Winch_61672
Winch_61672
Winch_61672
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. 24f
1500 LB CAPACITY
120VwithAC ELECTRIC WINCH
AUTOMATIC LOAD-HOLDING BRAKE
2. Do not pull more than rated load. Be aware of 7. Do not remove or cover warning labels and/
dynamic loading! Sudden load movement may or tags. These carry important safety information.
briefly create excess load causing product failure. If unreadable or missing, contact
Harbor Freight Tools for a replacement.
3. Do not operate winch with twisted, kinked, or
damaged wire rope. 8. The warnings, precautions, and instructions
Inspect wire rope carefully before every use. discussed in this instruction manual cannot
Inspection
Safety
to move and stay clear of the load. AMPERES LENGTH
(at full load) 25′ 50′ 100′ 150′
3. Locate pendant controls at a convenient
level above the operating floor. 0–6 18 16 16 14
6.1 – 10 18 16 14 12
4. Do not install where the load hook can
be lowered beyond the rated hook travel 10.1 – 12 16 16 14 12
under normal operating conditions. 12.1 – 16 14 12 Do not use.
Installation
your product will draw. An undersized cord will
cause a drop in line voltage resulting in loss
of power and overheating. Table A shows the
correct size to use depending on cord length
and nameplate ampere rating. If in doubt, use
the next heavier gauge. The smaller the
gauge number, the heavier the cord.
Operation
2. Perform a “Periodic (Thorough) Inspection” 4. Raise test loads only to the minimum extent needed
at least yearly, see page 9. and stay well clear of load at all times during testing.
Safety
Remote Control Wire Length 116″
IP Rating IP44
Installation
Installation Instructions
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.
1. The supporting structure the winch is mounted to 3. Secure the Fairlead (33) to the side of the
(including trolley, monorail, or crane) Mounting Channel (35). Use hardware of
must be designed to withstand the loads and SAE Grade 5 or higher. Torque to 12 ft. lb.
forces imposed by the winch for the rated load.
4. Bolt the Mounting Channel (35) to a surface
2. Secure the Mounting Frame (28) of the Winch capable of withstanding 1500 lb. of pulling force.
to the Mounting Channel (35). Use hardware of Use galvanized/zinc plated hardware of
Operation
SAE Grade 5 or higher. Torque to 12 ft. lb. Insert SAE Grade 5 or higher. Torque to 12 ft. lb.
Bolts, Nuts and Washers through the base of the
Mounting Frame and through the corresponding
holes in the Mounting Channel (35) - see Figure A.
16″
14″
12″ Inspection
Winch
Mounting
3.2″
Holes
~13/32″ Diameter
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.
Safety
TO PREVENT SERIOUS INJURY: Operation of a winch involves more than depressing the
UP or DOWN control. The use of winches is subject to certain hazards that cannot be met
by mechanical means, but only by the exercise of intelligence, care, common sense, and
experience in anticipating the motions that will occur as a result of operating the controls.
on the winch, and the safety and operating 6. Designate a work area that is clean and well‑lit.
instructions portion of this manual. The work area must not allow access by children
or pets to prevent distraction and injury.
2. WARNING! TO PREVENT SERIOUS INJURY
FROM WINCH FAILURE: 7. Route the power cord along a safe route to reach
Do not use damaged equipment. the work area without creating a tripping hazard or
If adjustments or repairs are necessary, exposing the power cord to possible damage. The
or any defects are known, have the power cord must reach the work area with enough
problem corrected before further use. extra length to allow free movement while working.
3. Do not operate a winch with an out-of-order sign. 8. There must not be objects, such as utility lines,
nearby that will present a hazard while working.
4. Only a qualified technician should
perform maintenance to the winch. 9. Inspect the winch as explained in
Frequent Inspection on page 8
after installation but before use.
Operation
Operating Controls
Reset
Button
Retract
Hook
Hook
Inspection
Clutch
Knob
Extend
Hook
Reset Button: If the winch suddenly stops operating, wait for it to cool completely,
then press the Reset Button to continue use.
