Chicago Electric 03633 Assembly And Operating Instructions Manual

Brand: Chicago Electric

Model: 03633

Type: Assembly And Operating Instructions Manual

ELECTRIC WINCH

9,000 LB. CAPACITY

Model 03633

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http//www.harborfreight.com

2003 by Harbor Freight Tools

manual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

REV 09/05

Due to continuing improvements, actual product may differ slightly from the product described herein.

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 2

PRODUCT SPECIFICATIONS

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly,

operating, inspection, maintenance and cleaning procedures, parts list and as-

sembly diagram. Keep your invoice with this manual. Write the invoice number on

the inside of the front cover. Keep this manual and invoice in a safe and dry place

for future reference.

GENERAL SAFETY WARNINGS AND PRECAUTIONS

1. KEEP WORK AREA CLEAN AND DRY. Cluttered, damp, or wet work areas

invite injuries.

2. KEEP CHILDREN AWAY FROM WORK AREA. Do not allow children to handle

this product.

3. STORE IDLE EQUIPMENT. When not in use, tools and equipment should be

stored in a dry location to inhibit rust. Always lock up tools and equipment, and

keep out of reach of children.

4. DO NOT USE THIS PRODUCT IF UNDER THE INFLUENCE OF ALCOHOL OR

DRUGS. Read warning labels on prescriptions to determine if your judgement or

reflexes are impaired while taking drugs. If there is any doubt, do not attempt to

use this product.

5. USE EYE PROTECTION. Wear ANSI approved safety impact eye goggles when

assembling and using this product. ANSI approved safety impact eye goggles

are available from Harbor Freight Tools.

metInoitpircseD

yticapaClluPeniLmumixaM )eniLelgniS(.sbL000,9

stnemeriuqeRlacirtcelECDtloV21

serutaeFgniloopSeerF

ekarBgnidloHdaoL,citamotuA

metsySraeGyratenalPegatS3

snoitarepOtuOrewoP/nIrewoP

elbaC'21htiwlortnoCetomeRdleHdnaH

daelriaFrelloReswaH

kooHhtiwelbaCtfarcriA,dezinavlaG,"8/3,'001

nrettaPgnitnuoM"5.4x"01

thgieWsdnuoP7.97

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 3

6. DRESS SAFELY. Do not wear loose clothing or jewelry, as they can become

caught in moving parts. Wear a protective hair covering to prevent long hair from

becoming caught in moving parts. If wearing a long-sleeve shirt, roll sleeves up

above elbows.

7. DO NOT OVERREACH. Keep proper footing and balance at all times to prevent

tripping, falling, back injury, etc.

8. INDUSTRIAL APPLICATIONS MUST FOLLOW OSHA REQUIREMENTS.

9. STAY ALERT. Watch what you are doing at all times. Use common sense. Do

not use this product when you are tired or distracted from the job at hand.

10. CHECK FOR DAMAGED PARTS. Before using this product, carefully check that

it will operate properly and perform its intended function. Check for damaged

parts and any other conditions that may affect the operation of this product. Re-

place or repair damaged or worn parts immediately.

11. REPLACEMENT PARTS AND ACCESSORIES: When servicing, use only

identical replacement parts. Only use accessories intended for use with this

product. Approved accessories are available from Harbor Freight Tools.

12. MAINTAIN THIS PRODUCT WITH CARE. Keep this product clean and dry for

better and safer performance.

13. MAINTENANCE: For your safety, service and maintenance should be performed

regularly by a qualified technician.

14. USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or

attachment to do the work of a larger industrial tool. There are certain applica-

tions for which this tool was designed. It will do the job better and more safely at

the rate for which it was intended. Do not modify this tool, and do not use this tool

for a purpose for which it was not intended.

15. WARNING: The warnings, precautions, and instructions discussed in this manual

cannot cover all possible conditions and situations that may occur. The operator

must understand that common sense and caution are factors, which cannot be

built into this product, but must be supplied by the operator.

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 4

SPECIFIC PRODUCT WARNINGS AND PRECAUTIONS

1. DO NOT EXCEED THE MAXIMUM RATED LOAD CAPACITY FOR THE

WINCH; (9,000 LBS. ROLLING). Overloading the Winch could cause serious

personal injury and/or property damage.

