Harbor Freight Tools 9000 lb. Off_Road Vehicle Electric Winch with Automatic Load_Holding Brake Product manual
Contents
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10. 15 SOUP nu manata eQ aa ea aan 8 Warrantiy s soe ee ee E 16 Operation oinen ier iiia 10 Wire Rope Size Type 3 8 X 65 9 5mm X 19 8m For Trucks and SUV s 7X19 Galvanized Steel Aircraft Wire Rope Power OUT 5 45 sec at Max Rated Load 10 x 4 5 254mm x 114 3mm 14 min 15 sec Rest Mounting Hardware Winch 4x G8 M10 1 50 X 30mm Fairlead 2x G8 M12 1 75 X 25mm Dun xo 0 05 Duru 2001 Overall Dimensions 21 5 8 X 6 3 8 X 10 1 8 LXDXH 3 8 Replaceable with Spring loaded Safety Latch Pang EE resistant to powerful water jets except remote control switch Winch Certification CE Layer Rated Line Pull Wire Rope Capacity 5049 Ib 2290 kg First Layer of Wire Rope Performance 1 9 8000 3629 9000 4802 Page 2 For technical questions please call 1 888 866 5797 Item 61325 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 A DANGER AWARNING ACAUTION NOTICE CAUTION Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury SAFETY Indicates a hazardous situation which if not avoided could result in minor or moderate injury Addresses practices not relat
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13. 45 45 Figure B Roller Fairlead Maximum Winching Angles 31 If the object to be pulled must be pulled at an angle in relation to the winch use a pulley sold separately and an anchor point directly in front of the winch as shown in Figure C to keep the Wire Rope pull straight Figure C Pulley Anchoring 32 Broken strands of wire rope will be sharp Wear heavy duty work gloves when handling the wire rope Do not slide wire rope through hands even with gloves on 33 Winch motor will be hot during and after use Keep clear 34 Do not power the hook all the way into the fairlead or winch 35 People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure Item 61325 Service Precautions 1 Wear ANSI approved safety goggles and 5 Maintain labels and nameplates on the winch heavy duty leather work gloves during service These carry important safety information LLI If unreadable or missing contact LL 2 Disconnect power to winch and allow it Harbor Freight Tools for a replacement lt to cool completely before service o l 6 WARNING The cord of this product contains Use supplied power cords wire rope or cables lead and or di 2 ethylhexyl phthalate DEHP listed in manual only Do not use thinner chemicals known to the State of California longe
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18. to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion 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 explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state BADLAND Fiji WINCHES 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 1 888 866 5797 1619 998 888 1 LL0 6 VO OllHEU EO 6009 XOG Od Dag SYEO UOISSIIN L6r SOPE1S oe ugen nb sovo l p solo p nd u lqule sooy
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21. Controller disconnect the Battery Cables from the battery switch the Motor Cable connections on the Motor Assembly then reconnect the Battery Cables 9 Disconnect the Pendant Controller when not in use 1 The wire rope must be properly coiled under tension to be able to support a load without damage 2 Uncoil the wire rope except for 5 full wraps 3 Recoil the wire rope back into the winch under at least 500 Ib of tension Item 61325 For technical questions please call 1 888 866 5797 Page 9 Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual A including all text under subheadings therein before set up or 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 plan usage to prevent accidents 1 Examine the wire rope Do not use the winch if 7 Hook onto the object using a pulling point tow the wire rope is frayed kinked or damaged strap tree strap or chain See Figure G 2 Fully charge the vehicle s battery 3 Check the Winch s electrical connections V All connections must be tight and clean 4 Putthe vehicle s transmission in Neutral 5 the vehicle where the winch is mounted is not supposed to be moved engage the emergency brake and block the wheels using wheel chocks sold separately Figure G Using a strap anchor point 6 To pull
