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Owner’s Manual & 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. 21b
When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright
©
2020 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.
To ols required for assembly and se rv ic e m ay n ot b e i nc lu de d .
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
Page 2 For technical questions, please call 1-888-866-5797. Item 57918
Table of Contents
Specifications ............................................................2
Safety ........................................................................3
Setup .........................................................................6
Operation ..................................................................13
Maintenance .............................................................14
Parts List and Diagram .............................................18
Warranty ...................................................................20
Specifications
Rated Single
Line Pull
12,000 lb (5443 kg)
Application
Vehicle Recovery /
For Trucks and SUV’s
Motor
Power IN &
Power OUT
Yes
Duty Cycle Rating
5% (45 sec at Max Rated Load;
14 min, 15 sec Rest)
Remote Control
Gear Train 3-Stage Planetary
Gear Ratio 210:1
Freespool Rotating Ring Gear
Brake Automatic Load Holding
Drum (Dia. x L)
Clevis Hook
3/8", Replaceable with
Spring-loaded Safety Latch
Fairlead Steel Roller Fairlead
Sound Rating 85 dB
Wire Rope
Size / Type
Battery
Battery Cables
Mounting Bolt
Pattern
Mounting
Hardware
Winch:
Fairlead:
Overall Dimensions
(L x D x H)
23.2" x 6.67" x 9.96"
Shipping Weight 103.95 lb (47.15 kg)
IP Rating IP68 / IP69K
Layer Rated Line Pull Wire Rope Capacity
1
12000 lb (5443 kg)
2
9517 lb (4317 kg)
3
7885 lb (3577 kg)
4
6732 lb (3054 kg)
First Layer of Wire Rope Performance
1
Line Pull lb (kg) Line Speed fpm (mpm) Amp Draw (
@
12V)
0 (0) 32.6 (9.9) 51
3000 (1361) 12.1 (3.7) 157
6000 (2722) 8.9 (2.7) 238
9000 (4082) 6.7 (2.0) 318
12000 (5443) 4.1 (1.25) 429
Page 3For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
WARninG SyMBOLS AnD DEFiniTiOnS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
Symbol Property or Statement
Wear heavy-duty, cut- and
abrasion-resistant leather gloves.
Wear AnSi-approved safety glasses.
Cut or sever hazard.
Roller entanglement hazard.
Hot surface burn hazard.
Fire hazard.
Caustic chemical (acid) hazard.
Explosion hazard.
Do not loop the wire rope around
object and hook onto itself.
Do not place finger(s) through hook.
Fingers may be caught and get
pulled into fairlead or drum.
Pull hook using strap only.
Symbol Property or Statement
Do not use winch in overwind
orientation. (Wire rope
enters/exits at the top.)
use winch only in
underwind orientation.
(Wire rope enters/exits at the bottom.)
VDC
Volts Direct Current
A
Amperes
CCA
Cold Cranking Amperes
HP
Horsepower
fpm
Feet Per Minute
mpm
Meters Per Minute
RPM
Revolutions Per Minute
iP
International Protection rating
Classifies the degrees of protection provided
against the intrusion of solid objects,
dust, accidental contact, and water.
G8
Grade 8
A fastener strength rating.
Page 4 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
iMPORTAnT SAFETy inFORMATiOn
WARninG! Read all instructions. Failure to follow all instructions listed on page 4 may result
in fire, serious injury and/or DEATH.
The warnings and precautions discussed 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. 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.
4. Mounting location and hardware
must support Winch and load.
5. Use supplied power cords and wire rope listed
in manual only. Do not use thinner/longer
cables or link multiple cables together.
6. Do not route electrical cables near sharp edges
or parts that will move or become hot.
7. Ventilate area well before and while working
on battery. Explosive invisible hydrogen gas
can accumulate and then explode when ignited
by a spark from the battery connection.
8. Only connect to a clean, corrosion free battery.
9. Do not lean over or come in contact with
battery while making connections.
10. Remove all metal jewelry before
working near battery.
11. Connect the red cable to the Disconnect Switch,
then connect the 12" 2AWG cable to the Disconnect
Switch and the positive battery terminal. Connect
the black cable to the negative battery terminal.
12. Insulate all exposed wiring and
terminals after installation.
13. Install Winch and Fairlead in underwind
orientation, so that the Wire Rope enters and
exits the Winch at the bottom of the drum.
Page 5For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Service Precautions
1. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during service.
2. Disconnect power to Winch and allow it
to cool completely before service.
3. Use supplied power cords, wire rope or cables
listed in manual only. Do not use thinner/
longer cables or link multiple cables together.
4. 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.
5. Maintain labels and nameplates on the Winch.
These carry important safety information.
If unreadable or missing, contact
Harbor Freight Tools for a replacement.
SAVE THESE inSTRuCTiOnS.
Page 6 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
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.
