Harbor Freight Tools 56385 User Manual Download

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Owner’s Manual & Safety Instructions

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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.

20d

When unpacking, make sure that the product is intact

and undamaged. If any parts are missing or broken,

please call 1-888-866-5797 as soon as possible.

Copyright

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2019 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.

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.

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

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Summary of Contents for 56385

Page 1: ...rence 20d When unpacking make sure that the product is intact and undamaged If any parts are missing or broken please call 1 888 866 5797 as soon as possible Copyright 2019 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 Diagrams within this manua...

Page 2: ...k 3 8 Replaceable with Spring loaded Safety Latch Fairlead Aluminum Fairlead Sound Rating 85 dB Synthetic Rope Size Type Ø0 375 x 80 Ø9 5mm x 24 4m Battery 12VDC Minimum 650 CCA Battery Cables Minimum 2 AWGx6 Mounting Bolt Pattern 10 x 4 5 254mm x 114 3mm Mounting Hardware Winch 8x Gr8 8 M10 x 30mm Fairlead 2x Gr8 8 M12 x 40mm Overall Dimensions L x D x H 23 2 x 6 67 x 9 96 590mm x 169 5mm x 253mm...

Page 3: ...n 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 explosion hazard Do not loop the synthetic 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 Symbol Property or Stat...

Page 4: ...es 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 synthetic 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 wor...

Page 5: ...vice 3 Use supplied power cords synthetic rope or cables listed in manual only Do not use thinner longer cables or link multiple cables together 4 Have the Winch serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the Winch is maintained 5 Maintain labels and nameplates on the Winch These carry important safety information If unreadable ...

Page 6: ...this product What s in the Box Winch x 1 Aluminum Fairlead x 1 Hook x 1 Remote Control x 1 Rope Protecting Mat x 2 Ground Cable x 1 Disconnect Switch x 1 Remote Control Cable x 1 Red Hook Strap x 1 Control Box Baseplate x 1 Sheath red black yellow x 3 Small Black Wire Connector x 1 Small Black Wire Extension x 1 Instruction Books Manual Guide to Winching Power Cables relocation kit x 3 Extended Co...

Page 7: ...ted capacity without damage or weakening Steel reinforcement plates may be needed or a certified welder may need to weld on additional bracing depending on the mounting location 5 Drill holes appropriate for the hardware at the marked locations note Depending on the vehicle application it may be beneficial to install the wiring before mounting the Winch Check all terminal access and plan wiring ro...

Page 8: ...l Box is disconnected and hanging freely Small Black Wire Ground Cable 4 Remove the Terminal Cover by unscrewing two M4x16 Screws holding it in place Remove the six Motor Terminal Nuts and three Copper Plates Retain all the hardware Terminal Cover Motor Terminal nuts Copper Plates M4x16 Screw 5 Remove four M6x25 Screws holding the Control Box in place and gently lift it off of the Winch M6x25 Scre...

Page 9: ...erminal Nuts removed in step 4 Motor Terminal nuts Control Box black red yellow 11 Use the Small Black Wire Connector and Small Black Wire Extension to lengthen the Small Black Wire from the Control Box Reconnect the Ground Cable and Small Black Wire to the backside of the Winch motor Small Black Wire extension Connector Black Ground Cable Red Battery Cable 12 Install the four decorative M6x12 Scr...

Page 10: ...e the Cables from the Winch to the battery following the precautions discussed above Refer to Figure C Disconnect Switch Black Ground Cable Red Battery Cable 12 Cable Socket Cover Small Black Wire Figure C Wiring Connections 4 Attach the 12 2AWG Disconnect Switch Cable to the positive terminal on the battery 5 Attach the 12 2AWG Cable from the battery to either terminal on the Disconnect Switch 6 ...

Page 11: ...operly coiled under tension to be able to support a load without damage 1 Find a suitable location where the Rope can be spooled onto the Winch while anchored to a solid object Approximately 70 feet will be required Alternately a snatch block sold separately may be used to reduce the distance to 35 feet 2 Move the Clutch Handle to the Freespool position and uncoil the Synthetic Rope until 5 wraps ...

Page 12: ...nthetic Rope out Wireless Operation 1 For wireless Remote Control operation turn on the Wireless Receiver Switch on the Control Box Wireless Receiver Wireless Receiver Switch Switch Control Control Box Box 2 Press and hold the ON OFF Switch on the Remote for approximately 2 seconds until the red indicator light comes on indicating the Remote Control is ready for use in OuT Rocker Switch On OFF Swi...

