Page 1
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
Page 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
Solenoid Assembly Mounting instructions
in the following section.
Mounting the Solenoid Assembly
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.
6. Verify that the installation surface has no
hidden components or structural pieces
that will be damaged before drilling.
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.
9. Attach the Hook to the loop at the end of
the Cable Assembly (36w).
Mounting using a different mounting plate:
Mounting Components
Solenoid Bracket (14s)
Solenoid
Assembly
(34w)
Figure 4
Motor
Motor Cables
(17s & 24s)
Battery Cables
(13s & 16s)
Mounting Option 1: Mounting the Solenoid
to the Mounting Frame
In this conguration, the Solenoid
Assembly (34w) is connected to the
Mounting Frame (sold separately), in line
with the Motor.
1. The plate must be rated to at least the
winch’s capacity.
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.
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.
4. Install the winch using the hardware
specied on the Specication chart.
5. Attach the Hook to the loop at the end of
the Cable Assembly (36w).
Solenoid Assembly
(34w)
Motor
Cables
(17s & 24s)
Motor Terminals
Figure 5
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.
Page 7For technical questions, please call 1-800-444-3353.SKU 91780
Page 8
Solenoid Assembly
(34w)
Battery Cables
(13s & 16s)
Bracket
Mounting
Holes
Solenoid
Assembly
(34w)
Motor
Mounting Frame
Figure 6
2.
Unthread the nuts, spring washers and
(Sold Separately -
SKU 90476)
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.
Mounting Option 2: Mounting the Solenoid
to the Solenoid Bracket (40w)
In this conguration, 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.
Solenoid
Bracket
(40w)
Bracket Tie-down
Figure 7
1.
To attach the Solenoid Assembly (34w)
Strap (41w)
Motor Cables
(17s & 24s)
to the Solenoid Bracket (40w):
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.
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.
d. Line up the Solenoid Assembly with the
end of the Motor Assembly and attach
the two Motor Cables (24s) to the motor
terminals.
Page 8 For technical questions, please call 1-800-444-3353. SKU 91780
Page 9
Solenoid
Assembly (34w)
Motor Cables
(17s & 24s)
Motor
Figure 8
2.
To attach the Solenoid Assembly/Bracket
Bracket mounted to
Tie Bar (10w) ends
Bracket
Tie-down
Strap (41w)
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).
d. Re-insert and tighten the Bolts (12-1w)
and Nuts (13w), securing the Solenoid
Bracket to the Tie Bar.
Turn the Power Switch of the
winch off and disconnect the
power and control cables before
making wiring connections.
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.
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 re 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.
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.
Wiring
TO PREVENT
SERIOUS INJURY
FROM EXPLOSION DUE TO
SPARKING AT THE BATTERY
CONNECTION:
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.
5. Attach the black Battery Cable (16s) to
the negative terminal of the battery.
Page 9For technical questions, please call 1-800-444-3353.SKU 91780
Page 10
Solenoid Assembly (34w)
OPERATION
Socket (6s)
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.
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.
Preparing the Wire Rope
BEFORE FIRST USE:
1. The wire rope must be properly coiled
under tension to be able to support a
load without damage.
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.
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.
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.
WARNING! Leave at least ve full
turns of wire rope on the drum.
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.
Page 10 For technical questions, please call 1-800-444-3353. SKU 91780
Page 11
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
• it halves the load on the winch through
pulley action.
Stationary
Winching
Vehicle
(Chock tires, and
set parking brake)
Carpet
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.
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.
Load
Safety Clasp
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.
Do not wrap the wire
rope around the object
and hook onto the wire
rope itself. This can
damage the object being
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.
9. 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.
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.
Page 11For technical questions, please call 1-800-444-3353.SKU 91780
Page 12
12. Attach the Switch Assembly (35w) to the
Socket (6s) on the Solenoid Assembly
(34w).
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.
15°
15°
45°
45°
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.
CAUTION Do not use the winch in a
constant duty application, it is
designed for INTERMITTENT USE
ONLY. Keep the duration of the
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.
17. When nished 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.
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.
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.
Page 12 For technical questions, please call 1-800-444-3353. SKU 91780
Page 13
MAINTENANCE AND
SERVICING
Procedures not specically
explained in this manual must
be performed only by a qualied
technician.
TO PREVENT
SERIOUS INJURY
FROM ACCIDENTAL
OPERATION:
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.
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.
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 qualied technician
as soon as possible to prevent corrosion.
Cable Replacement
1. Move the Cam Ring (11w) to the OUT
position.
2. Manually pull the Cable out to it’s full
length. Note how the existing cable is
connected to the inside of the drum.
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.
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.
5. Coil the wire rope 5 full wraps.
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.
6. Then, coil the wire rope into the winch
under at least 500 lb. of tension.
Page 13For technical questions, please call 1-800-444-3353.SKU 91780
Page 14
Troubleshooting
Problem Possible Causes Likely Solutions
Motor does not turn
on.