2. THE WINCH IS DESIGNED FOR INTERMITTENT USE ONLY. Do not use the

Winch in a constant duty application. The duration of the pulling job should be

kept as short as possible. If the Winch becomes very hot to the touch, stop the

Winch and let it cool down for several minutes. Never pull for more than one

minute at or near the rated load capacity.

3. MAKE SURE TO READ AND UNDERSTAND ALL INSTRUCTIONS AND

SAFETY PRECAUTIONS AS OUTLINED IN THE MANUFACTURER’S

MANUAL FOR THE VEHICLE/TRAILER TO WHICH THE WINCH WILL BE

ATTACHED.

4. MAKE SURE TO READ AND UNDERSTAND ALL INSTRUCTIONS AND

SAFETY PRECAUTIONS AS OUTLINED IN THE MANUFACTURER’S

MANUAL FOR THE OBJECT YOU WILL WINCH. Make sure to attach the Cable

Assembly (4A) of the Winch to the manufacturer’s recommended pulling point.

5. ALWAYS EXAMINE THE WINCH FOR STRUCTURAL CRACKS, BENDS,

DAMAGE, FRAYED CABLE, AND ANY OTHER CONDITIONS THAT MAY

AFFECT THE SAFE OPERATION OF THE WINCH. Do not use the Winch if

even minor damage appears.

6. MAINTAIN A SAFE WORKING ENVIRONMENT. Keep the work area well lit.

Make sure there is adequate surrounding workspace. Always keep the work area

free of obstructions, grease, oil, trash, and other debris.

7. ALWAYS KEEP HANDS AND FINGERS AWAY FROM THE GEARS OF THE

WINCH WHEN APPLYING OR RELEASING A LOAD. Remain clear of the

Cable Assembly (4A) when pulling a load. Do not stand in line with the Cable

Assembly, as it could whip violently should it break. People and animals should

be kept at a safe distance when using the Winch.

8. USE EXTREME CAUTION WHEN APPLYING OR RELEASING A LOAD.

Never allow the load to suddenly release. Slowly and carefully apply and release

the load.

9. NEVER WINCH A BOAT OR OTHER OBJECT WITH ANYONE IN OR ON IT.

Use a spotter to assist you in assuring that it is safe to operate the Winch. Make

sure this person is out of the way of the vehicle and the Steel Cable (4A) before

activating the Winch.

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 5

ASSEMBLY INSTRUCTIONS

NOTE: For additional references to the parts listed below, refer to the Assembly Dia-

grams (page 9-11). Note: See page 10 for Solenoid Bracket installation instructions.

NOTE: Depending on your level of knowledge regarding electrical wiring,

you may wish to have this procedure performed by a

qualified technician.

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts Lists (page 9-11)

are included. If any parts are missing or broken, please call Harbor Freight Tools at the

number shown on the cover of this manual as soon as possible.

10. THE WINCH IS DESIGNED FOR MOUNTING ON SQUARE OR RECTANGU-

LAR SURFACES ONLY. Do not attempt to mount the Winch on a rounded

surface.

11. THE WINCH IS NOT DESIGNED TO ACCOMMODATE ROPES OR FIBER-

GLASS STRAPS. Do not replace the Steel Cable (4A) with a Cable of lesser

strength.

12. THE STEEL CABLE (4A) MUST BE PULLED STRAIGHT IN. Keep the load in

line with the Winch. Pulling at an angle (off to the side) may cause excessive

stress on the Winch.

13. ALWAYS LEAVE AT LEAST FOUR TURNS OF STEEL CABLE (4A) ON THE

CABLE ASSEMBLY SHAFT TO PREVENT PULLING THE STEEL CABLE

COMPLETELY OUT OF THE WINCH.

14. DO NOT LEAVE THE WINCH UNATTENDED WHILE IT IS UNDER A LOAD.

15. WARNING: People with pacemakers should consult their physician(s) before

using this product. Electromagnetic fields in close proximity to a heart pacemaker

could cause interference to or failure of the pacemaker.

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 6

MOUNTING CHANNEL

(1; SOLD SEPARATELY)

SWITCH ASSY. (35)

CABLE ASSY. (36)

FEMALE CONNECTOR

(17B)

FIGURE A

CAM RING (11)

REV 09/05

2. Select a mounting site on the bed of a truck, trailer, or other suitable location.

WARNING: This Winch can generate 9,000 pounds pulling force. Make sure

the location selected can withstand this much force. It may be required to

use steel reinforcement plates (not included), and/or to weld on additional

bracing (not included), depending on the desired mounting location.