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23. Use a pulley block sold separately properly rated for the load to be pulled and designed to be operated vvith this vvinch s vvire rope o rx FIGURE A WHIPLASH DAMPENING BLANKET OR RUG 11 Re engage the clutch by moving the Clutch Handle to the Engaged position shown in Figure 1 Stationary A Winching Vehicle D b Chock tires a RY set parking brake b DENGE and leave in neutral We Carpet O Figure J Double Line setup Loop the wire rope around and connect F to another part of the vehicle s chassis or to a separate anchor point Do not anchor the Wire Rope back to the winch or winch mount Load Note If anchoring the winching vehicle only attach the line to the front of the vehicle WARNING Do not allow anyone to stand near If the anchor line is attached to the rear of the vehicle z the wire rope or in line with the wire rope behind the vehicle s frame may be damaged by the winch while it is under power If the wire rope the forces exerted by winching should slip or break it can suddenly whip back towards the winch causing a hazard for anyone in 12 Attach the Pendant Controller to the Socket TT the area Stand vvell to the side vvhile vvinching on the Solenoid Assembiy see Figure K 5 Figure K Pendant connection Item 61325 For technical questions please call 1 888 866 5797 Page 11 o m o
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25. technician service winch Motor runs but Clutch not engaged Move the Clutch Handle to the Engaged position Wire Rope drum If problem persists a qualified technician does not turn needs to check and repair Motor runs Insufficient current or voltage Battery weak recharge slowly or without Run winch with vehicle motor running normal power Loose or corroded battery Clean tighten or replace cable connections Incorrect power cords Use only supplied power cords Defective or stuck solenoid Tap solenoid to loosen contacts Repair or replace solenoid Defective Switch Assembly Replace Switch Assembly Follow all safety precautions whenever diagnosing or servicing the tool Disconnect power supply before service 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 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 OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERET
26. z 13 Operate the Pendant controls briefly to ensure they work properly see Figure L If operation is reversed the power cables may be connected backwards Correct any such issue before use Figure L Pendant Controls 14 Wheniit is safe to do so use the power switch on the Pendant Controller to retract the wire rope and winch the item as desired Do not power the hook all the way into the fairlead to prevent damage 15 Do not operate the winch at extreme angles Do not exceed the angles shown in Figure B for a roller fairlead For a hawse fairlead the angle should be as close to straight as possible FIGURE B ROLLER FAIRLEAD MAXIMUM WINCHING ANGLES Page 12 For technical questions please call 1 888 866 5797 16 If the object to be pulled must be pulled at an angle in relation to the winch use a pulley sold separately and an anchor point directly in front of the winch as shown in Figure C to keep the Wire Rope pull straight 17 WARNING Stop the winch and release tension on the wire rope before moving the rag or carpet placed on it 18 Do not continue use of the winch until the battery is completely run down 19 You may wish to keep the engine running while using this winch to continually recharge the battery However exercise extreme caution when working around a running vehicle and ONLY operate a vehicle in a
27. B s Sy osn oduu n ofeqes 210 L eulbed o180e jqe eBseo ej OYyoues j esed o190e ajqeo jap Q SU EI Jefoye plied lu louns o OJOS ue s iqe2 Jap UOOaIp Sie ej II l L opueno 02 zz eu Bed sp uli o sedijoq 9 NSUOD oS5noeid Ins i nb iduu is opezilmn Jos 4 eBieS iqos e e1epn e se uil oispduod un u n p as 1070W f 15 jue s iqe5 Je OPUe SIUIWUNS nu uo2 oN eB1e5 jeulwiou pepioede ns ap e3199 o e oznujw sew 10d ue s iqe2 UOI uo 52e1 Seale ON SO nulul solea BJULINP s nb eyed A odinba op je OYONW S JOJOW f IS lqisod Gas OWOD aAa q up 1 S uo 55e1 eae 21 ALNAWVOINN ALNALINYALNI OSN NN eded opeuasip n a ue SUOD OGUISIUEUOUD UN u pueui p nb s ul esed ue s iqe2 linn ON NOlONWV add 8 US l do SFLNAWVOINN A ojusiweuolouny us ln l A f US feqe opuen UgIONeDeJd ewa x oBuiequu uig u uuenunuo2 EUSIgO EI JeB1e5 1 eed lue s iqeo s 821 1 senu luu o u iweuonun JO JOW ja qe s p s3 61 o