Motor runs but cable
drum does not turn.
Motor runs slowly
or without normal
power.
Motor runs in one
direction only.
Motor overheats. 1. Incorrect power cords.
1. Switch not connected properly.
2. Loose power cord connections.
3. Battery needs charging.
4. Solenoid malfunctioning.
5. Defective Switch.
6. Defective motor.
7. Water has entered motor.
8. Internal damage or wear.
Clutch not engaged. Move the Cam Ring to the In position. If
1. Insufcient current or voltage.
2. Loose or corroded battery cable
connections.
3. Incorrect power cords.
1. Defective or Stuck solenoid.
2. Defective Switch Assembly.
2. Winch running time too long.
1. Connect Switch properly.
2. Tighten all connections.
3. Fully charge battery.
4. Tap solenoid to loosen contacts. Briey
apply 12 volts directly to coil terminals.
Clicking indicates proper activation.
5. Replace Switch.
6. Check for voltage at armature port with
Switch pressed. If voltage is present, replace
motor.
7. Allow to drain and dry. Run in short bursts
without load until completely dry.
8. Have technician service winch.
problem persists, a qualied technician needs
to check and repair.
1. Battery weak, recharge. Run winch with
vehicle engine running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
1. Tap Solenoid to loosen contacts. Repair or
replace solenoid.
2. Replace Switch Assembly.
1. Use only supplied power cords.
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 For technical questions, please call 1-800-444-3353. SKU 91780
Page 15
WINCH PARTS LIST & ASSEMBLY DIAGRAM
Part Description Qty
2w Fairlead 1
3w Bolt M10 x 34 4
5w Washer M10 2
6w Nut M10 6
7w End Bearing 1
8w Spring 6
9w Locking Ring 1
10w Tie Bar 2
11w Cam Ring 1
12w Bolt M8 x 30 4
13w Nut M8 4
14w Gear Ring 1
15w Gear Retainer Ring 1
16w Half Ring 2
17w Bolt M6 x 20 6
18w Gear - Output 1
20w Roll Pin Ø4 x 10 1
21w Cable Anchor 1
22w Bolt M6 x 12 1
23w Gear (Intermediate) 1
24w Gear (Input) 1
25w Thrust Disc 1
Part Description Qty
26w Thrust Washer 3
27w Bushing-Drum 2
28w Gasket 1
29w Cover Gear Housing 1
30w Screw M5 x 12 6
31w Drum 1
32w Break / Shaft Assembly 1
33w Motor End Bearing Assembly 1
34w Solenoid Assembly 1
35w Switch Assembly 1
36w Cable Assembly 80’ L x 1/4” D 1
37w Gear Carrier Assembly - Output 1
38w Gear Carrier Assembly - Intermediate 1
39w Gear Carrier Assembly - Input 1
40w Solenoid Bracket 1
41w Bracket Tie-Down Strap 1
42w Spring Washer 5 mm 6
43w Bolt M12 x 25 2
44w Nut M12 2
45w Fairlead Mounting Plate 1
46w Hook Strap 1
47w Bolt M10 x 34 (none standard) 2
Note: When ordering parts for Winch, include the sufx “w” after the part number.
5
REV 10c
Page 15For technical questions, please call 1-800-444-3353.SKU 91780
Page 16
SOLENOID PARTS LIST & ASSEMBLY DIAGRAM
Part Description Qty
1s Plastic Housing 1
2s Socket Cover 1
3s Flat Washer 6
4s Spring Washer 4
5s Screw M5 x 10 4
6s Socket 1
7s Screw M5 x 12 2
8s Copper Spacer 1
9s Screw M5 x 12 2
10s Solenoid 1
11s Ground Cable 1
12s Screw M6 x 30 4
Part Description Qty
13s Battery Cable (red) (+) 1
14s Solenoid Bracket 1
15s Nut M8 4
16s Battery Cable (Black) (-) 1
17s Motor Cable (Black) (-) 1
18s Nut M5 1
19s Spacer 3
20s Flat Washer 8
21s Spring Washer 8
22s Nut M6 8
23s Fiberglass Sleeve 1
24s Motor Cable (Black) (+) 1
REV 10c
Page 16 For technical questions, please call 1-800-444-3353. SKU 91780
Page 17
ROLLER FAIRLEAD PARTS LIST & ASSEMBLY DIAGRAM
Part Description Qty
1f Cap Nut 8
2f Lock Washer 8
3f Short Shaft 2
4f Nylon Bushing 8
Part Description Qty
5f Short Roller (Ø 3-3/8: x 1-3/8” 2
6f Long Shaft 2
7f Long Roller (Ø 4-3/4” x 1-3/8”) 2
8f Base 1
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.
Page 17For technical questions, please call 1-800-444-3353.SKU 91780
Page 18
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 veries 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 specic 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 For technical questions, please call 1-800-444-3353. SKU 91780
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