3. Align the Base of the Winch with the desired location, and mark for drilling the

four

mounting holes required to attach the Winch to the desired location. Then, drill

these four mounting holes on the vehicle/trailer.

4. Use

four

Capscrews (3), four Washers (5), four Lockwashers (4), and four Nuts (6)

to securely attach the Winch to the desired location.

5. Plan a route for the Winch’s two Battery Cables (9B, 6B), from the Winch’s Sole-

noid Assembly (10B) to the point of where the Battery Cables will be mounted on

the vehicle’s 12 Volt DC Battery. The route should 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, the Battery Cables may be routed

under the vehicle, attaching them to the frame using suitable fasteners (not in-

cluded). Do not attach the Battery Cables to the exhaust system, drive shaft,

emergency brake cable, fuel line, or any other components which may create

damage to the Battery Cables through heat or motion, or create a fire hazard. If a

hole is drilled through the bumper or any other part of the vehicle, make sure to

install a rubber grommet (not included) in the hole to prevent fraying of the Battery

Cables at that point. (See Figure A.)

NOTE: The Battery Cables (9B, 6B) should not be drawn taut. Make sure to

leave slack for some Cable movement.

7. Connect the RED/POSITIVE + Cable (9B) to the POSITIVE + terminal on the

vehicle’s 12 Volt Battery. (See Figure A.)

8. Connect the BLACK/NEGATIVE - Cable (6B) to the NEGATIVE - terminal on the

vehicle’s 12 Volt Battery. (See Figure A.)

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 7

OPERATING INSTRUCTIONS

To Estimate Pulling Capacity:

1. On flat, smooth ground the Winch has a pulling capacity of 9,000 pounds.

NOTE: The Winch’s pulling capacity is reduced as inclines increase. For ex-

ample, pulling capacity is reduced from 9,000 pounds on flat ground to approxi-

mately 1,600 pounds on a 45° incline. Refer to the Chart for estimated pulling

capacities (rolling weight) on various inclines. (See Figure B.)

Operating The Winch, Using One Strand Of The Cable:

1. When pulling an object: Place the vehicle’s transmission in “Park”. Set the emer-

gency brake, and block the wheels from rolling, using suitable chocks (not in-

cluded). Note: This type of winch is often used to extricate the vehicle it’s

mounted on. In such cases, the transmission should be in “Neutral” and the brake

off.

NOTE: You may wish to keep the vehicle’s engine running while using the Winch

to continually recharge the battery. However, use extreme caution when working

around a vehicle with its engine running.

3. Disengage the winch clutch by moving the Cam Ring (11) to the OUT position.

(See Figure A.)

3000

2000

1000

10 20

30 40

Maximum (Rolling) Weight Capacities On An Incline

Weight (Lbs.)

Degree Of Incline

FIGURE B

9000

8000

7000

6000

5000

4000

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 8

INSPECTION, MAINTENANCE, AND CLEANING

1. CAUTION: Always release a load from the Winch, and disconnect the Winch

from its 12 Volt DC electrical supply source, before performing any inspection,

maintenance, or cleaning.

2. BEFORE EACH USE, inspect the general condition of the Winch. Check for

loose screws, misalignment or binding of moving parts, cracked, bent or broken

parts, frayed Cable (36), and any other condition that may affect its safe operation.

Inspect the entire unit for corrosion that may be caused by exposure to salt water

or weather. If abnormal noise or vibration occurs, have the problem corrected

before further use. Do not use damaged equipment.

3. PERIODICALLY, use a premium quality, lightweight oil to lubricate the Cable (36).

4. EVERY SIX MONTHS, Grease all moving parts. Use any good quality, water-

proof, gear grease.

5. TO CLEAN, wipe with a clean, damp cloth. If necessary, a mild detergent may be

used.

4. Pull out the Cable (36) to the desired length, using the “Power Out” feature located

on the Switch Assembly (35).

Always leave at least

four

turns of Cable on the

Drum (31) to prevent pulling the Cable completely out of the Winch.

(See Figure A.)

5. Hook onto the object using a pulling point, tow strap, or chain (all not included).

Never wrap the Cable (36) around the object or hook onto the object itself. This

can cause damage to the object being pulled, and kink or fray the Cable.

