Chicago Electric Refrigerator 40764 User Manual

ELECTRIC WINCH  
12 VOLT  
Models40764, 93752,  
& 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  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
Read all instructions before using this tool!  
1.  
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.  
2.  
3.  
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.  
4.  
5.  
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.  
6.  
7.  
8.  
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 load.  
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.  
9.  
Remove adjusting keys and wrenches. Check that keys and adjusting wrenches are  
removed from the tool or machine work surface before operating.  
10. Avoid unintentional starting. Remove the Switch Ass’y (35) when not in use.  
11. Stay alert. Watch what you are doing, use common sense. Do not operate any equip-  
ment when you are tired.  
12. 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  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 3  
& 91905  
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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 use accessories intended for  
use with this tool. Approved accessories are available from Harbor Freight Tools.  
14. Do not 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 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.  
27. 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  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 4  
& 91905  
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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.  
2.  
3.  
Mount the Fairlead (2) to the Mounting Frame  
(1) using supplied bolts, nuts, and wash-  
ers.  
Winch  
Mount Electric Winch to the Mounting Frame  
(1) using Bolt (3) and Nut (6). See illustration  
to the right.  
Connect the Solenoid Output Power Lines  
(short-black) (17s, 24s) to either terminal  
of the Electric Winch as shown below, left.  
Securely tighten nuts.  
Mounting  
Frame (1)  
Fairlead (2)  
4.  
There are two options for mounting the so-  
lenoid:  
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.  
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40764, 93752,  
& 91905  
SKUs  
for technical questions, please call 1-800-444-3353.  
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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  
Bars (10) with the Bolts (12) and Nuts (13) that  
were previously removed. Tighten. Secure the  
Solenoid Bracket (40) to the Motor End Bearing  
Ass’y (33) by attaching the Bracket Tie Down  
Strap (41) around both the Solenoid Bracket  
and the Motor End Bearing Ass’y. Pull Strap  
until secure. Attach the Solenoid to the bracket  
using the Flat Washers (20s), Spring Washers  
(21s), and Nuts (22s).  
Bracket  
Nut  
Bracket  
Tie Down  
Strap  
5.  
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.  
6.  
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.  
7.  
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.  
9.  
Disengage the clutch by moving the Cam Ring (11) to the  
OUT position.  
(11)  
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.  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 6  
& 91905  
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Operation  
1.  
2.  
Disengage the clutch by moving the Cam Ring (11) to the OUT position.  
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.  
WARNINg!: 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.  
(6s)  
3.  
4.  
5.  
6.  
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).  
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 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  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 7  
& 91905  
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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 CableAssembly (36) periodically using a light penetrat-  
ing oil.  
Cable Assembly Replacement  
1.  
2.  
Move Cam Ring (11) to the OUT position.  
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.  
5.  
Retract Cable Assembly onto cable drum being careful not to allow kinking.  
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  
1. Insert Switch Assy all the way into connector  
2. Tighten nuts on all cable connections  
Motor does not  
turn On  
1. Switch Assy not connected  
properly  
2. Loose battery cable  
connections  
3. Tap solenoid to loosen contacts. Apply 12 volts to  
coil terminals directly. A clicking indicates proper  
activation  
3. Solenoid malfunctioning  
4. Defective Switch Assy  
5. Defective motor  
4. Replace Switch Assy  
5. Check for voltage at armature port with Switch  
pressed. If voltage is present, replace motor.  
6. Water has entered motor  
6. Allow to drain and dry. Run in short bursts without  
load until completely dry  
Motor runs but  
cable drum does  
not turn  
Cam Ring (clutch) not engaged  
Move the Cam Ring to the In position. If problem  
persists, a qualified technician needs to check and  
repair  
Motor runs slowly 1. Insufficient current or voltage 1. Battery weak, recharge. Run winch with vehicle  
or without normal  
power  
motor running  
2. Loose or corroded battery  
cable connections.  
