rope is frayed, kinked or
damaged.
2. Fully charge the vehicle’s battery.
Note: The attachment of the Motor Cables
(17s & 24s) determines the way the
toggle button on the Switch Assembly
(35w) operates. After the unit is mounted
and powered, check the direction of the
Power In and Power Out on the Switch
button. To change the direction on the
Switch, disconnect the Battery Cables
from the battery, switch the Motor Cable
connections on the Motor terminal, then
reconnect the Battery Cables.
3. Check the winch’s electrical connections.
All connections must be tight and clean.
4. Put the vehicle’s transmission in Neutral.
5. If the vehicle where the winch is mounted
is not supposed to move, engage the
emergency brake and block the wheels
using wheel chocks.
6. To pull out the wire rope, move the Cam
Ring (11w) to the OUT position, slide the
loop of the Hook Strap (46w) over the
hook, then pull on the Hook Strap to pull
out the wire rope.
Preparing the Wire Rope
BEFORE FIRST USE:
WARNING! Leave at least five full
turns of wire rope on the drum.
1. The wire rope must be properly coiled
under tension to be able to support a
load without damage.
2. Uncoil the wire rope, except for 5 full
wraps.
3. Recoil the wire rope back into the winch
under at least 500 lb. of tension.
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Safety Clasp
Double Line Rigging:
a. A double 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:
• it utilizes the lower layers of wire rope
that have higher capacity, and
7. Hook onto the object using a pulling
point, tow strap, tree strap, or chain.
Make sure the hook’s safety clasp is fully
closed.
• it halves the load on the winch through
pulley action.
Do not wrap the wire
rope around the object
and hook onto the wire
rope itself. This can
damage the object being
Stationary
Winching
Vehicle
(Chock tires, and
set parking brake)
Load
Carpet
pulled, and kink or fray the wire rope.
8. 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.
b. Connect the wire rope for a double line
system as shown above. Use a pulley
block (not included) properly rated for
the load to be pulled and designed to be
operated with this winch’s wire rope.
9. Place heavy rag or carpet
(not included) over wire
rope span 6 feet from
hook to help absorb
c. Loop the wire rope around the pulley and
connect to another part of the vehicle’s
chassis or to a separate anchor point.
Do not anchor the cable back to the
winch or winch mount.
the force released if
the wire rope breaks.
10. Re-engage the clutch by moving the
Cam Ring to the IN position.
11. 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 power. 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.
SKU 91780
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12. Attach the Switch Assembly (35w) to the CAUTION Do not use the winch in a
Socket (6s) on the Solenoid Assembly
(34w).
constant duty application, it is
designed for INTERMITTENT USE
ONLY. Keep the duration of the
13. When it is safe to do so, use the button
on the Switch Assembly to retract the
wire rope, and winch the item as desired.
Do not power the hook all the way
into the fairlead to prevent damage.
pulling job as short as possible. If the
motor becomes very hot to the touch,
stop and let it cool down for several
minutes. Do not pull for more than
one minute at or near the rated load.
Do not maintain power to the Winch if
the motor stalls. Double Line Rigging
will help prevent overloading and
should be used whenever practical.
15°
15°
17. When finished pulling the load, reverse
the direction of the winch just enough to
release tension on the Cable Assembly
(36w) so that you can unfasten the Hook
from the load and reel in the cable.
45°
45°
18. To prevent accidents, turn off the winch
and disconnect its power supply after
use. Clean, then store the winch indoors
out of children’s reach. If the cable is
wet, dry it then apply light oil right after
use.
14. Do not operate the winch at extreme
angles - do not exceed the angles shown
above. Pay attention to how the wire
rope is coiling onto the drum. If it is
building up on one end of the drum, stop,
uncoil the wire rope and recoil it from a
less severe angle to prevent damage.
If the object to be pulled must be pulled
at an angle in relation to the winch, use
a pulley and an anchor point directly in
front of the winch, as shown, to keep the
cable pull straight.
15. WARNING! Stop the winch and release
tension on the wire rope before moving
the rag or carpet placed on it.
16. Do not continue use of the winch until
the battery is completely run down. You
may wish to keep the engine running
while using this winch, to continually
recharge the battery. However, exercise
extreme caution when working around a
running vehicle.
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4. The winch’s internal mechanism is
permanently lubricated. Do not open
the housing. However, if the winch is
submerged, it should be opened, dried,
and relubricated by a qualified technician
as soon as possible to prevent corrosion.
MAINTENANCE AND
SERVICING
Procedures not specifically
explained in this manual must
be performed only by a qualified
technician.
Cable Replacement
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
1. Move the Cam Ring (11w) to the OUT
position.
OPERATION:
2. Manually pull the Cable out to it’s full
length. Note how the existing cable is
connected to the inside of the drum.
Unplug the Switch Assembly
(35w) connector from the Socket
(6s) on the Solenoid Assembly
(34w) and disconnect the Battery
Cables (13s & 16s) before
performing any inspection,
maintenance, or cleaning
procedures.
3. Remove the old Cable Assembly and
attach the new assembly.
CAUTION: Do not replace with inferior cable.
Always use an approved replacement
part from Harbor Freight Tools.
TO PREVENT SERIOUS INJURY
FROM WINCH FAILURE:
Do not use damaged equipment.
If abnormal noise or vibration
occurs, have the problem
4. The cable must be rewound in the
direction shown on the winch. Retract
the Cable onto the cable drum being
careful not to allow kinking.
corrected before further use.
5. Coil the wire rope 5 full wraps.
6. Then, coil the wire rope into the winch
under at least 500 lb. of tension.