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31. O OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Page 14 For technical questions please call 1 888 866 5797 Item 61325 Parts List and Diagram Part 1 Description Qty Part Description Qty 2 6 TeBar 0800071 10 EndBeaing 1 11 BoltMix1223 j 8 Gear Housing Cover VVasher Input sun gear Gear Carrier Asm Input Gear Carrier Asm Intermediate Gear Carrier Asm Output Record Product s Serial Number Here 22 GearRing 0 11 25 BoltM4x14 8 Svvitch Asm Circuit Breaker MAINTENANCE 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 61325 For technical questions please call 1 888 866 5797 Page 15 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 We shall in no event be liable for death injuries
32. Owner s Manual amp Safety Instructions 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 ere ADLAN WINCHES 9000 LB CAPACITY OFF ROAD VEHICLE WINCH Visit our website at http www harborfreight com Email our technical support at productsupport harborfreight com ITEM 61 325 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 2013 by Harbor Freight Tools All rights reserved portion of this manual or any artwork contained herein be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included Table of Contents ee Wee EE 2 Mainte arg6x uuu aa astakuy ada 13 ebe eet ar a eet Ee 3 Parts List and Diagram
33. S uu jg oduu l opeisewap sod pu rou OU JO OW 14 opueuoloun lue s uqe2 3 PUE O2911 99 9 onsiuluuns s qe2 sol Ju uueol un 2AN O21199 8 ollsiuluuns s qeO S JOJ OW J a qeqoid s uol nios s qisod sesneo Eul lqol i seuu qoid ap uol nios Ms O lt Lu Z lt lt gt m m el O 92619 OMY EUODUDL 19 Bled 0011109 9 ja yz eulbed ej ue osae qe2 jap ugINeedald 010095 B UB Ep qe2 ESU eed 3 2 9 se linsuo2 uuoJ p as nb iniun d OU opepin opu lu Ioquue epey oae ap odp j enBaldey Ol lA q 2 je soAewW o enBi jeulwou pepioedeo eun eBu s uoloeouio dszg jap SoUODEOIDUL se nb p lqe2 un lu uueolun 2N pepioedeo oz op lqeo un Jod oeldul l ON NOIONWOadd UOISOIJOD El eed lqisod B S OWOD Ue E J A OA A 1e5 s uqE o opeolJije5 o lu UN lu uul e u pioo5e Bi1 uuns as Is UIS 6 EI EIOE ON uoioeouqn sod lue s 1qe2 p OUJS U 4 61 g OUuBIA
34. UN UQIS LUSUE4 871 uoisiuusue1 ej JeUep p nd olu luueuoloe s Uplolsod ej US o 189 0 orqweo un UOD o n9 IUu A Jap uolsiluSu 1 EI UCD ue s iqe5 un seziln olu nuu ozund Us ODEOIOUUS o n3 u A jap UOISILUSUeL ej uoo sJUsWeDIUN lue s iqe2 f 2AN yu uew d SUEP o uoisouio2 EI nb Jeya eed o Jeolqn e OHEO S OLELdUu I OJEIPSWUI opeolJije5 o l un 02 10d l uels uqe2 j eGiewns s IS enbe ua lue s iqe2 j eli uins ON 1o dnuu lui q opuezilnn ap qe2 ll ns lue s iuqe2 Ia ozeipawu e ezu luuo2 01992 qe2 IS jue sun5o4I15 unbie e o euols id nb euosiJead ej e aeadjo6 see epey sieB ld i eBieS e s ofeq s dwuo epod ajqeo j uoisua ofeq o1990e qe2 b1 UOD Ju uul e1 e uo s id Ezil l ON qe2 jep euliocu Jod sed ON Sie ej oyoueb jap oj90e lqe jep s f je jue s iqe2 ezin seua UoloE do EI esueqed elJpod oae q 2 o Q seiqi 00G ep uoisu eun ofeq ol ligi1u l op ap qe2 f Hezin s luy 0180 qe2 sel lduloo seana SOUS je UQIDII EI Eve o ode l uis eun s uasos p nd ou JoqWEe je
35. ctivating the winch 11 Do not use the hand crank if equipped to assist the winch 12 Do not use vehicle to pull on the Wire Rope and assist the winch Item 61325 13 14 15 16 17 18 For technical questions please call 1 888 866 5797 Use as intended only Do not lift items vertically or use for aircraft purposes SAFETY Prevent entanglement Do not wear loose clothing or jewelry as they can be caught in moving parts Non skid footwear is recommended Wear restrictive hair covering to contain long hair Disconnect Pendant Controller before working near the Wire Rope drum fairlead or load to prevent accidental starting Inspect before every use do not use if damaged or parts loose Examine the winch for structural cracks bends damage frayed or kinked wire rope and any other conditions that may affect the safe operation of the winch Do not use the winch even if minor damage appears A kink permanently weakens the wire rope even after it is straightened out kinked wire rope can fail suddenly and must not be used Keep wire rope straight to avoid kinking the wire rope The illustrations to the right show how a kink forms to form At this point the winch should be stopped and the wire rope should be straightened out to prevent kinking b This wire rope is kinked It is too late to reverse the damage at this point the wire rope must be discarded It is perma