2. Clean, tighten, or replace  
Allow winch to cool down periodically  
Motor overheating Winch running time too long  
Motor runs in one 1. Defective or stuck solenoid  
1. Tap solenoid to loosen contacts. Repair or  
replace solenoid  
direction only  
2. Defective Switch Assy  
2. Replace Switch Assy  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 8  
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Parts Lists and Diagrams  
Winch Parts List  
IMPORTANT!  
When ordering parts, reference the appropriate number as follows:  
Sku 40764 - 8,000 lb.= 87495  
Sku 93752 - 9,000 lb.= 87478  
Sku 91905 - 10,000 lb.= 87496  
Item  
Description  
Q’ty  
Item  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
Description  
Cap Screw M6x12  
Q’ty  
1
1
Mounting Frame (Box B)  
1
Fairlead  
Gear, intermediate-sun  
Gear, input-sun  
1
(Single Piece Hawse for Sku 40764;Roller  
Fairlead Assembly for Skus 93752 & 91905  
– see Roller Fairlead parts list)  
1
2
1
Thrust Disc  
1
Thrust Washer  
3
3
Screw M10x34  
Nut M10  
6
6
1
6
1
2
1
4
4
1
1
2
6
1
1
1
1
Bushing  
2
6
Gasket  
1
7
End Bearing  
Spring  
Gear Housing Cover  
Screw M5x12  
1
8
6
9
Locking Ring  
Tie Bar  
Drum  
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
Brake/shaft assy  
Motor End Bearing Assy  
Solenoid Assy (see parts list S)  
Switch Assy  
1
Cam Ring  
1
Bolt M8 x 30  
Nut M8  
1
1
Ring Gear  
Cable Assy Ø3/8” x100’  
Gear Carrier Assy, output  
Gear Carrier Assy, intermediate  
Gear Carrier Assy, input  
Solenoid Bracket  
Bracket Tie-down Strap  
Spring Washer Ø5  
1
Gear Ring Retainer  
Brake Shoe  
Screw M6x20  
Gear Out-sun  
Shaft Bushing  
Roll Pin Ø3x10  
Cable Anchor  
1
1
1
1
1
1
NOTE: Some parts are listed and shown for illustration purposes only  
and are not available individually as replacement parts.  
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  
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  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 9  
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Winch Diagram  
40764, 93752,  
& 91905  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 10  
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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 lb.= 87478  
Sku 91905 - 10,000 lb.= 87496  
Part  
1f  
Description  
Q’ty  
Part  
5f  
Description  
Q’ty  
Frame  
1
2
2
2
Short Shaft  
Bushing  
C-clip  
2
8
8
2f  
Long Roller  
Long Shaft  
Short Roller  
6f  
3f  
7f  
4f  
Roller fairlead Diagram  
40764, 93752,  
& 91905  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 11  
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Solenoid Parts List  
IMPORTANT!  
When ordering parts, reference the appropriate number as follows:  
Sku 40764 - 8,000 lb.= 87495  
Sku 93752 - 9,000 lb.= 87478  
Sku 91905 - 10,000 lb.= 87496  
Item  
1s  
2s  
3s  
4s  
5s  
6s  
7s  
8s  
9s  
Description  
Plastic Housing  
Q’ty  
1
Item  
Description  
Q’ty  
1
13s + Battery Cable (Red)  
14s Base Plate  
Socket Cover  
1
1
Flat Washer  
6
15s Nut M8  
4
Spring Washer  
4
16s Battery Cable (Black)  
17s Output Cable (Black)  
18s Nut M5  
1
Combination-head Screw M5x10  
Socket  
4
1
1
2
Self-tapping Screw F 3x12  
Copper Spacer  
2
19s Spacer  
4
1
20s Flat Washer  
8
Combination-head ScrewM5x12  
2
21s Spring Washer  
22s Nut M6  
8
10s Solenoid  
1
8
11s Ground Cable  
12s Screw M6x30  
1
23s Fiberglass Sleeve  
24s + Output Cable (Red)  
1
4
1
Solenoid Diagram  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 12  
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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, 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 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  
40764, 93752,  
SKUs  
for technical questions, please call 1-800-444-3353.  
Page 13  
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