Chicago Electric Utility Vehicle 90282 User Manual

UTILITY WINCH - 2000 LBS.  
90282  
ASSEMBLY AND OPERATING INSTRUCTIONS  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Copyright © 2003 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.  
For technical questions and replacement parts, please call 1-800-444-3353  
 
3.  
4.  
5.  
Keep children away. Children must never be allowed in the work area. Do not let  
them handle machines, tools, or extension cords.  
Store idle equipment. When not in use, tools must be stored in a dry location to  
inhibit rust. Always lock up tools and keep out of reach of children.  
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 applications 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.  
6.  
Dress properly. Do not wear loose clothing or jewelry as they can be caught in  
moving parts. Protective, electrically non-conductive clothes and non-skid footwear  
are recommended when working. Wear restrictive hair covering to contain long hair.  
7.  
8.  
Do not overreach. Keep proper footing and balance at all times. Do not reach over  
or across running machines.  
Maintain tools with care. Keep tools sharp and clean for better and safer  
performance. Follow instructions for lubricating and changing accessories. Inspect  
tool cords periodically and, if damaged, have them repaired by an authorized  
technician.  
9.  
Disconnect power. Unplug tool when not in use.  
10. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches  
are removed from the tool or machine work surface before turning on.  
11. Avoid unintentional starting. Be sure the switch is in the Off position when not in  
use and before connecting power.  
12. Stay alert. Watch what you are doing, use common sense. Do not operate any tool  
when you are tired.  
13. Check for damaged parts. Before using any tool, any part that appears damaged  
should be carefully checked to determine that it will operate properly and perform its  
intended function. Check for alignment and binding of moving parts; any broken parts  
or mounting fixtures; and any other condition that may affect proper operation. Any  
part that is damaged should be properly repaired or replaced by a qualified  
technician. Do not use the tool if any switch does not turn On and Off properly.  
14. Replacement parts and accessories. When servicing, use only identical  
replacement parts. Use of any other parts will void the warranty. Only use accessories  
intended for use with this tool. Approved accessories are available from Harbor  
Freight Tools.  
15. Do not operate tool if under the influence of alcohol or drugs. Read warning  
labels if taking prescription medicine to determine if your judgment or reflexes are  
impaired while taking drugs. If there is any doubt, do not operate the tool.  
16. Maintenance. For your safety, service and maintenance should be performed  
regularly by a qualified technician.  
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17. Pacemaker safety warning. People with pacemakers should consult with their  
physician(s) before using this product; operation of equipment in close proximity to a  
heart pacemaker could cause interference or failure of the pacemaker.  
Note: Performance of this tool may vary depending on variations in local line voltage or tool  
battery power. Extension cord usage may also affect tool performance.  
Winch Warnings and Precautions  
1.  
2.  
Keeps hands and body away from Fairlead (cable intake slot) when operating.  
Secure vehicle in position with the emergency brake and wheel blocks before using  
winch. Never keep the vehicle in Park or in gear while using the Electric Winch.  
3.  
4.  
Do not exceed winch load weight capacity (see Specifications on page 2).  
Be certain winch is properly bolted to a structure (or vehicle) that can hold the winch  
load.  
5.  
6.  
7.  
Always use proper couplings when connecting winch cable hook to load.  
Do not lift items vertically. The winch was designed for horizontal pulling use only.  
Do not overload the winch (see Specifications on page 2). It will do the job better and  
safer at its rated capacity.  
8.  
9.  
Do not use inappropriate attachments to extend the length of the winch cable.  
Never pull people or pull loads over people.  
10. Never come in between the winch and the load when operating.  
11. Do not apply winch to load when cable is fully extended. Keep at least 4 full turns of  
cable on the reel.  
12. After moving an item with the winch, secure the item. Do not rely on the winch to hold  
it for an extended period.  
13. Examine winch before using. Components may be affected by exposure to chemicals,  
salts, and rust.  
14. Never fully extend cable while under load. Keep 4 complete turns of cable around the  
winch drum.  
15. When loading a boat into a trailer without keel or side hull rollers, make sure the trailer  
is submerged in the water (but not the Winch) when the boat is loaded by the winch.  
Attempting to drag the boat on to the trailer while on land can cause winch failure and  
possible injury.  
16. Never operate winch if cable shows any signs of weakening, is knotted or kinked.  
17. Winch does not have a locking mechanism. Secure load after moving.  
18. Do not cross over or under cable under load.  
19. Do not move vehicle with cable extended and attached to load to pull it. The cable  
could snap.  
20. Use leather gloves while handling cable.  
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21. Apply blocks to vehicle when parked on an incline.  
22. Re-spool cable properly in a smooth pattern as shown in the photo below.  
23. Not to be used for aircraft purposes.  
Warning:The warnings, cautions, and instructions discussed in this instruction manual  
cannot cover all possible conditions and situations that may occur. It must be under-  
stood by the operator that common sense and caution are factors which cannot be  
built into this product, but must be supplied by the operator.  
Unpacking  
When unpacking, check to make sure that the following parts are included.  
Clutch Knob (17)  
Remote Control (26)  
If any parts are missing or broken, please call Harbor Freight Tools at the number on the  
cover of this manual as soon as possible.  
Installation  
Warning: Injury or death could occur if this ElectricWinch comes apart from its mount-  
ing location when it is under load. For that reason, it should only be installed by a  
qualified technician.  
1.  
Align the Winch on the vehicle mounting frame (not supplied). Make drill marks  
through the mounting holes.  
It should be aligned and secured to a solid, flat part of the vehicle (capable of  
supporting the Winch and load capacity) where the full rated load will be evenly  
distributed. Also remember that the Winch is designed for horizontal pull, not vertical.  
Mounting Holes  
2.  