What’s in the Box
Winch x 1 Roller Fairlead x 1
Hook x 1
Remote Control x 1
Ground Cable x 1 Disconnect Switch x 1
Remote Control Cable x 1
Red Hook Strap x 1 Control Box Baseplate x 1 Sheath (red, black, yellow) x 3
Small Black
Wire Connector x 1
Small Black
Wire Extension x 1
Power Cables
(relocation kit) x 3
Extended Copper Screw x 3
Disconnect Switch Cable x 1
Terminal Box x 1
Terminal Box Cover x 1
Instruction Books
• Manual (this document)
• Guide to Winching
Page 7For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Mounting the Winch
1. Make sure the Winch will fit the chosen mounting
area. If relocating the Control Box is necessary
or desired, perform the removal and installation
of cables to the Winch before mounting. Refer
to Relocating the Control Box on page 8.
2. The mounting plate must be rated to
at least the Winch’s capacity.
3. Align the Winch perpendicular to center line of
the vehicle at the desired location, and mark the
locations of the winch base holes. Compare the
dimensions of the marked holes to Figure A.
4. Before drilling, verify that the installation
surface has no hidden components or
structural pieces that will be damaged.
nOTE: This Winch can generate extreme
forces. Select a location that can withstand the
rated capacity without damage or weakening.
Steel reinforcement plates may be needed or a
certified welder may need to weld on additional
bracing depending on the mounting location.
5. Drill holes appropriate for the hardware
at the marked locations.
note: Depending on the vehicle application, it may
be beneficial to install the wiring before mounting
the Winch. Check all terminal access and plan
wiring routes before mounting the Winch.
6. Install the Winch using hardware specified
on the specification chart. Tighten fasteners
to the following torque values:
Winch mounting fasteners
Figure A: Winch Dimensions
7. Mount the Fairlead centered on the Winch
to guide the Rope onto the Winch drum.
8. Install the Fairlead using hardware specified
on the specification chart. Tighten fasteners
to the following torque values:
Fairlead mounting fasteners
Figure B: Fairlead Mounting Dimensions
Page 8 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
Relocating the Control Box (optional)
TO PREVEnT SERiOuS inJuRy FROM EXPLOSiOn
DuE TO SPARKinG AT THE BATTERy COnnECTiOn:
unplug the Remote Control Cable and disconnect the Battery Cables
before making other wiring connections.
1. Engage the clutch on Winch.
2. Disconnect the vehicle battery
cables, negative terminal first.
3. Disconnect the Ground Cable and Small Black
Wire from terminal on rear of Winch. Make
sure the Small Black Wire that connects to the
Control Box is disconnected and hanging freely.
Small
Black
Wire
Ground
Cable
4. Remove the Terminal Cover by unscrewing two
the six Motor Terminal Nuts and three
Copper Plates. Retain all the hardware.
Terminal Cover
Motor
Terminal
nuts
Copper
Plates
Screw
5.
Box in place and gently lift it off of the Winch.
Screw
Control
Box
6. Attach the Control Box Baseplate to the Control Box
Screw
Control
Box
Control
Box
Baseplate
7. Install the three Extended Copper Screws
to the terminal on the motor. Mount the
screws. Do not overtighten screws.
Screw
Terminal
Box
Extended
Copper
Screw
Page 9For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
8. Connect three Power Cables (Control Box
Relocation Kit) to the Extended Copper
Screws on motor terminal using three of the
Motor Terminal Nuts removed in step 4.
Motor
Terminal
nuts
Power
Cables
9. Install the Terminal Box Cover on the Terminal
Screws. Do not overtighten screws.
Terminal
Box
Screw
Terminal
Box Cover
10. Connect three Power Cables (control box
relocation kit) to the Control Box using remaining
three Motor Terminal Nuts removed in step 4.
Motor
Terminal
nuts
Control
Box
black
red
yellow
11. Use the Small Black Wire Connector and
Small Black Wire Extension to lengthen
the Small Black Wire from the Control Box.
Reconnect the Ground Cable and Small Black
Wire to the backside of the Winch motor.
Small Black
Wire Extension
Connector
Black
Ground
Cable
Red
Battery
Cable
12.
Screws onto the Winch.
Screw
13. Place the Control Box on a solid mounting
surface in a suitable place near enough to the
Winch to allow the cables to be routed properly.
14. Verify that the installation surface has no
hidden components or structural pieces
that will be damaged before drilling.
15. Secure the Control Box assembly in place
with Baseplate mounting hardware.
Page 10 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
Wiring
TO PREVEnT SERiOuS inJuRy FROM EXPLOSiOn
DuE TO SPARKinG AT THE BATTERy COnnECTiOn:
unplug the Remote Control Cable and disconnect the Battery Cables
before making other wiring connections.
TO PREVEnT SERiOuS inJuRy FROM LEAKinG BATTERy ACiD:
Do not use a dirty, corroded or leaking battery.