Safety
3. Grasp the Hook and pull it out to the
desired length. Attach the Hook to the
item being pulled. Make certain that the
spring-loaded latch of the Hook is set.
Installation
shackles, hooks, lifting slings, etc. Load must be
attached to prevent accidental disconnection. 9. Do not operate the winch unless wire rope is seated
properly on the drum, pulleys, or sprockets.
6. Properly seat the sling or other device
in the base (bowl or saddle) of the hook 10. Do not pick up a load in excess of the rated
(see the left side diagram on Figure B). Do not load appearing on the winch or load block,
allow the hook hitch to support any part of the load. except during properly authorized tests.
Do not use a winch overload limiting device to
7. Do not apply the load to the point of the hook measure the maximum load to be pulled.
(shown in Figure B on the right side diagram).
11. Give specific attention to load balancing and
hitching or slinging to prevent load slipping.
Moving the Load
1. Do not engage in any activity which will divert the 9. Each time a load approaching rated capacity is
operator’s attention while operating the winch. handled, check winch brake action by pulling the
Operation
load just clear of supports and continuing only after
2. Respond to signals from a designated person only. verifying that the brake system is operating properly.
However, always obey a stop signal,
no matter who gives it. 10. Do not lower the load below the point where less
than two wraps of rope remain on each anchorage
3. Do not move a load with the winch until the operator of the winch drum, unless a lower limit device is
and all other personnel are clear of the load. provided, in which case no less than one wrap may
remain on each anchorage of the winch drum.
4. Make sure the load and winch will clear all
obstacles before moving or rotating the load. 11. WARNING! Do not carry any
load over any person.
6. Re-engage the clutch by turning the Clutch
Knob (24) until it locks in the IN position. 12. WARNING! TO PREVENT SERIOUS INJURY: Do
not carry personnel on the hook or the load.
7. Inch winches slowly into engagement with a load,
but avoid unnecessarily inching and 13. Do not use the upper (or lower, if provided) limit
quick reversals of direction. devices as a normal means of stopping the winch.
Inspection
Frequent Inspection
Installation
Perform the procedures in this section BEFORE f. hook attachment and securing means.
INITIAL USE and AT LEAST MONTHLY. Inspection
is needed more often for heavily used winches. 5. Frequent Winch Rope Inspection
All ropes should be visually inspected by
1. Check operating mechanisms for proper operation, the operator or other designated person at the
proper adjustment, and unusual sounds start of each shift. These visual observations should
such as, but not limited to, binding noise be concerned with discovering gross damage, such
of the wire rope and bearing squeal. as listed below,
2. Check winch upper limit device without a load on the which may be an immediate hazard:
hook at the beginning of each shift. Exercise care. a. distortion of the rope such as kinking,
Run the load block into its limit device at slow speed. crushing, unstranding, birdcaging,
main strand displacement, or core protrusion;
3. Frequent Braking System Inspection
b. general corrosion;
a. The braking system must automatically
stop and hold up to the rated load if the c. broken or cut strands;
Operation
4. Frequent Hook Inspection 2) one outer wire broken at the contact point
with the core of the rope which has worked its
Check hooks for the following problems: way out of the rope structure and protrudes
a. distortion, such as bending, twisting, or loops out from the rope structure.
or increased throat opening;
If such damage is discovered, either remove
b. wear; the rope from service or arrange for a qualified
c. cracks, nicks, or gouges; technician to give it a periodic (thorough) inspection.
d. latch engagement (if equipped); 6. Check wire rope reeving.
e. damaged or malfunctioning latch (if equipped);
Inspection
WARNING! TO PREVENT SERIOUS INJURY FROM WINCH FAILURE: Do not use damaged equipment.
If any defect or damage is noted, have the problem corrected before further use.