3.  
Remove the Winch and drill two 5/16 inch holes through the vehicle mounting frame.  
Secure the Winch to the vehicle mounting frame using Mounting Nuts, Bolts, and Lock  
Washers (not supplied). Securely tighten.  
REV 04/04  
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6.  
7.  
Remove the outer connection nuts from the winch motor and connect the red cable  
labeled (+) positive to the red terminal. Securely tighten.  
Connect the black cable labeled (–) negative to the black terminal. Securely tighten.  
Switch to Winch Connections  
Switch to Battery Fuse Connections  
8.  
Route the red and black Remote Control-to-Battery cables from the Switch on the  
cable of the remote control, to the battery fuse box terminal strip in the vehicle. The  
circuit fuse must be 70 amps.  
Caution: Remote control battery cables should not be drawn taut. Leave slack for some  
cable movement. Do not route cables near moving engine parts, or heated areas that  
could melt the cable insulation.  
9.  
Disconnect the positive (red) cable to the vehicle battery.  
You will now be making an electrical connection from the Remote Control-to-Battery  
cables to the vehicle electrical system (the vehicle’s fuse box terminal strip).  
Caution: Although the 12VDC battery cannot shock you, it can spark and heat up cables  
to the melting point, and can cause serious burns if not installed and fused correctly.  
That is why the battery is disconnected at this time.  
10. Locate an appropriate positive (+ red), fused, terminal point in the vehicle fuse box  
able to supply 70 amps of current and connect the red Remote Control-to-Battery  
cable directly to the fuse terminal (without splicing wires).  
11. Connect the black negative (—) cable to the vehicle metal frame, or a ground lug on or  
near the battery.  
12. Reconnect the red positive (+) battery cable lug to the battery.  
13. Disengage the clutch by pulling out, then turning the Clutch Knob (17) to lock in the  
OUT position.  
14. Pull the cable out about five feet for testing.  
15. Test Electric Winch for proper operation. Refer to the Operation section on the next  
page.  
REV 04/04  
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Operation  
Note: The vehicle battery must be fully charged and the engine running before using  
the Electric Winch.  
1.  
Disengage the clutch by pulling out, then turning the Clutch Knob (17) to lock in the  
OUT position.  
2.  
Grab the Hook (27) with the Manual Handle (25) and pull the cable to the desired  
length, then attach the Hook to item being pulled. Make sure the Hook spring-loaded  
latch is set.  
Caution: Always leave at least four turns of cable on the drum. Review Winch Safety  
Warnings and Precautions on page 3 before continuing.  
3.  
Re-engage the clutch by turning the Clutch Knob until it locks in the IN position.  
Caution: Avoid damaging the vehicle transmission. Do not have the transmission in  
Park or in any gear. Set the Emergency Brake and place wheel chocks, then put in neu-  
tral.  
4.  
While standing aside of the tow path, press (and hold) the IN pushbutton on the  
Remote Control to pull the load. If the load will not move, release pull switch and  
check for obstacles blocking the load, or check to see if load is too heavy for Winch  
capacity.  
Press (and hold) the OUT pushbutton to release the load.Wait until the motor stops  
before reversing directions.  
5.  
When the pulling is complete, secure the load so it cannot move in either direction.  
Caution: The Utility Winch is designed for intermittent use only, and should not be  
used in a constant duty application.The duration of the pulling job should be kept as  
short as possible. If the Winch motor 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. Do not maintain power to the Winch if the motor stalls as it can damage  
the motor or gears.  
Maintenance  
Lubrication  
1.  
All moving parts within the Winch have been lubricated using high temperature lithium  
grease at the factory. No internal lubrication is required.  
2.  
Lubricate cable periodically using a light penetrating oil.  
Cable Assembly Replacement (to be performed only by a qualified service tech.)  
1.  
2.  
Move Clutch Handle to the OUT position.  
Extend Wire Rope (27) cable to its full length. Note how the existing cable is  
connected to the inside of the drum.  
3.  
Remove old Cable Assembly and attach new one.  
Caution: Do not replace with inferior cable. Always use the approved replacement part  
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from Harbor FreightTools.  
4. Retract Cable onto cable drum being careful not to allow kinking.  
General  
1.  
2.  
Keep vehicle battery in good condition.  
Be sure that the Winch battery cables are not drawn tight against any surfaces which  
could possibly damage them.  
3.  
4.  
Periodically remove and clean cable connections to the battery fuse box and chassis  
ground. Corrosion will reduce performance or may cause a short.  
Cover the cables and Winch when not in use.  
Parts List  
Item #  
1
Description  
Motor  
2
Motor End Support  
Planetary Gear Assy.  
Inner Gear  
3
4
5
Left End Support  
M4-12  
Bolt  
6
7
Axle Sleeve  
Shaft  
8
9
Spring  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
Drum  
M5-8  
Fastening Block  
Bearing  
Gasket  
M5-12  
Screw  
Right End Support  
Laminated Spring  
Knob  
Pin  
M6-16  
M6-16  
Bolt  
Bolt  
Bolt  
M8-35  
Spacer  
Shim  
8 mm  
8 mm  
Screw  
M8 mm  
Manual Handle  
Remote Control  
Wire Rope and Hook Assy.  
NOTE: Some parts are listed and shown  
for illustration purposes only and are not  
available individually as replacement  
parts.  
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Assembly Drawing  
25  
26  
1
27  
2
3
8
4
9
5
10  
11  
6
7
12  
18  
13  
14  
15  
16  
17  
19  
21  
20  
22  
23  
24  
PLEASE READTHE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS  
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU-  
TOR MAKES ANY REPRESENTATION ORWARRANTY OF ANY KINDTOTHE BUYERTHAT 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 STATESTHAT 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.  
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