Page 13: ...ps and general winch operating procedures If this guide is unreadable or missing contact Harbor Freight Tools for a replacement Read the enTiRe iMPORTAnT SAFeTy inFORMATiOn section at the beginning of the Guide to Winching including all text under subheadings therein before use of this product The instructions included in the Guide to Winching are basic guidelines only and cannot cover all situati...

Page 14: ...l wiring corroded or loose terminals any other condition that may affect its safe operation Examine the Synthetic Rope Do not use the Winch if the Rope is frayed or has cut strands 2 AFTeR uSe wipe external surfaces of the Winch with clean cloth If the Winch is submerged during use rinse thoroughly with fresh clean water when finished 3 The Winch s internal mechanism is permanently lubricated Do n...

Page 15: ...3 Fully charge battery Run Winch with vehicle motor running 4 Replace Control Box 5 Turn ON Wireless Receiver Switch 6 Turn ON Wireless Remote 7 Turn ON Winch Disconnect Switch 8 Replace Remote batteries CR2032 quantity two 9 Check for voltage at armature port with Switch pressed If voltage is present replace motor 10 Check and tighten ground cable to Control Box 11 Replace motor Motor runs but dr...

Page 16: ...ANTY OF ANY KIND TO THE BUYER THAT 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 STATES THAT 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...

Page 17: ...AFeTy OPeRATiOn MAinTenAnCe SeTuP Record Product s Serial number Here note If product has no serial number record month and year of purchase instead note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts ...

Page 18: ...6 Transmission Shaft S8x289 1 27 Brake Assembly 1 28 Spline Drive Sleeve 1 29 Tab 2 30 Waterproof Sealing Ring 2 31 Radial Ring 2 Part Description Qty 32 Iron Bushing 2 33 Motor Assembly 1 34 Terminal Cover 1 35 Star Screw M4x16 2 36 Motor Cover 1 37 Winch Mounting Hardware 4 sets 38 Synthetic Rope 1 39 Fairlead 1 40 Fairlead Mounting Hardware 2 41 Hook 1 42 Remote Control Cable 1 43 Wireless Wire...

Page 19: ...66 5797 Item 56385 SAFeTy OPeRATiOn MAinTenAnCe SeTuP Assembly Diagram 5 6 7 8 9 10 11 12 13 14 15 16 17 37 35 40 4 34 36 18 19 20 21 23 39 41 42 43 44 45 48 49 50 60 51 52 56 57 58 53 55 54 59 47 24 25 26 27 28 29 22 30 33 31 1 2 3 3 32 19 46 38 61 62 ...

Page 20: ...lusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take advantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an expl...

Page 21: ...ls All rights reserved No portion of this guide or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools Diagrams within this guide may not be drawn proportionally GUIDE TO WINCHING 19e ...

Page 22: ...nching Straight Pull 14 Single Line Winching Snatch Block 16 Double Line Winching 18 Read the ENTIRE IMPORTANT SAFETY INFORMATION section beginning on page 4 of this guide including all text under subheadings therein before use of this product The instructions that follow are basic guidelines only and cannot cover all situations encountered during use The operator and assistants must carefully pla...

Page 23: ...nt leather gloves Wear ANSI approved safety glasses Cut or sever hazard Roller entanglement hazard Hot surface burn hazard Fire hazard Caustic chemical acid hazard Explosion hazard Do not loop the wire or synthetic 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 Symbol Property or State...

Page 24: ...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 rope is pulling In case it slips or breaks it will whiplash along this line 8 Do not use for lifting or moving people 9 Use a spotter to assist you in assuring that it is safe to operate the Winch Make sure the spotter is out of the way of the vehicle and the rope befor...

Page 25: ...ven after it is straightened out kinked wire rope can fail suddenly and must not be used 17 Keep children and bystanders away while operating Distractions can cause you to lose control 18 Stay alert watch what you are doing and use common sense when operating Do not use a winch while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating winches...

Page 26: ... not slide a wire or synthetic rope through hands even with gloves on 29 Winch motor will be hot during and after use Keep clear 30 Do not power the hook all the way into the fairlead or Winch 31 To prevent accidental starting unplug winch controls and any RF receivers immediately after extending or retracting This is especially important before rigging installing free spooling or servicing 32 Peo...

Page 27: ...ternator KEEP THE VEHICLE IN NEUTRAL The parking brake is not designed to hold the loads that the winch can apply If recovering another vehicle keep foot firmly on brake For self recovery carefully steer vehicle to avoid obstacles and spotter and keep foot off brake KEEP THE LINE STRAIGHT Winch with the rope as straight as possible to the winching vehicle Use a snatch block if needed Before You Go...