36. d SVGVNOISV9O 93 S3NOIS31 3VlIA3 VaVd ez ldull o oJu luulu ugui ol ds l OJUaIWIPEdO d JaINbyend Jezile 1 Q ap s lue s lqe sol opuew Ieuluu1 10 99U09 f jnu59u s q TVIN43dG3199V OLNAINYNOIONN 4 NN 30 VION3nO3SNOO S43AVYM Sd3NOIS31 GVLI AZ vadvd s 5 u nbildx ou nb solu iuuip 5oid 50 2 q p 091U99 un 091U99 01211105 O Ju lullu JUuE N a D ole ns 612100 0 jeno o 5 5 p nd lue1s iqe2o f ofeqe 0 210 p Saul SO ju uuesoinBii asyejadses ou onu uoo olu luuguolounj epeo iod CL A sojnulw p 504 je q p eieo eulxew pepioedes ns e G ofeqen O 9I9 UN uoo luels iqe2 s ld l l JOY sie u e5 l uis pepioeded ns e seuolouni p nd lue s iqeo un jeno EI jueinp solnuluu G opou d un odus n pepnue ej ul p olfeqe1 210 5 EpEorpul oleqe 01919 jap Bulxeul EI opu lp x ou upp s ue s lqe f nb lAz osupo s p CL sojnulw p 5000 je jap o ju luuguo ounij ap sopun
37. do opueno soqesesed ap s l ly S Jeouese Soup nBeuquu j nbolo opebieo odinb j opuend enBeiquia j esAOesep ON F ISNV 10d sopeqoide piou sis 1 Eug l n ofeqes sajuenb seJeB linn f V e ez eulbed EI Ud se ul SOP O SedI Og se u SOP so sedijod linn ajqisod p s nb aidwais epebieo ls e J9 eq ej nb ap Le eulbed EI Ud 21UEISaIOE jap 5 010 2 10 092 8 0 qe2 jap o leqe1 Bau esed Opesipul s euluuou spe oue j s Sie nb onbuuan u n p S 10 OW IS jue s iqe2 je opuesiuluins BNUIJUOD ON 22 jap un eeuoiseoo nb eBieo os x un olu uuoul un Jod 12919 p nd ee e ounu d 1 olu luulIAOui u ise31uueuIp sepe sel g u n 1 ebe ap pepioedeo ej oN L uoroezilnn ej ered s uoio ne5 id y eulbed 1Oquue OP Syed p Jod lue s iqe2 jep ebjes A s pu o190e lqe l nb eed ofeqe ps p pu s nb q p UQI99 1ID EI UB SOqedesed j A lue s iqe2 e su so s ndx s guluui A s qe2 SO sopo lSIE ugIOe e sUI EI sendseq EL Eq EI
38. ed to personal injury Property or Statement Symbol Property or Statement Wear heavy duty cut and De nee 7 WIER overwind orientation Wire rope abrasion resistant leather gloves F enters exits at the top Use winch only in Wear ANSI approved safety glasses Cut or sever hazard Roller entanglement hazard Hot surface burn hazard Fire hazard Caustic chemical hazard from battery acid Explosion hazard Do not loop the wire 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 underwind orientation Wire rope enters exits at the bottom Volts Direct Current Amperes Cold Cranking Amperes Horsepower Feet Per Minute Meters Per Minute Revolutions Per Minute International Protection rating Classifies the degrees of protection provided against the intrusion of solid objects dust accidental contact and water Grade 8 A fastener strength rating Item 61325 For technical questions please call 1 888 866 5797 Page 3 IMPORTANT SAFETY INFORMATION WARNING Read all instructions Failure to follow all instructions listed on pages 4 to 7 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 cauti
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40. he mounting location 6 3 in 160mm 20 94 in 532mm 4 Drill holes appropriate for the hardware at the marked locations Figure D Winch Dimensions 5 Install the winch using the hardware specified on the specification chart Mounting the Solenoid Assembly 1 Place the Solenoid Box in a suitable place near enough to the winch to allow the cables to be routed properly 2 Mark the where the screw holes will be 3 Verify that the installation surface has no hidden components or structural pieces that will be damaged before drilling 4 Drill pilot holes for the mounting screws 5 Secure in place with mounting screws BADLAND fii WINCHES Page 8 For technical questions please call 1 888 866 5797 Item 61325 Wiring AWARNING TO PREVENT SERIOUS INJURY FROM EXPLOSION gt DUE TO SPARKING AT THE BATTERY CONNECTION x Unplug the Pendant Connector 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 12V automotive or equivalent battery in good condition 1 Plan a route for the wiring from the point of the vehicle where the winch will be mounted or used to the battery This route must 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 you ma