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.
WARninG! TO PREVEnT SERiOuS inJuRy: Do
not attach the wires to the exhaust system, drive
shaft, emergency brake cable, fuel line, or any other
components which may create damage to the wiring
through heat or motion, or create a fire hazard.
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.
3. Route the Cables from the Winch to the battery,
following the precautions discussed above.
Refer to Figure C.
Disconnect
Switch
Black
Ground
Cable
Red
Battery
Cable
12"
Cable
Socket
Cover
Small
Black
Wire
Figure C: Wiring Connections
4. Attach the 12" 2AWG Disconnect Switch Cable
to the positive terminal on the battery.
5. Attach the 12" 2AWG Cable from the battery
to either terminal on the Disconnect Switch.
6. Attach the red Battery Cable from the Winch to
the remaining terminal on the Disconnect Switch.
7. Attach the black Ground Cable and the Small Black
Wire to the terminal at the rear of the Winch.
8. Attach the black Ground Cable from the Winch
directly to the negative terminal of the battery.
9. Lift the Socket Cover exposing the Remote Control
socket and Wireless Receiver Switch. Connect
the Remote Control Cable to the socket and the
Remote for wired remote control. For wireless
control do not use the Remote Control Cable and
turn on the Wireless Receiver Switch. Refer to
Remote Control Instructions on page 12.
10. Turn on the Disconnect Switch and operate the
remote controls briefly to test Winch function
and drum rotation direction. If operation is
reversed, the Battery Cables may be connected
backwards. Correct any such issue before use.
in
OuT
Figure D: Remote Controls
11. Disconnect and turn off the Remote
Control when not in use.
12. Turn off the Disconnect Switch when the
Winch is not in use or when the vehicle
has returned to on-highway operation.
Page 11For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Disconnect Switch
WARninG! TO PREVEnT SERiOuS inJuRy: Off-highway driving subjects the vehicle and
wiring to much higher vibrations than on-highway driving which can cause a breakdown of wiring
insulation over time. Use the high current Disconnect Switch included with this Winch to turn
OFF the power to the Winch when it is not in use to help reduce the risk of a short circuit.
1. To use the Winch, use the Disconnect Switch
to turn the power to the Winch ON.
2. When the Winch is not in use, turn the
Disconnect Switch OFF to reduce the risk of
a short on the main power to the Winch.
Preparing the Wire Rope
The Wire Rope must be properly coiled under tension
to be able to support a load without damage.
1. Find a suitable location where the Rope can be
spooled onto the Winch while anchored to a solid
object. Approximately 70 feet will be required.
Alternately, a snatch block (sold separately) may
be used to reduce the distance to 35 feet.
2. Move the Clutch Handle to the Freespool
position and uncoil the Wire Rope until 5 wraps
remain on the drum. Move the Clutch Handle
back wto the Engaged position.
3. Slowly and carefully move the vehicle in
reverse to remove slack from the line.
4. Place the vehicle in neutral. Spool the Wire
Rope back into the Winch while gently applying
the brakes. If the ground is flat, shallow
mud or dirt, the brakes can be fully applied.
Pavement can generate much higher loads,
in which case only light braking is needed.
5. Use a second person to monitor the rope
spooling evenly onto the drum.
6. The last layer of Rope can be
put on without tension.
Page 12 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
Remote Control instructions
Wired Operation
1. To use the Remote Control in a wired
configuration, connect the Remote Control Cable
to the bottom of the Remote Control and to the
Remote Control Socket on the Control Box.
in
OuT
Rocker
Switch
Blue indicator Light
Red indicator Light
Remote
Control Cable
Remote
Control Socket
2. The blue indicator light will come on indicating
the Remote Control is ready for use.
3. With the Clutch Handle in the Engaged
position, press IN on the Rocker Switch to
light will flash during winding.
in
OuT
4. Press OUT on the Rocker Switch
to extend the Wire Rope out.
Wireless Operation
1. For wireless Remote Control operation, turn on
the Wireless Receiver Switch on the Control Box.
Wireless Receiver Wireless Receiver
SwitchSwitch
Control Control
BoxBox
2. Press and hold the ON/OFF Switch on the
Remote for approximately 2 seconds until
the red indicator light comes on, indicating
the Remote Control is ready for use.
in
OuT
Rocker
Switch
On/OFF
Switch
Red indicator Light
3. With the Clutch Handle in the Engaged
position, press IN on the Rocker Switch to
light will flash during winding.
4. Press OUT on the Rocker Switch
to extend the Wire Rope out.
in
OuT
5. To turn off the Remote Control, press and
hold the ON/OFF Switch until the red indicator
light goes out, approximately 2 seconds.
Turn off the Wireless Receiver Switch.
note: The Remote Control will automatically shut itself
off after 2 minutes of inactivity to save the battery.
