Badland ZXR 2500 User Manual Download

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

Item 56258

AFE

PERA

int

Parts List and Assembly Diagram

Part

Description

Qty.

Motor

Gear Box

Ring Gear

Planetary Gear Assembly

Rotator Gear

Gear Box Cap

Drum Support Bushing

Screw M4 x 10

Clutch Shaft

Spline

Spring

Drum

Screw M5

Bushing

Nut M5

Tension Plate

Base Plate

Part

Description

Qty.

Clutch Handle

Countersunk Head Screw M5 x 10

Socket Head Cap Screw M6 x 16

Roller Fairlead

Wire Rope

Hook

Nut

Spring Washer

Flat Washer

Screw

Red Strap

Shackle

Control Box

Circuit Breaker

Wired Remote Control

Wireless Remote Control

Record Product’s Serial number Here:

note:

If product has no serial number, record month and year of purchase instead.

note:

Some parts are listed and shown for illustration purposes only, and are not available

individually as replacement parts. Specify UPC 193175364289 when ordering parts.

Summary of Contents for ZXR 2500

Page 1: ...rence 20j 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 2020 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 manua...

Page 2: ...aft Wire Rope Battery 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 Breaker Sound Rating 85 dB Overall Dimensions L x D x H 11 25 x 3 88 x 4 25 286 x 99 x 108mm Weight 14 7 lb 6 7 kg IP Rating IP 65 Winch and Controls resistant to water jets Layer R...

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 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 Property or S...

Page 4: ...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 ...

Page 5: ...m 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 must be discarded It is permanently damaged and must not be used c This is a kinked wire rope that has been straightened out Even though it has been pulled straight some wires in the wire rope are str...

Page 6: ...ide 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 should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure Wireless Operation Precautions 1 Do not us...

Page 7: ...ng 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 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 4 Drill holes appropriate fo...

Page 8: ...ll 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 discussed earlier 4 Attach the wires from the Receiver to the terminals on the Winch Refer to Figure E 5 Attach the red cable from the Circuit Breaker to the positive terminal on the battery Refer to Figure E ...

Page 9: ...ed 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 while the Winch line and load are in view Make sure that there are no bystanders nearby To prevent serious injury from accidental starting turn off remote after every use Wired Operation 1 To use the Wi...

Page 10: ...g 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 rope itself This can damage the object being pulled and kink or fray the Wire Rope 8 Attachment point must be centered in loop of hook and the hook s safety clasp must be fully closed See Figure H Fig...

Page 11: ...a For the Wired 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 for 3 seconds until LED lights up The retract button should retract the winch cable The extend button should power out the cable If operation is reversed the power cables may be connect...

Page 12: ...g 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 FCC StAtEMEnt Caution The user is cautioned that changes or modifications not expressly approved by the pa...

Page 13: ...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...

Page 14: ...eck 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 Remote damaged 1 Tap solenoid to loosen contacts Repai...

Page 15: ...ate 1 Part Description Qty 18 Clutch Handle 1 19 Countersunk Head Screw M5x10 2 20 Socket Head Cap Screw M6x16 2 21 Roller Fairlead 1 22 Wire Rope 1 23 Hook 1 24 Nut 2 25 Spring Washer 2 26 Flat Washer 2 27 Screw 2 28 Red Strap 1 29 Shackle 1 30 Control Box 1 31 Circuit Breaker 1 32 Wired Remote Control 1 33 Wireless Remote Control 1 Record Product s Serial number Here note If product has no seria...

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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