BADLAND APEX 5500, 57535 - Winch with Synthetic Rope Manual

BADLAND APEX 5500, 57535 - Winch with Synthetic Rope Manual

Advertisement

BADLAND APEX 5500, 57535 - Winch with Synthetic Rope Manual

Introduction

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.

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.


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

Specifications

Rated Single Line Pull 5500 lb (2494 kg)
Application ATV/UTV
Motor 12VDC 1.5 HP Permanent Magnet
Power IN & Power OUT Yes
Duty Cycle Rating 5% (45 sec at Max Rated Load; 14 min, 15 sec Rest)
Remote Control Wired, 10 ft (3m) long
Dash Rocker Switch Wired, 4 ft (1.2m) long
Geartrain 3-Stage Planetary
Gear Ratio 201:1
Freespool Cam Activated
Brake Auto. Load Holding Mechanical
Drum (Dia. x L) 2.36' x 5.16' (60mm x 131mm)
Hook 5/16' Clevis, with Spring-loaded Safety Latch
Fairlead Aluminum Hawse
Synthetic Rope Size / Type Ø1/4' x 50' (Ø6.3mm x 15.2m)
Battery 12 VDC, Minimum 12 Ah
Battery Cables 6 gauge, 3' (0.9 m) long
Solenoid Cables 6 gauge, 8' (2.4 m) long
Mounting Pattern 3' x 6.6' (76.2 mm x 167.8 mm)
Mounting Hardware

Winch:
4 x G8, M8-1.25 x 25 mm

Adaptor Plate:
2 x G8, M8-1.25 x 25 mm

Fairlead:
2 x G8, M8-1.25 x 20 mm

Socket Lead:
2 x G8, ST-M4 x 30 mm

Sound Rating 85 dB
Overall Dimensions (L x D x H) 15.87' x 4.72' x 5.0'
(403 x 120 x 127 mm)
Weight 20.78 lb (9.4 kg)
IP Rating IP 68 – Winch and Controls (except remote switch, resistant to powerful water jets)

Layers

Layer Rated Line Pull Synthetic Rope Capacity
5500 lb (2494 kg) 12.9' (3.94m)
4654 lb (2111 kg) 28.2' (8.59m)
4033 lb (1829 kg) 45.8' (13.97m)
3559 lb (1614 kg) 50.0' (15.24m)

First Layer of Synthetic Rope Performance

Line Pull lb (kg) Line Speed fpm (mpm) Amp Draw (@ 12V)
0 (0) 18.7 (5.7) 31
500 (227) 16.3 (4.9) 51
1500 (680) 15.0 (4.5) 88
2500 (1134) 13.5 (4.1) 126
3500 (1587) 11.4 (3.4) 171
4500 (2041) 10.1 (3.0) 218
5500 (2495) 7.9 (2.4) 291

WARNING SYMBOLS AND DEFINITIONS

warning 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.
NOTICE
CAUTION
Addresses practices not related to personal injury.

Symbols Meaning

Symbol Property or Statement Symbol Property or Statement
Wear heavy-duty, cut- and abrasion-resistant leather gloves. Do not use winch in overwind orientation. (Rope enters/exits at the top.)
Wear ANSI-approved safety glasses. Use winch only in underwind orientation. (Rope enters/exits at the bottom.)
Cut or sever hazard. Volts Direct Current
Roller entanglement hazard. Amperes
burn hazard Hot surface burn hazard. Cold Cranking Amperes
Fire hazard. Horsepower
Caustic chemical (acid) hazard. Feet Per Minute
Explosion hazard. Meters Per Minute
Do not loop the synthetic rope around object and hook onto itself. Revolutions Per Minute
Do not place finger(s) through hook. Fingers may be caught and get pulled into fairlead or drum. International Protection rating
Classifies the degrees of protection provided against the intrusion of solid objects, dust, accidental contact, and water.
Pull hook using strap only. 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

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 red wire to positive battery terminal and black wire to 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.