Page 13For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Operation
Before operating this Winch, refer to the Harbor Freight Tools publication Guide to Winching included with the
Winch for important operational safety information, winch basics, winching tips, and general winch operating
procedures. If this guide is unreadable or missing, contact Harbor Freight Tools for a replacement.
Read the EnTiRE iMPORTAnT SAFETy inFORMATiOn section at the beginning of the
Guide to Winching including all text under subheadings therein before use of this product.
The instructions included in the Guide to Winching are basic guidelines only and cannot
cover all situations encountered during use. The operator and assistants must carefully
plan usage to prevent accidents.
Page 14 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
TO PREVEnT SERiOuS inJuRy FROM ACCiDEnTAL OPERATiOn:
unplug the Remote Control Cable and disconnect the Battery Cables before performing any
inspection, maintenance, or cleaning procedures.
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
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
• any other condition that may
affect its safe operation.
Examine the Wire Rope. Do not use the Winch
if the Rope is frayed, kinked or damaged.
2. AFTER uSE, wipe external surfaces of
the Winch with clean cloth. If the Winch
is submerged during use, rinse thoroughly
with fresh, clean water when finished.
3. The Winch’s internal mechanism is permanently
lubricated. Do not open the housing.
Wire Rope Replacement
1. Move Clutch Handle to the Freespool position.
2. Extend the Wire Rope to its full length,
noting how the existing Rope is
connected to the inside of the drum.
3. Remove old Wire Rope and attach new assembly.
CAuTiOn! Do not replace with inferior wire rope.
Only use a wire rope rated to the same rating
cited on the specification chart or better.
4. Retract Wire Rope onto Rope drum being
careful not to allow kinking. Refer to
instructions for tensioning the Wire Rope
under Preparing the Wire Rope on page 11.
5. Test Winch for proper operation.
Page 15For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Troubleshooting
Problem Possible Causes Likely Solutions
Motor
overheats.
1. Incorrect power cords.
2. Winch running time too long.
3. Insufficient current or voltage.
4. Loose motor connections.
1. Use only supplied power cords.
2. Allow Winch to cool down periodically.
3. Fully charge battery. Run Winch
with vehicle motor running.
4. Check and tighten motor connections to Control Box.
Motor does
not turn on.
1. Remote Socket not
connected properly.
2. Loose battery cable connections.
3. Insufficient current or voltage.
4. Defective contactor.
5. Wireless Receiver
Switch turned OFF.
6. Wireless Remote turned OFF.
7. Winch Disconnect
Switch turned OFF.
8. Low batteries in Wireless Remote.
9. Defective motor.
10. Loose Control Box ground cable.
11. Internal wear or damage.
1. Insert Remote Socket all the way into connector.
2. Tighten nuts on all cable connections.
3. Fully charge battery. Run Winch
with vehicle motor running.
4. Replace Control Box.
5. Turn ON Wireless Receiver Switch.
6. Turn ON Wireless Remote.
7. Turn ON Winch Disconnect Switch.
8.
9. Check for voltage at armature port with Switch
pressed. If voltage is present, replace motor.
10. Check and tighten ground cable to Control Box.
11. Replace motor.
Motor runs
but drum does
not turn.
Clutch not engaged. Move the Clutch Handle to the Engaged position.
If problem persists, a qualified technician
needs to check and repair.
Motor runs
slowly or
without normal
power.
1. Insufficient current or voltage.
2. Loose or corroded battery
cable connections.
3. Incorrect power cords.
1. Battery weak, recharge.
Run Winch with vehicle motor running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
Motor runs in
one direction
only.
1. Defective contactor.
2. Defective Wireless Remote.
3. Loose motor connections.
1. Replace Control Box.
2. Replace Wireless Remote.
3. Check and tighten motor connections to Control Box.
Follow all safety precautions whenever diagnosing or servicing
the tool. Disconnect power supply before service.
Page 16 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
FCC STATEMEnT
Caution: The user is cautioned that changes or modifications not expressly approved by the party responsible for
compliance could void the user‘s authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the
following measures:
• Re-orient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected
• Consult the dealer or an experienced radio/TV technician for help
Page 17For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
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.
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. Specify UPC 193175425447 when ordering parts.