41. in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Unplug the Pendant connector and disconnect the Battery Cables before performing any O inspection maintenance or cleaning procedures TO PREVENT SERIOUS INJURY FROM WINCH FAILURE Do not use damaged equipment If abnormal noise or vibration occurs have the problem corrected before further use Cleaning Maintenance and Lubrication 1 BEFORE EACH USE inspect the general 2 AFTER USE wipe external surfaces condition of the winch Check for loose hardware of the winch with clean cloth misalignment or binding of moving parts cracked or broken parts damaged electrical wiring 3 Lubricate the wire rope occasionally with a light oil corroded or loose terminals and any other Xt gpa st b 4 The winch s internal mechanism is permanently condition that may affect its safe operation lubricated Do not open the housing Examine the wire rope Do not use the winch if ihe wire rope is frayed inked or damaged However if the winch is submerged it should be p yea ged opened dried and re lubricated by a qualified technician as soon as possible to prevent corrosion Wire Rope Replacement 1 Move Clutch Handle to the Released position CAUTION Do not replace with inferior Wire Rope I Only use a wire rope rated to the same rating 2 Extend the Wire Rope to its full leng
42. ion so that the wire rope enters and exits the winch at the bottom of the drum Item 61325 Operation Precautions 1 Do not exceed load capacity Be aware of dynamic loading Sudden load movement may briefly create excess load causing product failure 2 Do not maintain power to the winch if the motor stalls Verify load is within rated capacity for the wire rope layer see Winch Specifications on page 2 Make sure the battery is fully charged Use double line rigging whenever possible see Double Line Rigging on page 11 3 Wear ANSI approved safety goggles and heavy duty leather work gloves during operation 4 Do not disengage clutch under load Engage clutch before starting 5 Keep clear of fairlead when operating Do not try to guide vvire rope 6 Do not place finger s through hook Fingers may be caught and get pulled into fairlead or drum Use included strap to hold hook instead 7 Place heavy rag or carpet over vvire rope span 6 feet from hook to help absorb the force released if the vvire rope breaks See Figure A O rx Figure A Whiplash Dampening Blanket or Rug 8 Stay out of the direct line that the wire rope is pulling In case it slips or breaks it will whiplash along this line 9 Donot use for lifting or moving people 10 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 wire rope before a
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44. n outdoor area CAUTION Do not use the winch ina constant duty application it is designed for INTERMITTENT USE ONLY Keep the duration of the pulling job as short as possible If the motor becomes very hot to the touch stop and let it cool down for several minutes Do not pull for more than one minute at or near the rated load Do not maintain power to the Winch if the motor stalls Double Line Rigging will help prevent overloading and should be used whenever practical see Double Line Rigging on page 11 20 When finished pulling the load reverse the direction of the winch just enough to release tension on the Wire Rope so that you can unfasten the Hook from the load and reel in the Wire Rope Item 61325 Duty Cycle Duration of Use Avoid damage to the Winch by not winching for more than the prescribed duty cycle time The Duty Cycle defines the amount of time within at least a 15 minute period during which a Winch can operate at its maximum capacity without overheating 14 minutes For example this Winch with a 5 duty cycle at its 15 seconds maximum load must be allowed to rest for at least of rest 14 minutes 15 seconds after every 45 seconds of continuous operation Failure to carefully observe duty cycle limitations can easily over stress a Winch contributing to premature Winch failure 45 seconds winching D D D a a D Maintenance and Servicing Procedures not specifically explained A
45. nently damaged and must not be used SE c This is a kinked wire rope that has been straightened out Even though it has been pulled straight some wires in the wire rope are stretched and others are severely bent if not broken The unstretched wires will take more load and can fail suddenly before the rope reaches its capacity This wire rope must be discarded and not be used A kink permanently weakens the wire rope even after it is straightened out kinked wire rope can fail suddenly and must not be used Keep children and bystanders away while operating Distractions can cause you to lose control Page 5 o gt m lt 22 23 24 25 26 27 28 29 Page 6 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 may result in serious personal injury Do not overreach Keep proper footing and balance at all times This enables better control of the winch in unexpected situations Hook onto the object using a pulling point tow strap or chain Do not wrap the wire rope around the object and hook onto the wire rope itself This can cause damage to the object being pulled and kink or fray the wire rope Do not use a Recovery Strap while winching They are designed to stretch and can suddenly whip back toward