(See Figure A.)

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS

MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES

ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALI-

FIED 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 CERTI-

FIED 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 REPLACE-

MENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS

THERETO.

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 9

WINCH PARTS LIST

traPnoitpircseDytQtraPnoitpircseDytQ

1,emarFgnitnuoM )dedulcniton( 12201x6MwercspaC1

2daelriaF132nuS,etaidemretnI-raeG1

353x01MwercspaC4

42nuS,tupnI,raeG1

401ørehsawkcoL452csiDtsurhT1

501øtalF,rehsaW462rehsaWtsurhT3

601MtuN472murD-gnihsuB2

7gniraeBdnE1

82teksaG1

8gnirpS692gnisuoHraeG-revoC1

9gniRgnikcoL10321x4MwercS6

01raBeiT213murD1

11gniRmaC123.y'ssAtfahS/kaerB1

2152x6MwercspaC4

33.y'ssAgniraeBdnErotoM1

316MtuN443y'ssAdioneloS1

41gniR,raeG153y'ssAhctiwS1

51raeGgniR,reniateR163.aiD)mm8(61/5'59-ylbmessAelbaC1

61gniRflaH2

73tuptuo-y'ssAreirraCraeG1

7191x6MwercspaC683etaidemretni-y'ssAreirraCraeG1

81nus,tuptuO-raeG193tupnI-y'ssAreirraCraeG1

91tfahs-gnihsuB1

04tekcarBdioneloS1

029x3øniPlloR114partSgnidniBcitsalP1

12rohcnAelbaC1

Solenoid Bracket

Installation Instruction

To attach the Solenoid Bracket supplied.

Remove the 2 Capscrews (12) and the 2 Retaining

Nuts (13) from the Motor End Bearing Assy., then

aligning the solenoid Bracket with the 2 tie bar

mounting holes. Re-secure the Tie Bars and attach

the Solenoid Bracket to the Motor End Bearing Assy

(33) using the 2 Capscrews (12) and the 2 Retaining

Nuts (13) that were previously removed. Torque

tightly.

Support Bracket

Tie down strap

to hold support

Bracket in place.

Retain the Solenoid Bracket supplied to the Motor End Bearing Assy. (33) by

attaching the Tie Down Strap around both the Solenoid Bracket and the Motor End

Bearing Assy. Pull Strap until tightly secure.

REV 09/05

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 10

WINCH ASSEMBLY DIAGRAM

Brought to You by Augusta Flint

SKU 3633 For technical questions, please call 1-800-444-3353. Page 11

Part # Description Qty. Part # Description Qty.

1B Wire Assy. (Black, 10 Ga. x 3 Lg.) 1 14B Cover - Female 1

2B Wire Assy. (Black, 10 Ga. x 6 Lg.) 2 15B Lock Washer 2

3B Wire Assy. (Black, 10 Ga. x 1-1/2 1 16B Cover - Solenoid 1

4B Strap - Copper 2

17B

Connector –

Female, Molded

5B Washer (5/6) 1 18B Screw 2

6B Wire Assy. (Battery Black, 60) 1 19B Bracket 1

7B Strap - Copper 1 20B Capscrew 3

8B Wire Assy. (Black, 6 Ga. x 3-1/2 Lg.) 1 21B Spacer 3

9B Wire Assy. (Battery Red, 60) 1 22B Lock Washer (06) 3

10B Solenoid – 12 Volt 2 23B Nut (M6) 6

11B Washer 4 24B Nut Bushing 3

12B Nut 6 25B Screw 7

13B Terminal Tab 4

* Includes parts called “RED”, “YELLOW” and “GREEN”. See Diagram below.

SOLENOID ASSEMBLY PARTS LIST

NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-

able individually as replacement parts.

SOLENOID ASSEMBLY DIAGRAM

23B

22B

21B

25B

20B

19B

24B

25B

10B

11B

12B

RED

GREEN

13B

10B

11B

12B

13B

YELLOW

14B

18B

17B

16B

12B

15B

Brought to You by Augusta Flint

Chicago Electric 03633 Assembly And Operating Instructions Manual

Chicago Electric 03633 Assembly And Operating Instructions Manual

Chicago Electric 03633 Assembly And Operating Instructions Manual

Related papers

Other documents