Chicago Electric 91780 User Manual
5,500 LB. CAPACITY 12 VOLT
WINCH WITH ROLLER FAIRLEAD
Model
91780
SET UP AND OPERATING INSTRUCTIONS
Visit our website at: http://www.harborfreight.com
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
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.
IMPORTANT SAFETY
INFORMATION
NOTICE is used to
address practices not
related to personal injury.
CAUTION, without the
safety alert symbol, is
used to address practices not
related to personal injury.
WARNING Read all safety warnings
and instructions. Failure to follow the
warnings and instructions may result
in electric shock, re and/or serious
injury.
Save all warnings and instructions
for future reference.
In this manual, on the labeling, and
all other information provided with
this product:
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.
DANGER indicates a
hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING indicates a
hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION, used with
the safety alert
symbol, indicates a hazardous
situation which, if not avoided,
could result in minor or moderate
injury.
The warnings, precautions, 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.
INSTALLATION PRECAUTIONS
1. Mounting location and hardware must
support winch and load.
2. Wear ANSI-approved safety goggles
during installation, operation and service.
3. Use supplied power cords and wire rope
listed in manual only. Do not use thinner/
longer cables or link multiple cables
together.
4. Always connect the Red wire to the
positive battery terminal and the Black
wire to the negative battery terminal.
5. Do not use a dirty, corroded or leaking
battery. You may suffer injury from acid
burns.
Page 2 For technical questions, please call 1-800-444-3353. SKU 91780
6. Verify that the installation surface has no
hidden components or structural pieces
that will be damaged before drilling.
OPERATION PRECAUTIONS
1. Do not exceed load capacity. Be aware
of dynamic loading! Sudden load
movement may briey create excess
load causing product failure.
2. Wear ANSI-approved safety goggles and
heavy-duty leather work gloves during
operation.
3. Do not disengage clutch under load.
Engage clutch before starting.
10. Use as intended only. Do not lift items
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.
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
other condition that may affect the safe
operation of the winch. Do not use the
winch even if minor damage appears.
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
the force released if
the wire rope breaks.
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.
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.
13. Keep children and bystanders away
while operating. Distractions can cause
you to lose control.
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 inuence of drugs, alcohol
or medication. A moment of inattention
while operating winches may result in
serious personal injury.
15. Do not overreach. Keep proper footing
and balance at all times. This enables
better control of the winch in unexpected
situations.
16. People with pacemakers should
consult their physician(s) before use.
Electromagnetic elds in close proximity
to heart pacemaker could cause
pacemaker interference or pacemaker
failure.
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.
Page 3For technical questions, please call 1-800-444-3353.SKU 91780
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
wire rope itself. This can cause damage
to the object being pulled, and kink or
fray the wire rope.
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.
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.
thinner/longer cables or link multiple
cables together.
3. Have the winch serviced by a qualied
repair person using only identical
replacement parts. This will ensure that
the safety of the winch is maintained.
4. Maintain labels and nameplates on the
winch. These carry important safety
information. If unreadable or missing,
contact Harbor Freight Tools for a
replacement.
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.)
SAVE THESE
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
INSTRUCTIONS.
Page 4 For technical questions, please call 1-800-444-3353. SKU 91780
SPECIFICATIONS
Capacity 5,500 lb. Single Line Pull on Layer 1
Motor
Power Supply
Automatic Load
Holding Brake
Gear Train
Overall
Dimensions
Drum Size Ø2-1/2” Dia. x 5-1/2” W
Hook Opening 1/4”
Mounting Plate 6.54” x 4.5”
Mounting
Hardware
Power Cords 60”, 5 Gauge (AWG)
Remote Cable 12’ cord
Wire Rope
* “Aircraft” refers to the wire rope type, not the function
of the winch.
Performance of First Layer
Permanent Magnet
3.4 HP
12 VDC
650 CCA or larger battery
Yes
3-Stage Planetary
294:1 Ratio
- 17.24” L x 6.3” W x 6.30” H without
Solenoid over motor
- 18.1” L x 6.30” W x 10.63” H with
Solenoid over motor
6 Bolts (3w) M10 x 35 and Nuts M10
1/4” x 80’ Galvanized Steel
7,000 lb. Nominal Strength
(7 x 19 Aircraft* type)
Schematics
UNPACKING
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.
Line Pull
(lb.)
0 9.74 40
2,000 9.55 104
3,000 8.56 122
4,000 7.58 147
5,500 6.56 192
Line Speed
(ft./min)
Amp
Draw
Line Pull and Wire Rope Capacity by
Layer
Wire Rope
Layer
1 5500 15
2 4650 31.5
3 4000 50
4 3550 70
5 3180 78.7
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.
Rated Line
Pull (lb.)
Wire Rope
Capacity (ft.)
Motor
Solenoid
(34w)
Battery Cables
Fairlead Mounting
Plate (45w)
Cables
(17s & 24s)
(13s & 16s)
Figure 1
COMPONENTS
Winch
(Cable Assembly (36w))
Motor
Hook
Switch
Assembly
(35w)
Mounting Hardware
Cam Ring (11)
Fairlead
(2w)
Hook
Strap
(46w)
REV 10c
Page 5For technical questions, please call 1-800-444-3353.SKU 91780
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 the Winch
Mounting using the Mounting Frame
(Sold separately - SKU 90476):
Mounting Frame
(Sold Separately - SKU 90476)
Bolt (47w)
Washer
(5w)
Nut (6w)
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.
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. If the suggested mounting frame (SKU
90476 - sold separately) is not used, any
replacement mounting frame must be at
and rated to at least the winch’s capacity.
Hardware Identication:
Use to
attach
Fairlead
(2w)
to
Plate
(45w)
Flanged Nut
(44w)
Fairlead Mounting
Plate (45w)
Figure 2
1.
Mount the Fairlead (2w) to the Fairlead
Fairlead (2w)
Flanged Bolt
Mounting Plate (45w) using two Flanged
Bolts (43w) and Nuts (44w).
2. Mount the Fairlead/Mounting Plate
assembly to the Mounting Frame (sold
separately - SKU 90476) using two Bolts
(47w), Washers (5w) and Nuts (6w).
Mounting Frame
(Sold Separately
SKU 90476)
Winch
(43w)
Use to
attach
(45w) to
Frame
90476)
REV 10c
Plate
(SKU
Use to attach Winch to
Frame (SKU 90476)
Figure 3
3.
Mount the Winch to the Mounting Frame
using four Flanged Bolts (3w) and Nuts
(6w).
4. Mount the Solenoid Assembly (34w)
according to one of the options in the
Fairlead (2w)
Page 6 For technical questions, please call 1-800-444-3353. SKU 91780
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