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48. on are factors which cannot be built into this product but must be supplied by the operator o gt TI m lt Page 4 Installation Precautions Do not wear loose clothing or jewelry 7 Ventilate area well before and while working as they can be caught in moving parts on battery Explosive invisible hydrogen gas Non skid footwear is recommended can accumulate and then explode when ignited Wear restrictive hair covering to contain long hair by a spark from the battery connection Wear ANSI approved safety goggles and 8 Only connect to a clean corrosion free battery heavy duty leather work gloves during installation 9 Do notlean over or come in contact with Before installation confirm that area is clear battery while making connections of fuel lines brake lines electrical wires gas tanks or any other component which 10 Remove all metal jewelry before could be damaged during drilling working near battery Mounting location and hardware 11 Connect red wire to positive battery terminal must support winch and load and black wire to negative battery terminal Use supplied power cords and wire rope listed 12 Insulate all exposed wiring and in manual only Do not use thinner longer terminals after installation dek 13 Install winch and fairlead in underwind Do not route electrical cables near sharp edges or parts that will move or become hot For technical questions please call 1 888 866 5797 orientat
49. out the wire rope move the Clutch Handle to the Released position shown in Figure F slide the Do not wrap the wire rope around loop of the Hook Strap over the hook then pull on the object and hook onto the the Hook Strap to pull out the wire rope wire rope itself WARNING Leave at least five full This can damage the object being turns of wire rope on the drum pulled and kink or fray the wire rope 8 Attachment point must be centered in loop of hook and the hook s safety clasp must be fully closed See Figure H o m z Figure F Clutch released Figure H Correct and incorrect hook attachment 9 Do not use a Recovery Strap while winching They are designed to stretch and can suddenly whip back towards the operator during a winching operation Page 10 For technical questions please call 1 888 866 5797 Item 61325 10 Place a heavy rag or carpet sold separately over the wire rope span 6 feet from the hook to help absorb the force released if the wire rope breaks Double Line Rigging a A double line system should be used whenever possible It reduces the load on the winch allowing it to work longer with less heat buildup It reduces load on the winch in two ways It utilizes the lower layers of wire rope that have higher capacity and e It halves the load on the winch through pulley action b Connect the vvire rope for a double line system as shown in Figure J below
50. r cables or link multiple cables together to cause cancer and birth defects or other reproductive harm Wash hands after handling 4 Have the winch serviced by a qualified repair person California Health amp Safety Code 25249 5 et seq using only identical replacement parts This will ensure that the safety of the winch is maintained A SAVE THESE INSTRUCTIONS BADLAND fii WINCHES Item 61325 For technical questions please call 1 888 866 5797 Page 7 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 Mounting the Winch 1 The mounting plate must be rated to at least the winch s capacity 2 Align the winch perpendicular to center line of the vehicle at the desired location and mark the locations of the winch base holes Compare the dimensions of the marked holes to Figure D 8 58 in 218mm 6 85 in 174mm 3 Before drilling verify that the installation surface has no hidden components or structural pieces that will be damaged 8 8 in 223 6mm LZ 10 in 254 6mm NOTE This vvinch can generate extreme forces Select a location that can vvithstand the rated capacity vvithout damage or vveakening Steel reinforcement plates may be needed or a certified vvelder may need to vveld on additional bracing depending on t