Safety
resulting in appreciable loss of original strength,
allow inspection of components. such as described below, and have a qualified
1. First, follow all Frequent Inspection procedures. technician determine whether further use
Additionally: of the rope would constitute a hazard:
a. Check points listed in Frequent
2. Check fasteners for evidence of loosening. Winch Rope Inspection on page 8.
3. Check load blocks, suspension housings, clevises, b. Check for reduction of rope diameter
yokes, suspension bolts, shafts, gears, bearings, below nominal diameter due to loss of
pins, rollers, and locking and clamping devices for core support, internal or external corrosion,
evidence of wear, corrosion, cracks, and distortion. or wear of outside wires.
c. Check for severely corroded or broken
4. Check hook retaining nuts or collars, and
wires at end connections.
Installation
pins, welds, or rivets used to secure the
retaining members for evidence of damage. d. Check for severely corroded, cracked, bent,
worn, or improperly applied end connections.
5. Check load sprockets, idler sprockets, drums,
e. Inspect with special care the following
and pulleys for evidence of damage and wear.
sections of rapid deterioration:
6. Check the motor brake and load brake 1) sections in contact with saddles,
for evidence of wear. equalizer pulleys, or other pulleys
where rope travel is limited;
7. Check electrical apparatus for evidence of
pitting or deterioration of controller contacts. 2) sections of the rope at or near terminal ends
where corroded or broken wires may protrude;
8. Check supporting structure or trolley, 3) sections subject to reverse bends;
if used, for evidence of damage.
4) sections of rope which are normally
9. Check warning label for legibility and replacement. hidden during visual inspection, such
as parts passing over pulleys.
10. Check end connections of wire ropes for evidence
Operation
of wear, corrosion, cracks, damage, and distortion. 12. Check function labels on pendant
control(s) for legibility.
WARNING! TO PREVENT SERIOUS INJURY FROM WINCH FAILURE: Do not use damaged equipment.
If any defect or damage is noted, have the problem corrected before further use.
Storage Inspection
1. A winch that has been idle for a period 2. A winch that has been idle for a period of a
of a month or more, but less than a year, year or more, must be inspected according
must be inspected before being used according to the Periodic Inspection requirements and
Inspection
to the Frequent Inspection requirements. then tested according to the procedure in the
Testing section below before being used.
Testing
1. Before use, test repaired winches and winches 4. Test the trip-setting of limit devices under no-load
that have not been used for a year or more. conditions. Test first by hand, if practical, and then
under slowest speed. Test with increasing speeds
2. Check all functions of the winch, including retracting up to maximum speed. Check that actuating
and extending, with the winch unloaded first. mechanisms are located so that they will trip the
switches or limiting devices in sufficient time to
3. After testing in the unloaded state,
stop motion without causing damage to any part of
attach a 100 Ib. load and retest to check proper
the winch. On winches having adjustable trip-setting
load control and to check brake operation.
limit devices, take care to adjust to prevent the load
Operation
SaFety
4 Gear Ring 1 22 Cross Head Bolt M5 x 12 2
5 Clip 1 23 Inner Flat Head Bolt M5 x 132 2
6 Bushing-Gear Carrier 1 24 Clutch Knob 1
7 Input Gear Carrier Assembly 1 25 Spring Pin 1
8 Washer 1 26 Side Plate 1
9 Output Gear Carrier Assembly 1 27 Bushing 1
10 Spacer 1 28 Mounting Frame 1
11 Dish Gear 1 29 Inner Hex Head Bolt M5 x 16 2
12 Washer 1 30 Wire Rope & Hook 1
13 Tie Bar 2 31 Strap 1
14 Nut M5 2 32 Bolt M8 x 25, Washer, Spring Washer, Nut 3 sets
15 Tension Plate 1 33 Hawse Fairlead 1
16 Gear Box Cover 1 34 Hardware (Bolt M10x25 & Washer) 2 sets
inStallatiOn
17 Bushing 1 35 Mounting Channel 1
18 Flat Washer 6 36 Bolt M10 x 34, Nut 4 sets
OperatiOn
inSpectiOn
note: Some parts are listed and shown for illustration purposes only, and are not available
individually as replacement parts. Specify UPC 193175201126 when ordering parts.