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Truck/suv winch 12000lb
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Table Of Contents 41
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- Contents
- Table of Contents
- Troubleshooting
- Bookmarks
Table of Contents
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Table of Contents
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Specifications
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Warning Symbols and Definitions
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Installation Precautions
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Service Precautions
- Installation and Setup
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What’s in the Box
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Mounting the Winch
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Winch Dimensions
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Fairlead Mounting Dimensions
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Relocating the Control Box
- Wiring
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Wiring Connections
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Remote Controls
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Preparing the Synthetic Rope
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Disconnect Switch
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Remote Control Instructions
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Wired Operation
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Wireless Operation
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Operation
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Maintenance and Servicing
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Cleaning, Maintenance, and Lubrication
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Synthetic Rope Replacement
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Troubleshooting
- Parts List
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Assembly Diagram
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Table of Contents
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Warning Symbols
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Operation Precautions
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Whiplash Dampening Blanket or Winch Damper
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Important Safety Information
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Hawse Fairlead Maximum Winching Angles
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Roller Fairlead Maximum Winching Angles
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Snatch Block
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Basic Winching Tips
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Before You Go
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Resistance Types
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Grade Resistance
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Estimating Load
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Mire Resistance
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Tackle Resistance
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Wheel Depth Mire
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Fender Depth Mire
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Rope Layer
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Winch Basics
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Rope Angle
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Recovery Force Increase
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Direction Change
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Snatch Blocks
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Rope Inspection
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Wire Rope
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Synthetic Rope
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Setup
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Rigging
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Single Line Winching - S Traight Pull
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Duty Cycle
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Winching
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Overview
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Around a Corner
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Rigging Needed
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Single Line Winching - S Natch Block
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Vehicle off Trail
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Double Line — Self Recovery
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Double Line Winching
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Double Line — Other Vehicle Recovery
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Quick Links
- 1 Installation and Setup
- 2 Wiring
- 3 Parts List
- Download this manual
Owner's Manual & Safety Instructions
Save This Manual
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.
email our technical support at: productsupport@harborfreight.com
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
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.
Keep this manual for the safety warnings and precautions, assembly,
Visit our website at: http://www.harborfreight.com
®
. All rights reserved.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.
20d
Table ofContents
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Table of Contents
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Summary of Contents for Harbor Freight Tools Badland Apex
- Page 1 No portion of this manual or any artwork contained herein may be reproduced in Failure to do so can result in serious injury. 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 SAVE THIS MANUAL.
- Page 2 Table of Contents Specifications ............2 Maintenance .............14 Safety ................3 Parts List and Diagram ..........18 Setup .................6 Warranty ..............20 Operation ..............13 Specifications Rated Single Fairlead Aluminum Fairlead 12,000 lb (5443 kg) Line Pull Sound Rating 85 dB Vehicle Recovery / Synthetic Rope Application Ø0.375"...
- Page 3 WARninG SyMBOLS AnD DeFiniTiOnS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
- Page 4 iMPORTAnT SAFeTy inFORMATiOn WARninG! Read all instructions. Failure to follow all instructions listed on page 4 may result in fire, serious injury and/or DeATH. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.
- Page 5 These carry important safety information. cables listed in manual only. Do not use thinner/ If unreadable or missing, contact longer cables or link multiple cables together. Harbor Freight Tools for a replacement. SAVe THeSe inSTRuCTiOnS. Item 56385 For technical questions, please call 1-888-866-5797.
- Page 6 installation and Setup 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. What’s in the Box Winch x 1 Aluminum Fairlead x 1 Remote Control x 1 Remote Control Cable x 1 Hook x 1...
- Page 7 Mounting the Winch 1. Make sure the Winch will fit the chosen mounting 6. Install the Winch using hardware specified area. If relocating the Control Box is necessary on the specification chart. Tighten fasteners or desired, perform the removal and installation to the following torque values: of cables to the Winch before mounting.