Operation Precautions

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 synthetic rope layer — see Specifications. Make sure the battery is fully charged. Use double line rigging whenever possible. Refer to Double Line Rigging.
  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 synthetic rope.
  6. Do not place finger(s) through hook or shackle. Fingers 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 synthetic rope is pulling. If it slips or breaks, it will "whiplash" along this line. Place a heavy blanket or winch damper over the synthetic rope span 6 feet from hook to help absorb the force released if the synthetic rope breaks. Refer to Figure A.
    Whiplash Dampening Blanket or Winch Damper
    Figure A: Whiplash Dampening
    Blanket or Winch Damper
  8. Do not use for lifting or moving people.
  9. Use a spotter to assist you in ensuring that it is safe to operate the winch. Make sure the spotter is out of the way of the vehicle and the synthetic rope before activating the winch.
  10. Do not use the hand crank, if equipped, to "assist" the winch.
  11. Do not use vehicle to pull on the synthetic rope and "assist" the winch.
  12. Use as intended only. Do not lift items vertically or use for aircraft purposes.
  13. 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.
  14. Disconnect battery cables before working near the synthetic rope, drum, fairlead or load, to prevent accidental starting.
  15. Inspect before every use; do not use if damaged or parts loose. Examine the winch for structural cracks, bends, damage, frayed or damaged synthetic rope, and any other conditions that may affect the safe operation of the winch. Do not use the winch even if minor damage appears.
  16. Keep children and bystanders away while operating. Distractions can cause you to lose control.
  17. 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.
  18. Do not overreach. Keep proper footing and balance at all times. This enables better control of the winch in unexpected situations.
  19. Hook onto the object using a pulling point, tow strap or chain. Do not wrap the synthetic rope around the object and hook onto the rope itself. This can cause damage to the object being pulled, and fray the synthetic rope.
  20. 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.
  21. Secure load after moving.
    NO LOCKING MECHANISM.
  22. Keep at least 10 full turns of synthetic rope on drum. Synthetic rope requires more wraps than wire rope. The synthetic rope's connection to the drum is not intended to sustain a load, without the added support from the friction of at least 10 full turns of rope.
  23. Wrap synthetic rope under 500 lb. tension before use. Otherwise, synthetic rope may bind during operation.
  24. Keep clear of synthetic rope, hook, and load while winching. Do not step over synthetic rope.
    Do not push sideways against synthetic rope under tension; synthetic rope might break under this load and recoil back, striking the person pushing against it or a bystander.
  25. If synthetic rope begins to get entangled, stop winch immediately and release rope using switch.
  26. 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.
  27. 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.
    Roller Fairlead Maximum Winching Angles
    Figure B: Roller Fairlead Maximum Winching Angles
  28. If the object to be pulled must be pulled at an angle in relation to the winch, use a snatch block (sold separately) and an anchor point directly in front of the winch, as shown in Figure C, to keep the synthetic rope pull straight.
    Snatch Block
    Figure C: Snatch Block
  29. Wear work gloves to protect from cuts from debris when working with synthetic rope. Do not slide synthetic rope through hands, even with gloves on.
  30. Winch motor will be hot during and after use. Keep clear.
  31. Do not power the hook all the way into the fairlead or winch.
  32. 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.

Service Precautions

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.

warning SAVE THESE INSTRUCTIONS.

Installation and Setup

warningRead 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 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.
    Mounting the Winch
    Figure D: Winch Dimensions
  3. Before drilling, verify that the installation surface has no hidden components or structural pieces that will be damaged.

warning 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.

  1. Drill holes appropriate for the hardware at the marked locations.
  2. Install the Winch using hardware described under Specifications.

Mounting Winch Components

  1. Mount Solenoid box, Disconnect Switch, and Socket Lead in proper locations so that:
    1. Winch components are close enough to each other to allow wires to be routed properly.
    2. Vehicle component operation is not interfered with.
    3. Vehicle components are not damaged by drilling or driving screws.
    4. Winch components will not be damaged by stresses caused by vehicle operation.
  1. Mark the locations where the screw holes will be.
  2. Verify that the installation surface has no hidden components or structural pieces that will be damaged before drilling.
  3. Drill pilot holes for the mounting screws.
  4. Secure in place with mounting screws.

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.

  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. 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 earlier. Refer to Figure E.
    Wiring Connections
    Figure E: Wiring Connections
  4. Attach the wires from the solenoid to the terminals on the Winch.
  5. Attach the Disconnect Switch to the Positive Terminal on the battery.
  6. Attach the red Battery Cable to the Disconnect Switch.
  7. Attach the black Battery Cable directly to the negative terminal of the battery.
  8. Wire in the Remote Control, Dash Rocker Switch, and Socket Lead according to the diagrams on this page.
  9. The cable leading from the Socket Lead has a red ignition wire extending out from its side. Connect this to an ignition circuit (switched by the vehicle's key) to help prevent accidental starting. The Winch will not operate if that wire is not properly connected.
    1. Use a circuit tester to find a wire that energizes when the vehicle's key is turned to on, and turns off when the key is turned to off.
    2. That is an ignition controlled wire. Connect the red Socket Lead ignition wire to that wire. Refer to Figure F.

