Badland ZXR 9500 User Manual Download

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Page 2

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

Item 59408

Table of Contents

Specifications ............................................. 2
Safety ......................................................... 3
Setup .......................................................... 8
Operation ................................................... 10

Maintenance .............................................. 13
Parts List and Diagram .............................. 15
Warranty .................................................... 16

Specifications

Rated Single Line Pull 9,500 lb. (4,309 kg.)

Application

Vehicle Recovery /

For Trucks and SUV’s

Motor

12VDC 5.5 HP Series Wound

Power IN &

Power OUT

Yes

Duty Cycle Rating

5% (45 sec at Max Rated Load;

14 min, 15 sec Rest)

Wired Remote Control Wired, 12 ft (3.7m) long

Geartrain

3-Stage Planetary

Gear Ratio

218:1

Freespool

Sliding Ring Gear

Brake

Spring

Drum (Dia. X L)

2.5″ X 8.75″ (64mm X 222mm)

Clevis Hook

3/8″, Replaceable with

Spring-loaded Safety Latch

Fairlead

Roller with nylon bushings

Overload Protection

Disconnect Switch

Sound Rating

85 dB

Wire Rope Size / Type Ø0.33″ X 65′ (Ø8.3mm X 19.8m)

Nominal strength = 14,000 lb

7 X 19 Galvanized Steel

Aircraft Wire Rope

Battery

12VDC Minimum 650 CCA

Battery Cables

2.5 gauge, 6′ (1.8m) long

Mounting Bolt Pattern 10″ x 4.5″ (254mm x 114.3mm)

Mounting Hardware

Winch:

4x Gr8.8, M10-1.50 x 30mm,

32 ft. lb. (43.4 Nm)

Fairlead:

2x Gr8.8, M12-1.75 x 25mm,

55 ft. lb. (74.5 Nm)

Control Box:

4x G8, ST-M5 x 14mm

Overall Dimensions

(L X D X H)

21.57″ X 6.3″ X 9.7″

(548 x 161 x 247mm)

Weight

76.3 lb. (34.6 kg.)

IP Rating

IP66 - Winch and Controls

(resistant to powerful water jets,

except remote control switch)

Winch Certification

Layer

Rated Line Pull

Wire Rope Capacity

9500 lb. (4,309 kg.) 18.2′ (5.5m)

7700 lb. (3,493 kg.) 40.6′ (12.4m)

6500 lb. (2,948 kg.) 65′ (19.8m)

First Layer of Wire Rope Performance

Line Pull

lb. (kg.)

Line Speed

fpm (mpm)

Amp Draw

(@ 12V)

0 (0)

25.9 (7.89)

3000 (1361)

12.2 (3.72)

177

6000 (2722)

9.05 (2.76)

242

9500 (4,309)

6.9 (2.1)

330

Summary of Contents for ZXR 9500

Page 1: ...n 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 2022 by Harbor Freight Tools All rights reserved 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 ...

Page 2: ...tch Sound Rating 85 dB Wire Rope Size Type Ø0 33 X 65 Ø8 3mm X 19 8m Nominal strength 14 000 lb 7 X 19 Galvanized Steel Aircraft Wire Rope Battery 12VDC Minimum 650 CCA Battery Cables 2 5 gauge 6 1 8m long Mounting Bolt Pattern 10 x 4 5 254mm x 114 3mm Mounting Hardware Winch 4x Gr8 8 M10 1 50 x 30mm 32 ft lb 43 4 Nm Fairlead 2x Gr8 8 M12 1 75 x 25mm 55 ft lb 74 5 Nm Control Box 4x G8 ST M5 x 14mm...

Page 3: ...on resistant leather gloves 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 Symbol Propert...

Page 4: ... 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 wire 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 o...

Page 5: ... Do not use vehicle to pull on the Wire Rope and assist the winch 13 Use as intended only Do not lift items vertically or use for aircraft purposes 14 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 15 Disconnect Wired Remote Control before working near the Wire Rop...

Page 6: ...e rope under tension wire rope might break under this load and recoil back striking the person pushing against it or a bystander 27 If wire rope begins to get entangled stop winch immediately and release wire rope using switch 28 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 p...

Page 7: ...service 3 Use supplied power cords wire 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...

Page 8: ...ng depending on the mounting location 4 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 wench Check all terminal access before mounting the winch 5 Install the winch using hardware specified on the specification chart Tighten fasteners to the listed torque values 21 57 in 548mm...

Page 9: ...o install a rubber grommet in the hole to prevent fraying of the wires at that point 3 Route the Cables from the Control Box to the battery and from the Control Box to the Winch following the precautions discussed above See Figure E Control Box Black Yellow Winch Red Black Red Disconnect Switch Figure E Wiring Connections 4 Attach the Red Black and Yellow Cap Cables to the terminals on the Winch T...

Page 10: ... supposed to be moved engage the emergency brake and block the wheels using wheel chocks sold separately 6 To pull out the wire rope move the Clutch Handle to the Released position shown in Figure F slide the loop of the Hook Strap over the hook then pull on the Hook Strap to pull out the wire rope CAUTION Leave at least five full turns of wire rope on the drum Figure F Clutch released 7 Hook onto...

Page 11: ... 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 It halves the load on the winch through snatch block action b Connect the wire 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 t...

Page 12: ...ire Rope pull straight FIGURE C SNATCH BLOCK ANCHORING 17 CAUTION Stop the winch and release tension on the wire rope before moving the whiplash dampening blanket or winch 2 sold separately 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 ...

Page 13: ...oblem 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 and any other condition that may affect its safe operation Examine the wire rope Do not use the winch if the wire rope is fr...

Page 14: ...ble 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 Switch Assembly 1 Tap solenoid to loosen contacts Repair or replace solenoid 2 Replace Switch Assembly Follow all safety precautions whenever diagnosing or servicing...

Page 15: ...se 1 15 Hex Screw M4x16 8 16 Iron Bushing 2 17 O Ring 62x3 8 2 18 Sealing Ring 2 19 Washer 2 Part Description Qty 20 Drum Assembly 1 21 Control Box Mounting Screw 4 22 Transmission Shaft 1 23 Brake Assembly 1 24 Spline Bushing 1 25 Tie Plate Assembly 1 26 Control Box Assembly 1 27 Motor Assembly 1 28 Winch Mounting Hardware 4 29 Wire Rope 1 30 Fairlead Mounting Hardware 2 31 Roller Fairlead 1 32 C...

Page 16: ...lusion 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 expl...

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