- Page 8 Relocating the Control Box (optional) TO PReVenT SeRiOuS inJuRy FROM eXPLOSiOn Due TO SPARKinG AT THe BATTeRy COnneCTiOn: unplug the Remote Control Cable and disconnect the Battery Cables before making other wiring connections. 1. Engage the clutch on Winch. M6 x 2 5 Screw Control 2.
- Page 9 8. Connect three Power Cables (Control Box 11. Use the Small Black Wire Connector and Relocation Kit) to the Extended Copper Small Black Wire Extension to lengthen Screws on motor terminal using three of the the Small Black Wire from the Control Box. Motor Terminal Nuts removed in step 4.
- Page 10 Wiring TO PReVenT SeRiOuS inJuRy FROM eXPLOSiOn Due TO SPARKinG AT THe BATTeRy COnneCTiOn: unplug the Remote Control Cable and disconnect the Battery Cables before making other wiring connections. TO PReVenT SeRiOuS inJuRy FROM LeAKinG BATTeRy ACiD: Do not use a dirty, corroded or leaking battery. Only use a 12 ...
- Page 11 Disconnect Switch WARninG! TO PReVenT SeRiOuS inJuRy: Off-highway driving subjects the vehicle and wiring to much higher vibrations than on-highway driving which can cause a breakdown of wiring insulation over time. Use the high current Disconnect Switch included with this Winch to turn OFF the power to the Winch when it is not in use to help reduce the risk of a short circuit.
- Page 12 Remote Control instructions Wired Operation 1. To use the Remote Control in a wired 3. With the Clutch Handle in the Engaged configuration, connect the Remote Control Cable position, press IN on the Rocker Switch to the bottom of the Remote Control and to the to retract the Synthetic Rope ...
- Page 13 Operation Before operating this Winch, refer to the Harbor Freight Tools publication Guide to Winching included with the Winch for important operational safety information, winch basics, winching tips, and general winch operating procedures. If this guide is unreadable or missing, contact Harbor Freight Tools for a replacement.
- Page 14 Maintenance and Servicing Procedures not specifically explained in this manual must be performed only by a qualified technician. TO PReVenT SeRiOuS inJuRy FROM ACCiDenTAL OPeRATiOn: unplug the Remote Control Cable and disconnect the Battery Cables before performing any inspection, maintenance, or cleaning procedures. TO PReVenT SeRiOuS inJuRy FROM WinCH FAiLuRe: Do not use damaged equipment.
- Page 15 Troubleshooting Problem Possible Causes Likely Solutions Motor 1. Incorrect power cords. 1. Use only supplied power cords. overheats. 2. Winch running time too long. 2. Allow Winch to cool down periodically. 3. Insufficient current or voltage. 3. Fully charge battery. Run Winch with vehicle motor running.
- Page 16 PLeASe ReAD THe FOLLOWinG CAReFuLLy THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY 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.
- Page 17 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. Item 56385 For technical questions, please call 1-888-866-5797.
- Page 18 Parts List and Diagram Parts List Part Description Part Description Gearbox End Cover Iron Bushing Washer Motor Assembly Star Screw M6 x 2 0 Terminal Cover Gear Box Z69 Star Screw M4 x 1 6 Clutch Retaining Bolt Motor Cover Clutch Handle Winch Mounting Hardware...
- Page 19 Assembly Diagram Item 56385 For technical questions, please call 1-888-866-5797. Page 19...
- Page 20 Limited 90 Day Warranty Harbor Freight Tools 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 date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or to lack of maintenance.
- Page 21 . 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.
- Page 22 Table of Contents Warning Symbols .......... 3 Winch Basics ..........10 Important Safety Information ......4 Single Line Winching – S traight Pull ....14 Basic Winching Tips ........7 Single Line Winching – S natch Block .... 16 Before You Go ..........
- Page 23 WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
- Page 24 IMPORTANT SAFETY INFORMATION WARNING! Read all instructions. Failure to follow all instructions listed on pages 4 to 6 may result in fire, serious injury and/or DEATH. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.