Page 18 For technical questions, please call 1-888-866-5797. Item 57918
SAFETy OPERATiOn MAinTEnAnCESETuP
Parts List and Diagram
Parts List
Part Description Qty
1 Gearbox End Cover 1
2 Washer 1
3 10
4 Gear Box Z69 1
5 Clutch Retaining Bolt 1
6 Clutch Handle 1
7 Clutch Handle Washer 1
8 4
9 Bearing 1
10 Hex Sun Gear 1
11 Planetary Gear Assembly 1 1
12 Planetary Gear Assembly 2 1
13 Washer 1
14 Ring Gear Z66 1
15 Circlip Washer Ø125 1
16 Planetary Gear Assembly 3 1
17 Ring Gear Z57 1
18 1
19 4
20 Gearbox Base 1
21 Pin 2
22 Drum Assembly 1
23 Tie Bar 2
24 4
25 Control Box Assembly 1
26 1
27 Brake Assembly 1
28 Spline Drive Sleeve 1
29 Ta b 2
30 Waterproof Sealing Ring 2
Part Description Qty
31 Radial Ring 2
32 Iron Bushing 2
33 Motor Assembly 1
34 Terminal Cover 1
35 2
36 Motor Cover 1
37 Winch Mounting Hardware 4 sets
38 Wire Rope 1
39 Fairlead 1
40 Fairlead Mounting Hardware 2 sets
41 Hook 1
42 Remote Control Cable 1
43 1
45 Ground Cable 1
46 Disconnect Switch 1
47 Red Hook Strap 1
48 Power Cables (relocation kit) 3
49 Terminal Box 1
50 2
51 Terminal Box Cover 1
52 3
53 Control Box Baseplate 1
54 Baseplate Mounting Hardware 4 sets
55 Extended Copper Screw 3
56 Sheath 3
57 Small Black Wire Extension 1
58 Small Black Wire Connector 1
59 4
60 Disconnect Switch Cable 1
Page 19For technical questions, please call 1-888-866-5797.Item 57918
SAFETyOPERATiOnMAinTEnAnCE SETuP
Assembly Diagram
5
6
7
8
9
10
11
12
13
14
15
16
17
37
35
40
4
34
36
18
19
20
21
23
39
41
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26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797
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 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.
WWW.HARBORFREIGHT.COM
Copyright
©
2019 by Harbor Freight Tools
®
. All rights reserved. No portion of this guide 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 guide may not be drawn proportionally.
GUIDE TO WINCHING
19e
Page 2 For technical questions, please call 1-888-866-5797. Winching
Guide
Table of Contents
Warning Symbols .......................................... 3
Important Safety Information ......................... 4
Basic Winching Tips ...................................... 7
Before You Go ............................................... 7
Estimating Load ............................................. 8
Winch Basics ................................................ 10
.............. 14
............ 16
Double Line Winching................................... 18
Read the ENTIRE IMPORTANT SAFETY INFORMATION section beginning
on page 4 of this guide including all text under subheadings therein before
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.
Page 3For technical questions, please call 1-888-866-5797.Winching
Guide
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
Symbol Property or Statement
Wear heavy-duty, cut- and
abrasion-resistant leather gloves.
Wear ANSI-approved safety glasses.
Cut or sever hazard.
Roller entanglement hazard.
Hot surface burn hazard.
Fire hazard.
Caustic chemical (acid) hazard.
Explosion hazard.
Do not loop the wire or synthetic rope
around object and hook onto itself.
Do not place finger(s) through hook.
Fingers may be caught and get
pulled into fairlead or drum.
Pull hook using strap only.
Symbol Property or Statement
Do not use winch in overwind
orientation. (Rope enters/
exits at the top.)
Use winch only in
underwind orientation.
(Rope enters/exits at the bottom.)
VDC
Volts Direct Current
A
Amperes
CCA
HP
Horsepower
fpm
Feet Per Minute
mpm
Meters Per Minute
RPM
Revolutions Per Minute
IP
International Protection rating
Classifies the degrees of protection provided
against the intrusion of solid objects,
dust, accidental contact, and water.
G8
Grade 8
A fastener strength rating.
Page 4 For technical questions, please call 1-888-866-5797. Winching
Guide
IMPORTANT SAFETY INFORMATION
WARNING! Read all instructions. Failure to follow all instructions listed on
pages 4 to 6 may result in fire, serious injury and/or DEATH.
The warnings and precautions discussed 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.
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. Do not maintain power to the Winch
if the motor stalls. Verify load is within
rated capacity for the wire or synthetic
fully charged. Use double line rigging
whenever possible. Refer to Double
Line Winching on page 18.
3. Wear ANSI-approved safety
goggles and heavy-duty leather
4. Do not disengage clutch under load.
Engage clutch before starting.
5. Keep clear of fairlead when operating.
Do not try to guide rope.
6. Do not place finger(s) through hook.
Fingers may be caught and get pulled
into fairlead or drum. Use included
7. Stay out of the direct line that the rope
it will “whiplash” along this line.
8. Do not use for lifting or moving people.
9. Use a spotter to assist you in assuring
that it is safe to operate the Winch.
way of the vehicle and the rope
before activating the Winch.
10. Do not use vehicle to pull on the
rope and “assist” the Winch.
11.
to help absorb the force released if
Refer to Figure A.
Figure A: Whiplash Dampening
Blanket or Winch Damper
12. Use as intended only. Do not lift items
vertically or use for aircraft purposes.
13. Prevent entanglement. Do not wear
loose clothing or jewelry, as they can be
is recommended. Wear restrictive hair
covering to contain long hair.
