BADLAND APEX 12000, 56385 - Winch with Synthetic Rope Manual

Specifications

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.
	Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
	Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
	Addresses practices not related to personal injury.

Safety Symbols

Symbol	Property or Statement
	Wear heavy-duty, cut- and abrasion-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.
	Do not use winch in overwind orientation. (Synthetic rope enters/exits at the top.)
	Use winch only in underwind orientation. (Synthetic 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.

IMPORTANT SAFETY INFORMATION

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.

Installation Precautions

1. 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.
2. Wear ANSI-approved safety goggles and heavy-duty leather work gloves during installation.
3. Before installation confirm that area is clear of fuel lines, brake lines, electrical wires, 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 working on battery. Explosive invisible hydrogen gas can accumulate and then explode when ignited by a spark from the battery connection.
8. Only connect to a clean, corrosion free battery.
9. Do not lean over or come in contact with battery while making connections.
10. Remove all metal jewelry before working near battery.
11. Connect the red cable to the Disconnect Switch, then connect the 12" 2AWG cable to the Disconnect Switch and the positive battery terminal. Connect the black cable to the negative battery terminal.
12. Insulate all exposed wiring and terminals after installation.
13. Install Winch and Fairlead in underwind orientation, so that the Synthetic Rope enters and exits the Winch at the bottom of the drum.

Service Precautions

1. Wear ANSI-approved safety goggles and heavy-duty leather work gloves during service.
2. Disconnect power to Winch and allow it to cool completely before service.
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 or missing, contact Harbor Freight Tools for a replacement.

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

Mounting the Winch

1. Make sure the Winch will fit the chosen mounting area. If relocating the Control Box is necessary or desired, perform the removal and installation of cables to the Winch before mounting. Refer to Relocating the Control Box.
2. The mounting plate must be rated to at least the Winch's capacity.
3. 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 A.
   
4. Before drilling, verify that the installation surface has no hidden components or structural pieces that will be damaged.

NOTE: This Winch can generate extreme forces. Select a location that can withstand the rated 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 routes before mounting the Winch.

6. Install the Winch using hardware specified on the specification chart. Tighten fasteners to the following torque values:

   Winch mounting fasteners

   30 – 33 ft-lb

7. Mount the Fairlead centered on the Winch to guide the Rope onto the Winch drum.
8. Install the Fairlead using hardware specified on the specification chart. Tighten fasteners to the following torque values:

   Fairlead mounting fasteners

   53 – 5 7 ft-lb

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.
2. Disconnect the vehicle battery cables, negative terminal first.
3. Disconnect the Ground Cable and Small Black Wire from terminal on rear of Winch. Make sure the Small Black Wire that connects to the Control Box is disconnected and hanging freely.
   
4. Remove the Terminal Cover by unscrewing two M4 x 10 Screws holding it in place. Remove the six Motor Terminal Nuts and three Copper Plates. Retain all the hardware.
   
5. Remove four M6 x 20 Screws holding the Control Box in place and gently lift it off of the Winch.
   
6. Attach the Control Box Baseplate to the Control Box using the four M6 x 2 0 Screws removed in step 5.
   

7. Install the three Extended Copper Screws to the terminal on the motor. Mount the Terminal Box on the Winch using two M6 x 12 screws. Do not overtighten screws.
   
8. Connect three Power Cables (Control Box Relocation Kit) to the Extended Copper Screws on motor terminal using three of the Motor Terminal Nuts removed in step 4.
   
9. Install the Terminal Box Cover on the Terminal Box using three M5 x16 Self-Tapping Screws. Do not overtighten screws.
   
10. Connect three Power Cables (control box relocation kit) to the Control Box using remaining three Motor Terminal Nuts removed in step 4.
    
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.
    
12. Install the four decorative M6 x 12 Screws onto the Winch.
    
13. Place the Control Box on a solid mounting surface in a suitable place near enough to the Winch to allow the cables to be routed properly.
14. Verify that the installation surface has no hidden components or structural pieces that will be damaged before drilling.
15. Secure the Control Box assembly in place with Baseplate mounting hardware.

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 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 may wish to route the wires under the vehicle, attaching it to the frame using suitable fasteners.

TO PREVENT SERIOUS INJURY: Do not attach the wires to the exhaust system, drive shaft, emergency brake cable, fuel line, or any other components which may create damage to 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 Winch to the battery, following the precautions discussed above. Refer to Figure C.
   
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. Attach the red Battery Cable from the Winch to the remaining terminal on the Disconnect Switch.
7. Attach the black Ground Cable and the Small Black Wire to the terminal at the rear of the Winch.
8. Attach the black Ground Cable from the Winch directly to the negative terminal of the battery.
9. Lift the Socket Cover exposing the Remote Control socket and Wireless Receiver Switch. Connect the Remote Control Cable to the socket and the Remote for wired remote control. For wireless control do not use the Remote Control Cable and turn on the Wireless Receiver Switch. Refer to Remote Control Instructions.
10. Turn on the Disconnect Switch and operate the remote controls briefly to test Winch function and drum rotation direction. If operation is reversed, the Battery Cables may be connected backwards. Correct any such issue before use.
    