      Figure F: Wiring to vehicle's keyed ignition

warning Note: If not attaching the Winch to a vehicle, attach the ignition wire to the positive battery terminal. IF THIS IS NOT DONE, THE WINCH WILL NOT OPERATE.

  1. After the unit is mounted and powered, turn on the Disconnect Switch and operate the Power In and Power Out button on the Remote Control 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.
  2. Disconnect and turn off the Remote Control when not in use.
  3. Turn off the Disconnect Switch when the Winch is not in use or when the vehicle has returned to on-highway operation.

Disconnect Switch


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
  2. to turn the power to the Winch ON.

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. Turn the Clutch Knob counterclockwise to the Released (freespool) position. Turn the Knob completely until it stops. Uncoil the Synthetic Rope until 5 wraps remain on the drum. Turn the Clutch Knob clockwise 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.

Operation

warning 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. The operator and assistants must carefully plan usage to prevent accidents.

Clutch Operation


Do not adjust the clutch unless there is no load on the Synthetic Rope.

  1. To engage the clutch, turn the Clutch Knob clockwise completely until it stops. Refer to Figure G.
  2. To release the clutch (freespool), turn the Clutch Knob counterclockwise completely until it stops. Refer to Figure G.

Clutch Operation
Figure G: Clutch Operation

Basic Operation

warning Note: If a winch is to be used to pull a vehicle, it should optimally be rated to a single line pull at least twice the vehicle's weight.

  1. Examine the Synthetic Rope. Do not use the Winch if the Synthetic Rope is frayed or has cut strands.
  2. Fully charge the vehicle's battery.
  3. Check the Winch's electrical connections. All connections must be tight and clean.
  4. Put the vehicle's transmission in Neutral.
  5. If 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).
  6. To pull out the Synthetic Rope, move the Clutch Knob to the Released position – see instructions for your Winch model under the Clutch Operation section. Slide the loop of the Hook Strap over the Hook, then pull on the Hook Strap to pull out the Synthetic Rope.

    Leave at least ten full turns of Synthetic Rope on the drum.
  7. Hook onto the object using a pulling point, tow strap, tree strap, or chain. See Figure H. Shackle not shown between tree strap and hook.
    Using a strap anchor point
    Figure H: Using a strap anchor point


Do not wrap the Synthetic Rope around the object and hook onto the Rope itself. This can damage the object being pulled and fray the Synthetic Rope.

  1. Attachment point must be centered in loop of hook and the hook's safety clasp must be fully closed. See Figure I.
    Correct and incorrect hook attachment
    Figure I: Correct and incorrect hook attachment
  2. 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.
  3. 10. Place a heavy blanket or winch damper (sold separately) over the Synthetic Rope span 6 feet from the hook to help absorb the force released if the Synthetic Rope breaks.
    Whiplash Dampening Blanket or Winch Damper
    Figure A: Whiplash Dampening
    Blanket or Winch Damper
  4. Turn the Clutch Knob to the Engaged position. See the instructions for your Winch model under Clutch Operation.


TO PREVENT SERIOUS INJURY: Do not allow anyone to stand near the Synthetic Rope, or in line with the Rope behind the Winch while it is under power. If the Synthetic Rope should slip or break, it can suddenly whip back towards the Winch, causing a hazard for anyone in the area. Stand well to the side while winching.

Double Line Rigging

  1. 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 Synthetic Rope that have higher capacity, and
    • It halves the load on the winch through pulley action.
  2. Connect the Synthetic Rope for a double line system as shown in Figure J below. Use a snatch block (sold separately) properly rated for the load to be pulled and designed to be operated with this winch's Synthetic Rope.

    Stationary Winching Vehicle (Chock tires, set parking brake, and leave in neutral):
    Double Line setup
    Figure J: Double Line setup
  3. Loop the Synthetic Rope around the snatch block and connect to another part of the vehicle's chassis or to a separate anchor point. Do not anchor the Rope back to the winch or winch mount.

warning Note: If anchoring the winching vehicle, only attach the anchor line to the front of the vehicle. If the anchor line is attached to the rear of the vehicle, the vehicle's frame may be damaged by the forces exerted by winching.