14. Disconnect remote control and turn
near the rope, drum, fairlead or load,
to prevent accidental starting.
15. Inspect before every use; do not use
if damaged or parts loose. Examine
frayed or cut synthetic rope, and any
other conditions that may affect the safe
operation of the Winch. Do not use the
Winch even if minor damage appears.
Page 5For technical questions, please call 1-888-866-5797.Winching
Guide
16.
wire rope can fail suddenly and must
not be used. Keep wire rope straight
a.
about to form. At this point
the winch should be
stopped and the wire rope
should be straightened out
b. This wire
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.
c.
been straightened out. Even though it
has been pulled straight, some wires
in the wire rope are stretched, and
load and can fail suddenly before the
rope reaches its capacity. This wire rope
must be discarded and not be used.
rope, even after it is straightened
suddenly and must not be used.
17. Keep children and bystanders
away while operating. Distractions
can cause you to lose control.
18. 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.
19. Do not overreach. Keep proper
footing and balance at all times.
This enables better control of the
Winch in unexpected situations.
20.
tow strap or chain. Do not wrap the rope
rope itself. This can cause damage to the
21. Do not use a Recovery Strap while
winching. They are designed to stretch
operator during a winching operation.
22. Do not operate the Winch at extreme
angles. Do not exceed the angles
shown in Figure B for a roller fairlead
and Figure C for a hawse fairlead.
45°
45°
15°
15°
Figure B: Roller Fairlead
Maximum Winching Angles
15°
15°
15°
15°
Figure C: Hawse Fairlead
Maximum Winching Angles
Page 6 For technical questions, please call 1-888-866-5797. Winching
Guide
23. If the object to be pulled must be pulled
at an angle in relation to the Winch,
and an anchor point directly in front
of the Winch, as shown in Figure D,
Figure D: Snatch Block
24. Wrap rope under tension before use.
Otherwise, rope may bind during operation.
25.
winching. Do not step over rope.
Do not push sideways against rope
under tension; rope might break under
this load and recoil back, striking the
person pushing against it or a bystander.
26. If rope begins to get entangled, stop Winch
immediately and release rope using switch.
27.
transmission in neutral. Winching with
to handle that type of load.
28.
when handling a wire rope. Do not
slide a wire or synthetic rope through
hands, even with gloves on.
29. Winch motor will be hot during
and after use. Keep clear.
30.
into the fairlead or Winch.
31. To prevent accidental starting, unplug
winch controls and any RF receivers
immediately after extending or retracting.
This is especially important before rigging,
installing, free spooling, or servicing.
32.
Electromagnetic fields in close proximity to
Service Precautions
1. Wear ANSI-approved safety
goggles and heavy-duty leather
2. Disconnect power to Winch and allow
it to cool completely before service.
3. Use supplied power cords, rope or
cables listed in manual only. Do
not use thinner/longer cables or
4. 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.
5. Maintain labels and nameplates
on the Winch. These carry important
safety information. If unreadable
or missing, contact Harbor Freight
Tools for a replacement.
SAVE THESE INSTRUCTIONS.
Page 7For technical questions, please call 1-888-866-5797.Winching
Guide
Basic Winching Tips
• ESTABLISH A DANGER ZONE:
no people enter during the winching operation or
when the line is under tension.
• FIRST LAYER WINCHING:
Winch with the most rope out possible to
utilize the maximum power of the winch and
prevent overloading and overheating.
• WINCH RECOVERIES ARE SLOW:
precautions. The loads that the
winch can generate are extreme.
• USE A SNATCH BLOCK:
When in doubt of the
recovery load or if the two
each other, use a snatch
• KEEP VEHICLE RUNNING:
The winch will place an enormous amount
of strain on the vehicle electrical system.
Keeping the engine at 2000 RPM can
provide some help from the alternator.
• KEEP THE VEHICLE IN NEUTRAL:
hold the loads that the winch can apply.
carefully steer vehicle to avoid obstacles
• KEEP THE LINE STRAIGHT:
Winch with the rope as straight as possible to the
Before You Go
1.
to the winch for abrasion and heat
damage. Replace if worn or damaged.
2. The winch is an intermittently used
for proper operation in three mode
•••
2. Inspect the rope for signs of abrasion
damage. Replace if damaged. See Rope
Inspection on page 13 for more detail.
3. Ensure you have basic rigging
safety glasses, and gloves. A snatch
Damper Tree Strap Safety Gear
Page 8 For technical questions, please call 1-888-866-5797. Winching
Guide
Estimating Load
learn. It allows you to properly setup rigging for a successful recovery the first time
and reduces the chance of equipment damage and danger to bystanders.
Resistance Types
• Grade Resistance: The resistance
of pulling a vehicle up a slope.
• Mire Resistance: The resistance
of pulling a vehicle from soft terrain,
such as mud, sand or snow.
