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Chicago Electric 91780 - page 1
5,500 LB. CAP ACITY 12 VOL T WINCH WITH ROLLER F AIRLEAD Model 91780 SET UP AND OPERA TING 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 . SA VE THIS MANUAL. Copyright © 2004 by Harbor Freight T ools ® . All rights reserved. No portion o ...
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Chicago Electric 91780 - page 2
Page 2 For technical questions, please call 1-800-444-3353. SKU 91780 SA VE 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 ha ...
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Chicago Electric 91780 - page 3
Page 3 For technical questions, please call 1-800-444-3353. SKU 91780 6. V erify that the installation surface has no hidden components or structural pieces that will be damaged before drilling. OPERA TION PRECAUTIONS 1. Do not exceed load capacity . Be aware of dynamic loading! Sudden load movement may briey create excess load causing product f ...
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Chicago Electric 91780 - page 4
Page 4 For 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 ...
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Chicago Electric 91780 - page 5
Page 5 For technical questions, please call 1-800-444-3353. SKU 91780 SPECIFICA TIONS Capacity 5,500 lb. Single Line Pull on Layer 1 Motor Permanent Magnet 3.4 HP Power Supply 12 VDC 650 CCA or larger battery Automatic Load Holding Brake Ye s Gear T rain 3-Stage Planetary 294:1 Ratio Overall Dimensions - 17.24” L x 6.3” W x 6.30” H without So ...
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Chicago Electric 91780 - page 6
Page 6 For technical questions, please call 1-800-444-3353. SKU 91780 INST ALLA TION AND SETUP Read the ENTIRE IMPORT ANT SAFETY INFORMA TION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Mounting the Winch 1. Select a mounting site on the vehicle bumper , truck bed, boat ...
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Chicago Electric 91780 - page 7
Page 7 For technical questions, please call 1-800-444-3353. SKU 91780 Solenoid Assembly Mounting instructions in the following section. 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. V erify that the installation surface has no ...
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Chicago Electric 91780 - page 8
Page 8 For technical questions, please call 1-800-444-3353. SKU 91780 2. Solenoid Assembly (34w) Mounting Frame (Sold Separately - SKU 90476) Figure 6 Unthread the nuts, spring washers and 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 ...
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Chicago Electric 91780 - page 9
Page 9 For technical questions, please call 1-800-444-3353. SKU 91780 2. Figure 8 Motor Motor Cables (17s & 24s) Bracket mounted to T ie Bar (10w) ends Solenoid Assembly (34w) Bracket T ie-down Strap (41w) T o attach the Solenoid Assembly/Bracket to the Motor Assembly: a. Slide the Bracket T ie-down Strap (41w) over the hook in the center of th ...
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Chicago Electric 91780 - page 10
Page 10 For technical questions, please call 1-800-444-3353. SKU 91780 6. Figure 9 Solenoid Assembly (34w) Socket Cover (2s) Socket (6s) Switch Assembly (35w) 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 attach ...
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Chicago Electric 91780 - page 11
Page 1 1 For technical questions, please call 1-800-444-3353. SKU 91780 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 ...
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Chicago Electric 91780 - page 12
Page 12 For technical questions, please call 1-800-444-3353. SKU 91780 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 dam ...
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Chicago Electric 91780 - page 13
Page 13 For technical questions, please call 1-800-444-3353. SKU 91780 MAINTENANCE AND SER VICING Procedures not specically explained in this manual must be performed only by a qualied technician. TO PREVENT SERIOUS INJUR Y FROM ACCIDENT AL OPERA TION: Unplug the Switch Assembly (35w) connector from the Socket (6s) on the Solenoid Assembly (3 ...
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Chicago Electric 91780 - page 14
Page 14 For technical questions, please call 1-800-444-3353. SKU 91780 T roubleshooting Problem Possible Causes Likely Solutions Motor does not turn on. 1. Switch not connected properly . 2. Loose power cord connections. 3. Battery needs charging. 4. Solenoid malfunctioning. 5. Defective Switch. 6. Defective motor . 7. W ater has entered motor . 8. ...
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Chicago Electric 91780 - page 15
Page 15 For technical questions, please call 1-800-444-3353. SKU 91780 WINCH P ARTS LIST & ASSEMBL Y DIAGRAM Part Description Qty 2w Fairlead 1 3w Bolt M10 x 34 4 5w W asher M10 2 6w Nut M10 6 7w End Bearing 1 8w Spring 6 9w Locking Ring 1 10w T ie Bar 2 11 w Cam Ring 1 12w Bolt M8 x 30 4 13w Nut M8 4 14w Gear Ring 1 15w Gear Retainer Ring 1 16 ...
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Chicago Electric 91780 - page 16
Page 16 For technical questions, please call 1-800-444-3353. SKU 91780 Part Description Qty 1s Plastic Housing 1 2s Socket Cover 1 3s Flat W asher 6 4s Spring W asher 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 11 s Ground Cable 1 12s Screw M6 x 30 4 Part Description Qty 13s Battery Cable ...
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Chicago Electric 91780 - page 17
Page 17 For technical questions, please call 1-800-444-3353. SKU 91780 Part Description Qty 1f Cap Nut 8 2f Lock W asher 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 ROLLER F AIRLEAD P ARTS LIST & ASSEMBL Y DIAGRAM Record Pr ...
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Chicago Electric 91780 - page 18
Page 18 For technical questions, please call 1-800-444-3353. SKU 91780 90 Day W arranty Harbor Freight T ools 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 dat ...
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