Harbor Freight Tools 68146 Owner's Manual

ATV/UTV Winches

Installation and Operating Instructions

2,000 lb. Model 68146

Read this Operator’s Manual carefully before using this tool. Failure to understand and follow the contents of this manual may result in electrical shock, fire and/or serious personal injury.

When unpacking, make sure that the product 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.

Visit our website at: http://www.harborfreight.com

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.

3,000 lb.

Model 68145

Manual Revised 11j

5,000 lb.

Model 68144

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68146 2,000 lb. Winch Specifications

Rated Single Line Pull

Application Utility/Shop/ATV

Motor 12VDC 1 HP Permanent Magnet

Power IN & Power OUT

Duty Cycle Rating 5% (45 sec at Max Rated Load;

Handlebar Controller Wired, 7 ft (2.1m) long

Geartrain Planetary

Gear Ratio 153:1

Freespool Yes

Brake Auto. Load Holding Dynamic

Drum (Dia. X L) 1.25″ X 2.8″ (32mm X 71mm)

Hook 1/4″ Eye Hook

Fairlead Roller with nylon bushings

Sound Rating 85 dB

2,000 lb. (907 kg.)

Yes

14 min, 15 sec Rest)

Layer Rated Line Pull Wire Rope Capacity

Wire Rope Size / Type

Battery 12VDC, Minimum 12 Ah

Battery Cables 10 gauge, 5.8′ (1.78m) long

Mounting Pattern 3.15″ (80mm)

Mounting Hardware Winch: 2x G8, M8-1.25 X 35mm

Overload Protection In line Circuit Breaker

Overall Dimensions (L X D X H)

Weight 14.7 lb. (6.7 kg.)

IP Rating IP 65 - Winch and Controls

Winch Certification CE

Ø5/32″ x 50′ (Ø4mm X 15.2m) Nominal strength=2,800 lb

7X19 Galvanized Steel Aircraft Wire Rope

Fairlead:

2x G8, M8-1.25 X 19mm

11.25″ X 3.88″ X 4.25″ (286 X 99 X 108mm)

(resistant to water jets)

First Layer of Wire Rope Performance

2000 lb. (907 kg.) 6′ (1.8m)

1635 lb. (742 kg.) 13.7′ (4.2m)

1385 lb. (628 kg.) 22.5′ (6.9m)

1200 lb. (544 kg.) 32.8′ (10m)

1055 lb. (479 kg.) 44.5′ (13.6m)

950 lb. (431 kg.) 50′ (15.2m)

Line Pull lb. (kg.) Line Speed fpm (mpm) Amp Draw (@ 12V)

0 (0) 13.3 (4.1) 10

500 (227) 10.8 (3.3) 30

1000 (454) 8.3 (2.5) 55

1500 (680) 6.2 (1.9) 80

2000 (907) 4.1 (1.2) 106

Page 3For technical questions, please call 1-800-444-3353.ATV Winch

68145 3,000 lb. Winch Specifications

Rated Single Line Pull

Application ATV/UTV

Motor 12VDC 1 HP Permanent Magnet

Power IN & Power OUT

Duty Cycle Rating 5% (45 sec at Max Rated Load;

Pendant Controller Wired, 12 ft (3.7m) long

Handlebar Controller Wired, 8 ft (2.4m) long

Geartrain 3-Stage Planetary

Gear Ratio 136:1

Freespool Cam Activated

Brake Auto. Load Holding Mechanical

Drum (Dia. X L) 2″ x 2.9″ (50mm x 74mm)

Hook 1/4″ Clevis, with Spring-loaded

Fairlead Roller with nylon bushings

Wire Rope Size / Type

3,000 lb. (1,361 kg.)

Yes

14 min, 15 sec Rest)

Safety Latch

Ø3/16″ x 50′ (Ø4.8mm X 15.2m)

Nominal strength=4,200 lb 7X19 Galvanized Steel Aircraft Wire Rope

Battery 12VDC, Minimum 12 Ah

Battery Cables 6 gauge, 6′ (1.83m) long

Solenoid Cables 6 gauge, 3′ (0.92m) long

Mounting Pattern 3″ x 4.88″ (76.2mm x 124mm)

Mounting Hardware Winch:

4x G8, M8-1.25 X 25mm

Adaptor Plate:

2x G8, M8-1.25 X 25mm

Fairlead:

2x G8, M8-1.25 X 20mm

Socket Lead:

2x G8, ST-M4 X 30mm

Overload Protection In line Circuit Breaker

Sound Rating 85 dB

Overall Dimensions (L X D X H)

Weight 25 lb. (11.3 kg.)

IP Rating IP 67 - Winch and Controls

Winch Certification CE

13.3″ X 4.25″ X 4.5″ (338 X 108 X 114mm)

(except remote switch,

resistant to immersion up to 3′)

Layer Rated Line Pull Wire Rope Capacity

First Layer of Wire Rope Performance

3000 lb. (1361 kg.) 8′ (2.4m)

2600 lb. (1179 kg.) 17.3′ (5.3m)

2250 lb. (1021 kg.) 28′ (8.5m)

1990 lb. (903 kg.) 41′ (12.5m)

1790 lb. (812 kg.) 50′ (15.2m)

Line Pull lb. (kg.) Line Speed fpm (mpm) Amp Draw (@ 12V)

0 (0) 23 (7) 20

1000 (454) 13.1 (4) 81

2000 (907) 11 (3.4) 135

3000 (1361) 6.6 (2) 205

Page 4 For technical questions, please call 1-800-444-3353. ATV Winch

68144 5,000 lb. Winch Specifications

Rated Single Line Pull

Application ATV/UTV

Motor 12VDC 1.5 HP

Power IN & Power OUT

Duty Cycle Rating 5% (45 sec at Max Rated Load;

Pendant Controller Wired, 12 ft (3.7m) long

Handlebar Controller Wired, 8 ft (2.4m) long

Geartrain 3-Stage Planetary

Gear Ratio 136:1

Freespool Cam Activated

Brake Auto. Load Holding Mechanical

Drum (Dia. X L) 2″ x 4.7″ (50mm x 120mm)

Hook 1/4″ Clevis, with Spring-loaded

Fairlead Roller with nylon bushings

Wire Rope Size / Type

5,000 lb. (2268 kg.)