• Tackle Resistance: The added resistance
Grade Resistance
For recoveries or applications that pull a vehicle up a slope, grade resistance is a factor in the
recovery load. This is because there are many other variables to consider off-road that add
For the majority of off-road recoveries, the grade resistance
can be equal to the gross vehicle weight (GVW).
For smooth ramps used to load a trailer or other
situations that are not as varied, you can use the
following to estimate the recovery load. To
estimate load you will need the gross vehicle
• GVW can be found on the nameplate of
the vehicle, or by a weigh station scale.
• % Grade = Rise / Run
Reference the chart to find the estimated
recovery load resistance.
Grade Angle % of GVW
20% 11 20%
40% 22 37%
60% 31 51%
80% 39 62%
100% 45 71%
Page 9For technical questions, please call 1-888-866-5797.Winching
Guide
Mire Resistance
For recoveries in mud, sand, or snow, mire resistance becomes a factor. Mire resistance
is the added resistance that the soft terrain adds as the vehicle is submerged beneath
•
•
• Cab Depth = 3x GVW
A snatch block is a great
way to double the pulling
power of your winch.
Tackle Resistance
Wheel Depth Mire
Fender Depth Mire
Cab Depth Mire
Page 10 For technical questions, please call 1-888-866-5797. Winching
Guide
Winch Basics
Rope Layer
Imagine trying to hold a full length shovel horizontal by the
Now imagine holding a shorter shovel by the end of the handle. Maybe
not easy, but certainly easier than the full length shovel.
This is an example of how the winch must exert torque on the drum for the various
layers of rope on the drum. The outermost layer of rope is represented by the full
length shovel, and the first layer of rope is represented by the short shovel.
The winch and the vehicle electrical system have a limited amount of power
available, so it is important to use the power in the most efficient way possible.
The winch can pull to 100% full rated
load only on the first layer of rope
that touches the drum.
For a constant load, as each layer of
rope winds on, the winch must exert
more torque on the drum, because of
the added leverage of each layer.
WARNING! To prevent serious injury from
sudden detachment of the winch rope leave
at least 5 full wraps of rope on the drum.
Page 11For technical questions, please call 1-888-866-5797.Winching
Guide
Rope Angle
Your winch is designed to handle off-angle pulls for brief periods. However, extended pulls
change the direction or move the anchor point.
Try to winch with the rope as straight into the winch as possible.
If you do have to winch off-angle, do not exceed the angles shown below.
Spotter must be outside danger zone. Have spotter watch for even winding of rope on
drum. If rope starts winding unevenly on the drum, stop winching and adjust rigging
or vehicle position. Freespool the winch to remove the rope bunching on the drum
15
º
MAX
15
º
MAX
45
º
MAX
45
º
MAX
Roller Fairlead Maximum Winching Angles
Roller Fairlead
15
º
MAX
15
º
MAX
15
º
MAX
15
º
MAX
Hawse Fairlead Maximum Winching Angles
Hawse Fairlead
Page 12 For technical questions, please call 1-888-866-5797. Winching
Guide
Snatch Blocks
of vehicle recoveries.
of a rope. In the diagram a 4 ton vehicle is attached to a rope
Notice that the tension in each of the ropes is
must carry the combined load of the ropes.
This is a simplified example neglecting the angle of
pull of the ropes. As the angle between the ropes
Example 1: Direction Change
In a direction change situation, the objective is
to pull from a direction that has a greater impact
does not provide any increase to the recovery
force but it does change the direction of the pull.
Example 2: Recovery Force Increase
force than the winch can provide, a double line
pull should be used. This can help reduce the
load on the winch and decrease the electrical
load on the vehicle.
In this example the weight becomes the
is again connected to an anchor point. The
usefulness of this rigging is to leverage
the doubled force of the two ropes that the
force to be double that of a single line pull.
Additionally the double line rigging will require
more rope off the drum, allowing the winch to
pull force.
8T
Snatch Block
Winching
Vehicle
Recovery
Vehicle
4T
4T
4T
Load
Page 13For technical questions, please call 1-888-866-5797.Winching
Guide
Rope Inspection
The rope on the winch is the highest wear item in the winching system, and the
most dangerous if not inspected regularly. Wire rope and synthetic rope have
WARNING! To prevent serious Injury from razor sharp broken strands, wear heavy-
duty work gloves when handling wire rope. Do not run hands along wire rope, even
•
•
•
•
Synthetic Rope
CAUTION! Wear work gloves to protect from cuts from
debris when working with synthetic rope.
•
be replaced; minor abrasion or a
•
•
•
load to remove the compression.
Page 14 For technical questions, please call 1-888-866-5797. Winching
Guide
Setup
WARNING! To prevent serious injury from electrical fire: check the
electrical cables to your winch for abrasion or heat damage before
use. Replace worn or damaged cables immediately.