11. Disconnect and turn off the Remote Control when not in use and before driving vehicle.
12. Turn off the Disconnect Switch when the Winch is not in use or when the vehicle has returned to on-highway operation.

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.

1. To use the Winch, use the Disconnect Switch to turn the power to the Winch ON.
2. When the Winch is not in use, turn the Disconnect Switch OFF to reduce the risk of a short on the main power to the Winch.

Preparing the Synthetic Rope

The Synthetic Rope must be properly 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 remain on the drum. Move the Clutch Handle back to the Engaged position.
3. Slowly and carefully move the vehicle in reverse to remove slack from the line.
4. Place the vehicle in neutral. Spool the Synthetic Rope back into the Winch while gently applying the brakes. If the ground is flat, shallow mud or dirt, the brakes can be fully applied. Pavement can generate much higher loads, in which case only light braking is needed.
5. Use a second person to monitor the rope spooling evenly onto the drum.
6. The last layer of Rope can be put on without tension.

Remote Control Instructions

Wired Operation

1. To use the Remote Control in a wired configuration, connect the Remote Control Cable to the bottom of the Remote Control and to the Remote Control Socket on the Control Box.
   
2. The blue indicator light will come on indicating the Remote Control is ready for use.
3. With the Clutch Handle in the Engaged position, press IN on the Rocker Switch to retract the Synthetic Rope — the red indicator light will flash during winding.
   
4. Press OUT on the Rocker Switch to extend the Synthetic Rope out.

Wireless Operation

1. For wireless Remote Control operation, turn on the Wireless Receiver Switch on the Control 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.
   
3. With the Clutch Handle in the Engaged position, press IN on the Rocker Switch to retract the Synthetic Rope — the red indicator light will flash during winding.
4. Press OUT on the Rocker Switch to extend the Synthetic Rope out.
   
5. To turn off the Remote Control, press and hold the ON/OFF Switch until the red indicator light goes out, approximately 2 seconds. Turn off the Wireless Receiver Switch.
   Note: The Remote Control will automatically shut itself off after 2 minutes of inactivity to save the battery.

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.
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 situations encountered during use. The operator and assistants must carefully plan usage to prevent accidents.

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. if abnormal noise or vibration occurs, have the problem corrected before further use.

Cleaning, Maintenance, and Lubrication

1. BEFORE EACH USE, inspect the general condition of the Winch. Check for:
   • loose hardware
   • misalignment or binding of moving parts
   • cracked or broken parts
   • damaged electrical 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 not open the housing.

Synthetic Rope Replacement

1. Move Clutch Handle to the Freespool position.
2. Extend the Synthetic Rope to its full length, noting how the existing Rope is connected to the inside of the drum.
3. Remove old Synthetic Rope and attach new assembly.
   
   Do not replace with inferior synthetic rope. Only use a synthetic rope rated to the same rating cited on the specification chart or better.
4. Retract Synthetic Rope onto Rope drum. Refer to instructions for tensioning the Synthetic Rope under Preparing the Synthetic Rope.
5. Test Winch for proper operation.

Troubleshooting

Problem	Possible Causes	Likely Solutions
Motor overheats.	Incorrect power cords. Winch running time too long. Insufficient current or voltage. Loose motor connections.	Use only supplied power cords. Allow Winch to cool down periodically. Fully charge battery. Run Winch with vehicle motor running. Check and tighten motor connections to Control Box.
Motor does not turn on.	Remote Socket not connected properly. Loose battery cable connections. Insufficient current or voltage. Defective contactor. Wireless Receiver Switch turned OFF. Wireless Remote turned OFF. Winch Disconnect Switch turned OFF. Low batteries in Wireless Remote. Defective motor. Loose Control Box ground cable. Internal wear or damage.	Insert Remote Socket all the way into connector. Tighten nuts on all cable connections. Fully charge battery. Run Winch with vehicle motor running. Replace Control Box. Turn ON Wireless Receiver Switch. Turn ON Wireless Remote. Turn ON Winch Disconnect Switch. Replace Remote batteries — CR2032, quantity two. Check for voltage at armature port with Switch pressed. If voltage is present, replace motor. Check and tighten ground cable to Control Box. Replace motor.
Motor runs but drum does not turn.	Clutch not engaged.	Move the Clutch Handle to the Engaged position. If problem persists, a qualified technician needs to check and repair.
Motor runs slowly or without normal power.	Insufficient current or voltage. Loose or corroded battery cable connections. Incorrect power cords.	Battery weak, recharge. Run Winch with vehicle motor running. Clean, tighten, or replace. Use only supplied power cords.
Motor runs in one direction only.	Defective contactor. Defective Wireless Remote. Loose motor connections.	Replace Control Box. Replace Wireless Remote. Check and tighten motor connections to Control Box.
Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service.

Visit our website at: http://www.harborfreight.com
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.