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

Item 56258 

        

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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.  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 Wire Rope.  Do not use the Winch 

if the Wire Rope is frayed, kinked or damaged.

2. 

AFTER USE,

 wipe external surfaces 

of the Winch with clean cloth.

3.  Lubricate the Wire Rope occasionally with a light oil.

4.  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.

Wire Rope Replacement

1.  Move Clutch Handle to the released (freespool) 

position.  Refer to 

Clutch Operation

 on page 9.

2.  Extend the Wire Rope to its full length, 

noting how the existing Wire Rope is 

connected to the inside of the drum.

3.  Remove old Wire Rope and attach new assembly.

CAUTION!

 Do not replace with inferior wire rope.  

Only use a wire rope rated to the same rating 

cited on the specification chart or better. 

4.  Retract Wire Rope onto Wire Rope 

drum being careful not to allow kinking.  

Refer to instructions for tensioning the Wire Rope 

under 

Preparing the Wire Rope

 on page 8.

5.  Test Electric Winch for proper operation.

Wireless Remote Control Battery Replacement

1.  Remove screws from battery cover 

on back of Wireless Remote.

2.  Remove battery cover carefully.

3.  Remove used batteries from unit and replace with 

same.  Dispose of used batteries in accordance 

with all applicable local, state and federal laws.

Note:

 Position batteries in proper polarity. 

4.  Replace battery cover and tighten screws securely.

Summary of Contents for ZXR 2500

Page 1: ...ence 21h 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 2021 by Harbor Freight Tools All...

Page 2: ...12VDC Minimum 12 Ah Battery Cables 10 gauge 5 8 1 78m long Mounting Pattern 3 15 80mm Mounting Hardware Winch 2x G8 M8 1 25 x 35mm Fairlead 2x G8 M8 1 25 x 19mm Overload Protection In line Circuit Br...

Page 3: ...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...

Page 4: ...ot 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 cl...

Page 5: ...At this point the winch should be stopped and the wire rope should be straightened out to prevent kinking b This wire rope is kinked It is too late to reverse the damage at this point the wire rope m...

Page 6: ...de wire rope through hands even with gloves on 31 Winch motor will be hot during and after use Keep clear 32 Do not power the hook all the way into the fairlead or winch 33 People with pacemakers shou...

Page 7: ...g 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 cap...

Page 8: ...tall a rubber grommet in the hole to prevent fraying of the wires at that point 3 Route the cables from the Receiver to the battery and from the Receiver to the Winch following the precautions discuss...

Page 9: ...d 2 To change clutch positions a Pull clutch handle out b Turn it 90 while it is pulled out then release it a b Figure F Clutch operation Remote Control Instructions WARNING Only operate the Winch whi...

Page 10: ...point tow strap tree strap or chain See Figure G Shackle not shown between tree strap and hook Figure G Using a strap anchor point Do not wrap the Wire Rope around the object and hook onto the wire r...

Page 11: ...d Remote Control The IN position should retract the winch cable The OUT position should power out the cable b For the Wireless Remote Control Activate the Wireless Remote by pressing the ON OFF button...

Page 12: ...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 d...

Page 13: ...ight oil 4 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 s...

Page 14: ...ck 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 v...

Page 15: ...Qty 15 Motor Assembly 1 16 Bolt 2 17 Mounting Bracket 1 18 Solenoid Assembly 1 19 Roller Fairlead 1 20 Steel cable 5 32 50 1 21 Hardware Kits 1 22 Screw 2 23 Remote Control 1 24 5 16 Hook 1 25 Termina...

Page 16: ...usion 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 INCLU...

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