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Badland APEX 57535 Owner's Manual & Safety Instructions
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Badland APEX 57535 Owner's Manual & Safety Instructions

Long drum utv winch
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Owner's Manual & Safety Instructions
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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
2020 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,
5500
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.
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Summary of Contents for Badland APEX 57535

  • Page 1 Owner’s Manual & 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.
  • Page 2 Specifications Rated Single Battery 12VDC, Minimum 12 Ah 5500 lb (2494 kg) Battery Cables 6 gauge, 3′ (0.9m) long Line Pull Solenoid Cables 6 gauge, 8′ (2.4m) long Application ATV/UTV Mounting Pattern 3″ x 6.6″ (76.2mm x 167.8mm) Motor 12VDC 1.5 HP Permanent Magnet Mounting Hardware Winch: Power IN &...
  • 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 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 Operation Precautions 1. Do not exceed load capacity. Be aware of 12. Use as intended only. dynamic loading! Sudden load movement may Do not lift items vertically or use briefly create excess load causing product failure. for aircraft purposes. 2. Do not maintain power to the winch if the motor 13.
  • Page 6 24. Keep clear of synthetic rope, hook, and load while 28. If the object to be pulled must be pulled at an winching. Do not step over synthetic rope. angle in relation to the winch, use a snatch block Do not push sideways against synthetic rope (sold separately) and an anchor point directly under tension;...
  • 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 plate must be rated to at least 5.16 in.
  • Page 8 Wiring TO PREVENT SERIOUS INJURY FROM EXPLOSION DUE TO SPARKING AT THE BATTERY CONNECTION: 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.
  • Page 9 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 10 Operation 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. The instructions that follow are basic guidelines only and cannot cover all situations encountered during use.
  • Page 11 7. Hook onto the object using a pulling point, 11. Turn the Clutch Knob to the Engaged position. tow strap, tree strap, or chain. See Figure H. See the instructions for your Winch model Shackle not shown between tree strap and hook. under Clutch Operation on page 10.
  • Page 12 16. WARNING! TO PREVENT SERIOUS 14. Do not operate the Winch at extreme angles. INJURY: Stop the Winch and release tension Do not exceed the angles shown in Figure B for a roller fairlead. For a hawse fairlead, the angle on the Synthetic Rope before moving the should be as close to straight as possible.
  • Page 13 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: 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 14 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 15 Parts List and Assembly Diagram Part Description Part Description Hex Socket Screw M6x18 Gear Box Motor Assembly Hex Socket Screw M6x50 Nut M8 Clutch Knob Brake Base Badge Brake Spring Hex Socket Screw M6x25 Brake Fork Pin 2.5x14 Brake Fork Locating Ring Tie Bar Brake Housing Synthetic Rope...
  • Page 16 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.
  • Page 17 GUIDE TO WINCHING WWW.HARBORFREIGHT.COM Copyright © 2019 by Harbor Freight Tools ® . 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 18: Table Of Contents

    Table of Contents Warning Symbols .......... 3 Winch Basics ..........10 Important Safety Information ......4 ....14 Basic Winching Tips ........7 .... 16 Before You Go ..........7 Double Line Winching........18 Estimating Load ..........8 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.

  • Page 19: Warning Symbols

    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 20: Important Safety Information

    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 21 19. Do not overreach. Keep proper footing and balance at all times. wire rope can fail suddenly and must This enables better control of the not be used. Keep wire rope straight Winch in unexpected situations. tow strap or chain. Do not wrap the rope about to form.
  • Page 22 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. and an anchor point directly in front transmission in neutral.

  • Page 23: Basic Winching Tips

    Basic Winching Tips • ESTABLISH A DANGER ZONE: no people enter during the winching operation or when the line is under tension. • FIRST LAYER WINCHING: Winch with the most rope out possible to utilize the maximum power of the winch and prevent overloading and overheating.

  • Page 24: Estimating Load

    Estimating Load 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 • Grade Resistance: The resistance • Tackle Resistance: The added resistance of pulling a vehicle up a slope.
  • Page 25 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 Wheel Depth Mire • • Fender Depth Mire • Cab Depth = 3x GVW Cab Depth Mire A snatch block is a great way to double the pulling...

  • Page 26: Winch Basics

    Winch Basics Rope Layer Imagine trying to hold a full length shovel horizontal by the 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 27 Rope Angle Your winch is designed to handle off-angle pulls for brief periods. However, extended pulls change the direction or move the anchor point. Try to winch with the rope as straight into the winch as possible. If you do have to winch off-angle, do not exceed the angles shown below. Spotter must be outside danger zone.
  • Page 28 Snatch Blocks of vehicle recoveries. Snatch Block of a rope. In the diagram a 4 ton vehicle is attached to a rope Winching Notice that the tension in each of the ropes is Vehicle must carry the combined load of the ropes. Load This is a simplified example neglecting the angle of pull of the ropes.
  • Page 29 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 WARNING! To prevent serious Injury from razor sharp broken strands, wear heavy- duty work gloves when handling wire rope.
  • Page 30 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. 2. PUT ON GLOVES. Regardless of vehicle that is generally straight on and gloves are always a good idea.
  • Page 31 ESTABLISH A DANGER ZONE. At least 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. If the rope should slip or break, it can suddenly whip back towards the winch or anchor, causing a hazard for anyone in the area established by the danger zone.
  • Page 32 Overview Not every recovery can be handled with a straight line pull. Often the most effective recovery a single line pull, the pull direction can be changed without moving the winching vehicle. Around a Corner pull harder, it also allows the vehicle to remain connected to the farthest anchor once the Pay special attention to the danger zone, since it is much larger than a straight line pull.
  • Page 33 Vehicle Off Trail vehicle to the road is using an angled pull since this pulls the vehicle most directly onto the perform the recovery. Pay special attention to the danger zone, since it is much larger than a straight line pull. USE ALL OF THE PRECAUTIONS AND STEPS Snatch Block...

  • Page 34: Double Line Winching

    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. For self recovery efforts that require more force than a single line pull can provide, use a rated to withstand the estimated load to recover the vehicle.
  • Page 35 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. USE ALL OF THE PRECAUTIONS AND STEPS Tree Strap &...
  • Page 36 26541 Agoura Road • Calabasas, CA 91302 • 1-888-866-5797...