1.
vehicle that is generally straight on and
that allows for sufficient rope out to
obtain maximum power from the winch.
2. PUT ON GLOVES. Regardless of
gloves are always a good idea.
3. Place the winch into freespool.
Rigging
1.
WARNING! To prevent serious injury from sudden detachment of the
winch rope leave at least 5 full wraps of rope on the drum.
2. Secure the winch rope to the anchor point.
Do not wrap the winch rope directly around
3.
the rigging.
4.
THE HOOK LATCH MUST CLOSE.
5. Place a winch damper or other heavy object
on the line, 1/3 of the total distance from the
Use double line rigging whenever practical to prevent
overloading and overheating of the winch.
Page 15For technical questions, please call 1-888-866-5797.Winching
Guide
6. ESTABLISH A DANGER ZONE. At least
sure no people enter during the winching
operation or when the line is under tension.
WARNING!
Do not allow anyone to stand near
the rope, or inline with the rope behind the
winch or anchor point while it is under power. If the rope should slip or break, it can
suddenly whip back towards the winch or anchor, causing a hazard for anyone in the
area established by the danger zone. Stand well to the side when winching.
Winching
For self recovery:
Place winch vehicle in NEUTRAL
•
Keep foot OFF brake
For other vehicle recovery:
Place winch vehicle in NEUTRAL
•
Keep foot ON brake
1. Re-engage the freespool clutch, and plug-
in or connect the remote to the winch.
2.
Designate one person as a spotter to watch
rope is spooling on the drum correctly.
3. Perform the winching operation, with the
vehicle in NEUTRAL or DRIVE. Watch your
spotter, and monitor the battery voltage
while winching. Increase the engine
RPM to raise the battery voltage level.
4. When the vehicle is recovered engage
and wind the rope fully into the winch
USING THE HOOK STRAP.
5. Unplug or disconnect the remote and
store it in the vehicle for the next use.
NOTICE: Your winch is designed
for INTERMITTENT USE ONLY. If
the motor stalls, STOP OPERATION
and use a snatch block.
Duty Cycle (Duration of Use)
Avoid damage to the Winch by not winching for more than the prescribed
duty cycle time. The Duty Cycle defines the amount of time, within a
15 minute period, during which a Winch can operate at its maximum
capacity without overheating. For example, a Winch with a
5% duty cycle at its maximum load must be allowed to rest
for at least 14 minutes, 15 seconds after every 45 seconds
of continuous operation. Failure to carefully observe duty
cycle limitations can easily over-stress a Winch contributing
to premature Winch failure.
at least
14 minutes,
15 seconds
of rest
45 seconds winching
Page 16 For technical questions, please call 1-888-866-5797. Winching
Guide
Overview
Not every recovery can be handled with a straight line pull. Often the most effective recovery
a single line pull, the pull direction can be changed without moving the winching vehicle.
Around a Corner
pull harder, it also allows the vehicle to remain connected to the farthest anchor once the
Pay special attention to the danger zone, since it is much larger than a straight line pull.
USE ALL OF THE PRECAUTIONS AND STEPS
Snatch
Block
Tree Strap
& Shackle
Tree Strap
& Shackle
Rigging Needed:
•
•
•
Page 17For technical questions, please call 1-888-866-5797.Winching
Guide
Vehicle Off Trail
vehicle to the road is using an angled pull since this pulls the vehicle most directly onto the
perform the recovery.
Pay special attention to the danger zone, since it is much larger than a straight line pull.
USE ALL OF THE PRECAUTIONS AND STEPS
Snatch
Block
Tree Strap
& Shackle
Rigging Needed:
•
•
•
For self recovery:
Place winch vehicle in NEUTRAL
•
Keep foot OFF brake
For other vehicle recovery:
Place winch vehicle in NEUTRAL
•
Keep foot ON brake
Page 18 For technical questions, please call 1-888-866-5797. Winching
Guide
Double Line Winching
Overview
Certain recoveries require more force than a single line pull can provide. In these situations
a double line pull is necessary to develop enough force to recover the vehicle.
For self recovery efforts that require more force than a single line pull can provide, use a
rated to withstand the estimated load to recover the vehicle.
USE ALL OF THE PRECAUTIONS AND STEPS
Snatch
Block
Tree Strap
& Shackle
Rigging Needed:
•
•
•
For self recovery:
Place winch vehicle in NEUTRAL
•
Keep foot OFF brake
Page 19For technical questions, please call 1-888-866-5797.Winching
Guide
This can be especially helpful in low traction conditions such as snow or mud.
Pay special attention to the danger zone, since it is much larger than a straight line pull.
USE ALL OF THE PRECAUTIONS AND STEPS
Snatch
Block
Tree Strap
& Shackle
Rigging Needed:
•
•
•
For other vehicle recovery:
Place winch vehicle in NEUTRAL
•
Keep foot ON brake
26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797