Page 28: ...ecause there are many other variables to consider off road that add resistance For example the ground is not smooth or solid like pavement the vehicle s wheels may not turn smoothly the vehicle s steering may be broken and a host of other factors For the majority of off road recoveries the grade resistance can be equal to the gross vehicle weight GVW For smooth ramps used to load a trailer or othe...

Page 29: ...is used to estimate the recovery load Wheel Depth 1x GVW Fender Depth 2x GVW Cab Depth 3x GVW A snatch block is a great way to double the pulling power of your winch Tackle Resistance Each shackle that is used in the recovery rigging adds a small amount of resistance to the winch Each snatch block used in the recovery adds about 10 to the recovery load add this to the recovery load on the winch Ex...

Page 30: ...outermost layer of rope is represented by the full length shovel and the first layer of rope is represented by the short shovel The winch and the vehicle electrical system have a limited amount of power available so it is important to use the power in the most efficient way possible The winch can pull to 100 full rated load only on the first layer of rope that touches the drum For a constant load ...

Page 31: ...Spotter must be outside danger zone Have spotter watch for even winding of rope on drum If rope starts winding unevenly on the drum stop winching and adjust rigging or vehicle position Freespool the winch to remove the rope bunching on the drum flange and evenly spool the rope back on the drum then continue the recovery Or plan ahead and use a snatch block to ensure that an off angle pull will be ...

Page 32: ... change situation the objective is to pull from a direction that has a greater impact on the stuck vehicle In this example the weight is the stuck vehicle and the snatch block is attached to an anchor point The snatch block does not provide any increase to the recovery force but it does change the direction of the pull Example 2 Recovery Force Increase In a situation where the recovery will take m...

Page 33: ...work gloves when handling wire rope Do not run hands along wire rope even with gloved hands some wire strands can be sharp enough to pierce gloves Kinked Strands Replace Separated Strand Replace Broken Strands Replace Twisted Rope Replace Synthetic Rope CAUTION Wear work gloves to protect from cuts from debris when working with synthetic rope Abrasion Severe abrasion must be replaced minor abrasio...

Page 34: ...point Don t forget any rigging you will need such as a tree strap and shackle WARNING To prevent serious injury from sudden detachment of the winch rope leave at least 5 full wraps of rope on the drum 2 Secure the winch rope to the anchor point Do not wrap the winch rope directly around a tree or rock Not only will this damage or kill the tree but it will also damage the rope where the hook attach...

Page 35: ...d to make sure the rope is spooling on the drum correctly 3 Perform the winching operation with the vehicle in NEUTRAL or DRIVE Watch your spotter and monitor the battery voltage while winching Increase the engine RPM to raise the battery voltage level 4 When the vehicle is recovered engage parking brakes remove all rigging and wind the rope fully into the winch USING THE HOOK STRAP 5 Unplug or di...

Page 36: ...und a Corner When stuck on a hill or tight trail and an anchor point is too close to winch effectively a snatch block can be used Not only does this lower the rope layer so that the winch can pull harder it also allows the vehicle to remain connected to the farthest anchor once the snatch block is removed Pay special attention to the danger zone since it is much larger than a straight line pull DA...

Page 37: ... the trail to attach a snatch block to and perform the recovery Pay special attention to the danger zone since it is much larger than a straight line pull DANGER ZONE USE ALL OF THE PRECAUTIONS AND STEPS FROM SINGLE LINE WINCHING STRAIGHT PULL Snatch Block Tree Strap Shackle Rigging Needed 1x Tree Strap 2x Shackles Possibly more depending on tow points of stuck vehicle 1x Snatch Block For self rec...

Page 38: ...fforts that require more force than a single line pull can provide use a double line rigging back to the winching vehicle Make sure the rigging at the anchor is rated to withstand the estimated load to recover the vehicle DANGER ZONE USE ALL OF THE PRECAUTIONS AND STEPS FROM SINGLE LINE WINCHING STRAIGHT PULL Snatch Block Tree Strap Shackle Rigging Needed 1x Tree Strap 2x Shackles Possibly more de...

Page 39: ...This can be especially helpful in low traction conditions such as snow or mud Pay special attention to the danger zone since it is much larger than a straight line pull DANGER ZONE USE ALL OF THE PRECAUTIONS AND STEPS FROM SINGLE LINE WINCHING STRAIGHT PULL Snatch Block Tree Strap Shackle Rigging Needed 1x Tree Strap 2x Shackles Possibly more depending on tow points of stuck vehicle 1x Snatch Bloc...

Page 40: ...26541 Agoura Road Calabasas CA 91302 1 888 866 5797 ...

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