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53. s the operator during a winching operation Secure load after moving NO LOCKING MECHANISM Keep at least 5 full turns of wire rope on drum The wire rope s connection to the drum is not intended to sustain a load without the added support from the friction of at least 5 full turns of wire rope Wrap wire rope under 500 Ib tension before use Otherwise wire rope may bind during operation Keep clear of wire rope hook and load while winching Do not step over wire rope Do not push sideways against wire rope under tension wire rope might break under this load and recoil back striking the person pushing against it or a bystander If wire rope begins to get entangled stop winch immediately and release wire rope using switch Do not submerge winch in water If winch gets submerged accidentally it needs to be immediately disassembled cleaned dried and re lubricated by a qualified technician to prevent permanent damage from corrosion Only winch with the winching vehicle s transmission in neutral Winching with a vehicle s transmission in gear or park may damage the transmission A vehicle s transmission is not designed to handle that type of load For technical questions please call 1 888 866 5797 30 Do not operate the winch at extreme angles Do not exceed the angles shown in Figure B for a roller fairlead For a hawse fairlead the angle should be as close to straight as possible 15
54. th cited on the specification chart or better noting how the existing Wire Rope is connected to the inside of the drum 4 Retract Wire Rope onto Wire Rope drum being careful not to allow kinking 3 Remove old Wire Rope and attach new assembly Refer to instructions for tensioning the wire rope under Preparing the Wire Rope on page 9 5 Test Electric Winch for proper operation Item 61325 For technical questions please call 1 888 866 5797 Page 13 MAINTENANCE lt gt a om m gt O m Troubleshooting Problem Possible Causes Likely Solutions Motor overheats 1 Incorrect power cords 1 Use only supplied power cords 2 Winch running time too long S Allow winch to cool down periodically Motor does 1 Switch Assembly not Insert Switch Assembly all the way into connector not turn on connected properly Loose battery cable connections 12 Tighten nuts on all cable connections Vehicle battery needs charging 13 Fully charge battery Solenoid malfunctioning 4 Tap solenoid to loosen contacts Apply 12 volts to coil terminals directly A clicking indicates proper activation Defective Switch Assembly 5 Replace Switch Assembly Defective motor 6 Check for voltage at armature port with Switch pressed If voltage is present replace motor Water has entered motor 7 Allow to drain and dry Run in short bursts without load until completely dry 8 Internal damage or wear 8 Have
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56. y wish to route the wires under the vehicle attaching it to the frame using suitable fasteners Do not attach the wires to the exhaust system drive shaft emergency brake cable fuel line or any other components which may create damage the wiring through heat or motion or create a fire hazard 2 If you drill through the bumper or any part of the body to route the wires be sure to install a rubber grommet in the hole to prevent fraying of the wires at that point 3 Route the Cables from the Solenoid to the battery and from the Solenoid to the Winch following the precautions discussed above See Figure E Solenoid Circuit Breaker W 4 Black Winch Figure E Wiring Connections Preparing the Wire Rope 4 Attach the Red Black and Yellow Cables to the terminals on the Winch The Winch terminals are color coded 5 Attach the Circuit Breaker to the Positive Terminal on the battery 6 Attach the red Battery Cable to the Circuit Breaker 7 Attach the black Battery Cable directly to the negative terminal of the battery SETUP 8 Lift the Socket Cover exposing the electrical switch connector Insert the Pendant connector into the Socket Note The attachment of the Motor Cables determines the direction of the Pendant Controller s button After the unit is mounted and powered check the direction of the Power In and Power Out on the Pendant Controller button If you wish to change the direction on the Pendant
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