Permanent Magnet

Yes

14 min, 15 sec Rest)

Safety Latch

Ø1/4″ x 50′ (Ø6.3mm X 15.2m)

Nominal strength=7,000 lb 7X19 Galvanized Steel Aircraft Wire Rope

Battery 12VDC, Minimum 12 Ah

Battery Cables 6 gauge, 6′ (1.83m) long

Solenoid Cables 6 gauge, 3′ (0.92m) long

Mounting Pattern 3″ x 6.6″ (76.2mm x 167.6mm)

Mounting Hardware Winch:

4x G8, M8-1.25 X 25mm

Adaptor Plate:

2x G8, M8-1.25 X 25mm

Fairlead:

2x G8, M8-1.25 X 20mm

Socket Lead:

2x G8, ST-M4 X 30mm

Overload Protection In line Circuit Breaker

Sound Rating 85 dB

Overall Dimensions (L X D X H)

Weight 33 lb. (15 kg.)

IP Rating IP 66 - Winch and Controls

Winch Certification CE

15.8″ X 4.6″ X 4.7″ (400 X 116 X 119mm)

(except remote switch, resistant to powerful water jets)

Layer Rated Line Pull Wire Rope Capacity

First Layer of Wire Rope Performance

5000 lb. (2268 kg.) 50′ (15.2m)

4080 lb. (1851 kg.) 36.1′ (11m)

3450 lb. (1565 kg.) 22′ (6.7m)

2985 lb. (1354 kg.) 9.8′ (3m)

Line Pull lb. (kg.) Line Speed fpm (mpm) Amp Draw (@ 12V)

0 (0) 20.5 (6.2) 30

1000 (454) 16.1 (4.9) 83

2000 (907) 12.8 (3.9) 136

3000 (1361) 10.7 (3.3) 168

4000 (1814) 8.6 (2.6) 232

5000 (2268) 6.1 (1.9) 296

Page 5For technical questions, please call 1-800-444-3353.ATV Winch

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

Symbol Definitions

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.

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.

Page 6 For technical questions, please call 1-800-444-3353. ATV Winch

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.

VDC

CCA

fpm

mpm

RPM

Volts Direct Current

Amperes

Cold Cranking Amperes

Horsepower

Feet Per Minute

Meters Per Minute

Revolutions Per Minute

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.

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.)

International Protection rating

Classifies the degrees of protection provided against the intrusion of solid objects, dust, accidental contact, and water.

Grade 8 A fastener strength rating.

WARNING! Read all instructions.

Failure to follow all instructions listed on pages 8 to 11 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.

Page 7For technical questions, please call 1-800-444-3353.ATV Winch

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 red wire to positive battery terminal and black wire to 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 8 For technical questions, please call 1-800-444-3353. ATV Winch

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 rope layer, see Winch Specifications on pages 3 to 5. Make sure the battery is fully charged. Use double line rigging whenever

possible, see ″Double Line Rigging″ on page 18.

3. Wear ANSI-approved safety goggles and heavy-duty leather work gloves during operation.

4. Do not disengage clutch under load.

Engage clutch before starting.

10. Do not use the hand crank, if equipped, to “assist” the winch.

11. Do not use vehicle to pull on the Wire Rope and “assist” the winch.

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 caught in moving parts.

Non-skid footwear is recommended. Wear restrictive

hair covering to contain long hair.

14. Disconnect battery cables before working near the Wire Rope, drum, fairlead or load, to prevent accidental starting.

15. Inspect before every use; do not use if damaged or

parts loose. Examine the winch for structural cracks,

bends, damage, frayed or kinked wire rope, and any other conditions that may affect the safe operation of the winch. Do not use the winch even if minor damage appears. A kink permanently weakens the wire rope, even after it is straightened out; kinked wire rope can fail suddenly and must not be used.

5. Keep clear of fairlead when operating. Do not try to guide wire rope.

6. Do not place finger(s) through hook. Fingers may be caught and get pulled into fairlead or drum. Use included strap to hold hook instead.

7. Stay out of the direct line that the wire rope is pulling. If it slips or breaks, it will “whiplash” along this line.

Place heavy rag or carpet over wire rope span 6

feet from hook to help absorb the force released if the wire rope breaks. (See Figure A.)

FIGURE A — WHIPLASH

DAMPENING BLANKET OR RUG

8. Do not use for lifting or moving people.

9. Use a spotter to assist you in ensuring 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.

16. Keep wire rope straight to avoid kinking the wire rope.

The illustrations below show how a kink forms and how to prevent kinking.

a. This illustration shows a kink about

to form. At this point the winch should be stopped and the wire rope should be straightened out to prevent kinking.

b. This wire rope is

kinked. 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. This is a kinked wire rope that has been

straightened out. Even though it has been pulled

straight, some wires in the wire rope are stretched, and others are severely bent, if not broken. The unstretched wires will take more load and can fail suddenly before the rope reaches its capacity. This wire rope must be discarded and not be used.

A kink permanently weakens the wire rope, even after it is straightened out; kinked wire rope can fail suddenly and must not be used.

Page 9For technical questions, please call 1-800-444-3353.ATV Winch

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