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

Item 56258 

        

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Important Safety Information

  WARNING! 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 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 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 wire rope enters and exits the 

winch at the bottom of the drum.

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 wire rope layer

see 

Specifications

 on 

page 2.  Make sure the battery is fully charged.  

Use double line rigging whenever possible.  

Refer to 

Double Line Rigging

 on page 11.

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 wire 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.

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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