- Page 25 16. A kink permanently weakens a wire rope, 19. Do not overreach. Keep proper even after it is straightened out; kinked footing and balance at all times. wire rope can fail suddenly and must This enables better control of the not be used.
- Page 26 23. If the object to be pulled must be pulled 26. If rope begins to get entangled, stop Winch at an angle in relation to the Winch, immediately and release rope using switch. use a snatch block (sold separately) 27. Only winch with the winching vehicle′s and an anchor point directly in front transmission in neutral.
- Page 27 Basic Winching Tips • ESTABLISH A DANGER ZONE: At least 20 f t on each side of the winch line and beyond the vehicle and anchor point. Make sure no people enter during the winching operation or when the line is under tension. •...
- Page 28 Estimating Load The ability to determine the load that the recovery will take is an important skill to learn. It allows you to properly setup rigging for a successful recovery the first time and reduces the chance of equipment damage and danger to bystanders. Resistance Types •...
- Page 29 Mire Resistance For recoveries in mud, sand, or snow, mire resistance becomes a factor. Mire resistance is the added resistance that the soft terrain adds as the vehicle is submerged beneath the ground level. The vehicle’s GVW is used to estimate the recovery load. Wheel Depth Mire •...
- Page 30 Winch Basics Rope Layer Imagine trying to hold a full length shovel horizontal by the very end of the handle — p retty hard, right? Now imagine holding a shorter shovel by the end of the handle. Maybe not easy, but certainly easier than the full length shovel. This is an example of how the winch must exert torque on the drum for the various layers of rope on the drum.
- Page 31 Rope Angle Your winch is designed to handle off-angle pulls for brief periods. However, extended pulls on one side of the drum can cause damage to the winch and rope. Use a snatch block to change the direction or move the anchor point. Try to winch with the rope as straight into the winch as possible.
- Page 32 Snatch Blocks Snatch blocks are the second most important accessory for your winch (the first being shackles). Being able to change the line direction for pulls around corners and multiple line pulls makes them extremely versatile. Let’s understand how they work before we show examples of vehicle recoveries.
- Page 33 Rope Inspection The rope on the winch is the highest wear item in the winching system, and the most dangerous if not inspected regularly. Wire rope and synthetic rope have different wear and replacement criteria — i t is important to highlight both. Wire Rope ...
- Page 34 Single Line Winching — S traight Pull Setup WARNING! To prevent serious injury from electrical fire: check the electrical cables to your winch for abrasion or heat damage before use. Replace worn or damaged cables immediately. 1. MAKE A PLAN. Pick a sturdy anchor 2.
- Page 35 ESTABLISH A DANGER ZONE. At least 20 f t on each side of the winch line and beyond the vehicle and anchor point. Make sure no people enter during the winching operation or when the line is under tension. WARNING! Do not allow anyone to stand near the rope, or inline with the rope behind the winch or anchor point while it is under power.
- Page 36 Single Line Winching — S natch Block Overview Not every recovery can be handled with a straight line pull. Often the most effective recovery requires an angle that cannot be accomplished from straight on. By using a snatch block on a single line pull, the pull direction can be changed without moving the winching vehicle.
- Page 37 Vehicle Off Trail If a vehicle leaves the trail and becomes stuck, often the most effective way to return the vehicle to the road is using an angled pull since this pulls the vehicle most directly onto the trail. Find a suitable anchor on the opposite side of the trail to attach a snatch block to, and perform the recovery.
- Page 38 Double Line Winching Overview Certain recoveries require more force than a single line pull can provide. In these situations a double line pull is necessary to develop enough force to recover the vehicle. Double Line — S elf Recovery For self recovery efforts that require more force than a single line pull can provide, use a double line rigging back to the winching vehicle.
- Page 39 Double Line — O ther Vehicle Recovery By placing the hook end at a stationary anchor or other vehicle and attaching a snatch block to the recovery vehicle, the load on the winching vehicle is reduced by 50%. 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.
- Page 40 26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797...
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