Cleaning, Maintenance, and
Lubrication
1. BEFORE EACH USE, inspect the
general condition of the winch. Check
for loose hardware, misalignment or
binding of moving parts, cracked or
broken parts, damaged electrical wiring,
corroded or loose terminals, and any
other condition that may affect its safe
operation. Examine the wire rope. Do
not use the winch if the wire rope is
frayed, kinked or damaged.
2. AFTER USE, wipe the external surfaces
of the winch with a clean cloth.
3. Lubricate the wire rope occasionally with
a light oil.
SKU 91780
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Troubleshooting
Problem
Possible Causes
Likely Solutions
1. Connect Switch properly.
Motor does not turn 1. Switch not connected properly.
on.
2. Loose power cord connections.
2. Tighten all connections.
3. Fully charge battery.
3. Battery needs charging.
4. Solenoid malfunctioning.
4. Tap solenoid to loosen contacts. Briefly
apply 12 volts directly to coil terminals.
Clicking indicates proper activation.
5. Defective Switch.
6. Defective motor.
5. Replace Switch.
6. Check for voltage at armature port with
Switch pressed. If voltage is present, replace
motor.
7. Water has entered motor.
7. Allow to drain and dry. Run in short bursts
without load until completely dry.
8. Internal damage or wear.
Motor runs but cable Clutch not engaged.
drum does not turn.
8. Have technician service winch.
Move the Cam Ring to the In position. If
problem persists, a qualified technician needs
to check and repair.
Motor runs slowly
or without normal
power.
1. Insufficient current or voltage.
1. Battery weak, recharge. Run winch with
vehicle engine running.
2. Loose or corroded battery cable
connections.
2. Clean, tighten, or replace.
3. Incorrect power cords.
1. Defective or Stuck solenoid.
3. Use only supplied power cords.
1. Tap Solenoid to loosen contacts. Repair or
replace solenoid.
Motor runs in one
direction only.
2. Defective Switch Assembly.
1. Incorrect power cords.
2. Replace Switch Assembly.
1. Use only supplied power cords.
Motor overheats.
2. Winch running time too long.
2. Allow winch to cool down periodically.
Follow all safety precautions whenever diagnosing or servicing the winch.
Disconnect power supply before service.
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 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.
Page 14
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SKU 91780
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WINCH PARTS LIST & ASSEMBLY DIAGRAM
Part
2w Fairlead
Description
Qty
1
Part
Description
Qty
3
26w Thrust Washer
3w Bolt M10 x 34
5w Washer M10
6w Nut M10
7w End Bearing
8w Spring
4
2
6
1
27w Bushing-Drum
28w Gasket
29w Cover Gear Housing
30w Screw M5 x 12
31w Drum
2
1
1
6
6
1
9w Locking Ring
10w Tie Bar
11w Cam Ring
12w Bolt M8 x 30
13w Nut M8
14w Gear Ring
1
2
1
4
4
1
1
2
6
1
1
1
1
1
1
1
32w Break / Shaft Assembly
33w Motor End Bearing Assembly
34w Solenoid Assembly
35w Switch Assembly
36w Cable Assembly 80’ L x 1/4” D
37w Gear Carrier Assembly - Output
38w Gear Carrier Assembly - Intermediate
39w Gear Carrier Assembly - Input
40w Solenoid Bracket
41w Bracket Tie-Down Strap
42w Spring Washer 5 mm
43w Bolt M12 x 25
44w Nut M12
45w Fairlead Mounting Plate
46w Hook Strap
1
1
1
1
1
1
1
1
1
1
6
2
2
1
1
2
15w Gear Retainer Ring
16w Half Ring
17w Bolt M6 x 20
18w Gear - Output
20w Roll Pin Ø4 x 10
21w Cable Anchor
22w Bolt M6 x 12
23w Gear (Intermediate)
24w Gear (Input)
25w Thrust Disc
47w Bolt M10 x 34 (none standard)
Note: When ordering parts for Winch, include the suffix “w” after the part number.
5
REV 10c
SKU 91780
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Page 15
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SOLENOID PARTS LIST & ASSEMBLY DIAGRAM
Part
Description
Qty
1
1
6
4
Part
Description
Qty
1
1
4
1
1s Plastic Housing
13s Battery Cable (red) (+)
14s Solenoid Bracket
15s Nut M8
2s Socket Cover
3s Flat Washer
4s Spring Washer
5s Screw M5 x 10
6s Socket
16s Battery Cable (Black) (-)
17s Motor Cable (Black) (-)
18s Nut M5
4
1
1
1
7s Screw M5 x 12
8s Copper Spacer
9s Screw M5 x 12
10s Solenoid
2
1
2
1
19s Spacer
20s Flat Washer
21s Spring Washer
22s Nut M6
3
8
8
8
11s Ground Cable
12s Screw M6 x 30
1
4
23s Fiberglass Sleeve
24s Motor Cable (Black) (+)
1
1
REV 10c
Page 16
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SKU 91780
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ROLLER FAIRLEAD PARTS LIST & ASSEMBLY DIAGRAM
Part
1f
2f
3f
4f
Description
Qty
Part
5f
6f
7f
8f
Description
Short Roller (Ø 3-3/8: x 1-3/8”
Long Shaft
Long Roller (Ø 4-3/4” x 1-3/8”)
Base
Qty
Cap Nut
8
8
2
8
2
2
2
1
Lock Washer
Short Shaft
Nylon Bushing
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.
SKU 91780
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Page 17
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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 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.
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353
Page 18
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SKU 91780
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