Badland ZXR 9500 User Manual

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Owner’s Manual & Safety Instructions
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No portion of this manual or any artwork contained herein may be reproduced in
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Diagrams within this manual may not be drawn proportionally. Due to continuing
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Tools required for assembly and service may not be included.
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

Badland ZXR 9500 Specifications

General

Motor	5.5 hp Series Wound
Gear Ratio	161.28:1
Gear Train	3-Stage Planetary
Rated Line Pull	9500 lbs
Cable	5/16"
Fairlead	Roller
Remote Control	12V wired remote
Braking	Automatic load-holding brake
Battery Requirements	12V

Summary

Specifications

Wire Rope Capacity

Details rated line pull and capacity for different rope layers.

First Layer of Wire Rope Performance

Shows line pull, speed, and amp draw for the first layer.

Warning Symbols and Definitions

Safety Alert Symbols

Explains DANGER, WARNING, CAUTION, and NOTICE symbols.

Hazard and Property Symbols

Defines symbols for hazards like cut/sever and properties like VDC, Amperes.

Important Safety Information

Installation Precautions

Safety steps to follow during winch installation.

Operation Precautions

General Operation Safety

Covers load capacity, motor stalls, clutch, wire rope handling, and avoiding kinks.

Safe Winching Practices

Includes advice on entanglement, fairlead clearance, and using dampening blankets.

Operation Precautions (Continued)

Safe Winching Practices

Details on keeping clear, avoiding side pressure, submerging, and vehicle transmission.

Winching Angles and Anchoring

Advises on extreme angles, using snatch blocks, and pacemaker considerations.

Service Precautions

General Service Safety

Safety guidelines for performing maintenance and service on the winch.

Installation and Setup

Mounting the Winch

Instructions for securely mounting the winch to a suitable surface.

Mounting the Control Box

Steps for installing the control box near the winch.

Wiring

Wiring Precautions

Safety warnings related to battery connections and wiring.

Wiring Connections

Diagram and steps for connecting the winch wiring to the battery.

Preparing the Wire Rope

Instructions for properly coiling and tensioning the wire rope.

Operation

Pre-Operation Checks

Ensuring wire rope condition, battery charge, and electrical connections.

Attaching the Hook

Guidance on correctly hooking the object using straps or chains.

Double Line Rigging

Benefits of Double Line Rigging

Explains how double line systems reduce load and heat buildup.

Double Line Setup Procedure

Steps for connecting wire rope using a snatch block for a double line system.

Operation (Continued)

Remote Control Operation

Testing the wired remote control and operating the winch.

Winching Angles and Duty Cycle

Guidance on extreme angles, intermittent use, and motor cooling.

Duty Cycle and Maintenance

Duty Cycle Explanation

Defines duty cycle and its importance for preventing winch overheating.

Cleaning, Maintenance, and Lubrication

Procedures for inspecting, cleaning, and lubricating the winch.

Wire Rope Replacement

Instructions for replacing the wire rope, including tensioning.

Troubleshooting

Motor Issues

Addresses problems like motor not turning or overheating.

Winch Operation Issues

Troubleshoots drum not turning or motor running slowly.

Parts List and Diagram

Parts List

A comprehensive list of all parts included with the winch.

Assembly Diagram

An illustrated diagram showing the assembly of winch components.

Limited 90 Day Warranty

Warranty Coverage

Details the terms and conditions of the 90-day limited warranty.

Warranty Claims

Instructions on how to make a warranty claim and return procedures.