  1. Operate the controls briefly to ensure they work properly.
    • The IN position should retract the winch cable.
    • The OUT position should power out the cable. If operation is reversed, the power cables may be connected backwards. Correct any such issue before use.
  2. When it is safe to do so, use the power switch on the Remote Control to retract the Synthetic Rope, and winch the item as desired. Do not power the Hook all the way into the Fairlead to prevent damage.
  3. 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.
    Roller Fairlead Maximum Winching Angles
    Figure B: Roller Fairlead Maximum Winching Angles
  4. If the object to be pulled must be pulled at an angle in relation to the Winch, use a snatch block (sold separately) and an anchor point directly in front of the Winch, as shown in Figure C, to keep the Synthetic Rope pull straight.
    Snatch Block
    Figure C: Snatch Block

  5. TO PREVENT SERIOUS INJURY: Stop the Winch and release tension on the Synthetic Rope before moving the blanket or winch damper placed on it.
  6. Do not continue use of the Winch until the battery is completely run down.
  7. When possible, keep the engine running while using this Winch, to continually recharge the battery and prevent the battery from being drained so much that the vehicle cannot start. However, exercise extreme caution when working around a running vehicle and ONLY operate a vehicle in an outdoor area.

    Do not use the Winch in a 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.
  8. When finished pulling the load, reverse the direction of the Winch just enough to release tension on the Synthetic Rope so that you can unfasten the Hook from the load and reel in the Rope.
  9. Disconnect the Remote Control (if equipped) after use.

Duty Cycle (Duration of Use)

Duty Cycle (Duration of Use)
at least 14 minutes, 15 seconds of rest

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 a 15 minute period, during which a Winch can operate at its maximum capacity without overheating. For example, this Winch with a 5% duty cycle at its maximum load must be allowed to rest for at least 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.

Maintenance and Servicing

warning 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. 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.
  1. AFTER USE, wipe external surfaces of the Winch with clean cloth.
  2. The Winch's internal mechanism is permanently lubricated. Do not open the housing. However, if the Winch is submerged, it should be opened, dried, and re-lubricated by a qualified technician as soon as possible to prevent corrosion.

Synthetic Rope Replacement

  1. Turn the Clutch Knob counterclockwise to the Released (freespool) position. Turn the Knob completely until it stops. Refer to Clutch Operation.
  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.

  1. Retract Synthetic Rope onto Rope drum. Refer to instructions for tensioning the Synthetic Rope under Disconnect Switch.
  2. Test Winch for proper operation.

Troubleshooting

Problem Possible Causes Likely Solutions
Motor overheats.
  1. Incorrect power cords.
  2. Winch running time too long.
  3. Insufficient current or voltage.
  4. Loose motor connections.
  1. Use only supplied power cords.
  2. Allow Winch to cool down periodically.
  3. Fully charge battery. Run Winch with vehicle motor running.
  4. Check and tighten motor connections to Solenoid.
Motor does not turn on.
  1. Remote Control not connected properly.
  2. Loose battery cable connections.
  3. Vehicle battery needs charging.
  4. Solenoid malfunctioning.
  5. Defective Remote Control.
  6. Winch Disconnect Switch turned OFF.
  7. Defective motor.
  8. Water has entered motor.
  9. Internal damage or wear.
  1. Insert Remote Control cord all the way into connector.
  2. Tighten nuts on all cable connections.
  3. Fully charge battery.
  4. Tap Solenoid to loosen contacts.
    Apply 12 volts to coil terminals directly. A clicking indicates proper activation.
  5. Replace Remote Contro.
  6. Turn ON Winch Disconnect Switch.
  7. Check for voltage at armature port with Switch pressed. If voltage is present, replace motor.
  8. Allow to drain and dry. Run in short bursts without load until completely dry.
  9. Have technician service Winch.
Motor runs but drum does not turn. Clutch not engaged. Turn the Clutch Knob to the Engaged position. If problem persists, a qualified technician needs to check and repair.
Motor runs slowly or without normal power.
  1. Insufficient current or voltage.
  2. Loose or corroded battery cable connections.
  3. Incorrect power cords.
  1. Battery weak, recharge. Run Winch with vehicle motor running.
  2. Clean, tighten, or replace.
  3. Use only supplied power cords.
Motor runs in one direction only.
  1. Defective or stuck Solenoid.
  2. Defective Remote Control.
  1. Tap Solenoid to loosen contacts. Repair or replace Solenoid.
  2. Replace Remote Control.
warning 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 THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
Record Your Product's Serial Number.

warning Note: If product has no serial number, record month and year of purchase instead.
warning Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Specify UPC 193175417060 when ordering parts.

Visit our website at: http://www.harborfreight.com
Email our technical support at: productsupport@harborfreight.com

For technical questions, please call 1-888-866-5797.

Documents / Resources

References

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download BADLAND APEX 5500, 57535 - Winch with Synthetic Rope Manual

Advertisement

Need Assistance?

Do you have a question about the APEX 5500 that isn't answered in the manual? Leave your question here.

Error while submitting your question. Please, reload page and try again.

Thank you! Your question has been received!

Table of Contents