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Item 56258 

        

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Double Line Rigging

a.  A double line system should be used whenever 

possible.  It reduces the load on 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 pulley action.

b.  Connect the wire rope for a double line 

system as shown in Figure I below.  Use a 

snatch block (sold separately) properly rated 

for the load to be pulled and designed to be 

operated with this Winch’s wire rope.

Stationary 

Winching Vehicle  

(Chock tires, 

set parking brake, 

and leave in neutral)

Load

Damper

Figure I:  Double Line setup

c.  Loop the wire rope around the snatch block and 

connect to another part of the vehicle’s chassis or 

to a separate anchor point.  

Do not anchor the 

Wire Rope back to the Winch or winch mount.

Note:

 If anchoring the winching vehicle, 

only attach the anchor line to the front of the 

vehicle.  If the anchor line is attached to the 

rear of the vehicle, the vehicle

s frame may be 

damaged by the forces exerted by winching.

WARNING! TO PREVENT SERIOUS INJURY 

AND DEATH: 

Operate the Winch only while you have a clear view 

of the Winch, wire rope and entire winching operation.  

Stop winching if your view becomes obstructed.

12. Operate the controls briefly to 

ensure they work properly.
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 connected backwards.  

Correct any such issue before use.

13. When it is safe to do so, use the power switch on 

the Controller to retract the Wire Rope, and winch 

the item as desired.  

Do not power the hook all 

the way into the fairlead to prevent damage.

14. Do not operate the Winch at extreme angles.  

Do not exceed the angles shown in Figure B for 

a roller fairlead.  For a hawse fairlead, the angle 

should be as close to straight as possible.

15°

15°

45°

45°

Figure B: Roller Fairlead Maximum Winching Angles

15. If the object to be pulled must be pulled at an 

angle in relation to the Winch, use a snatch 

block (sold separately) and an anchor point 

directly in front of the Winch, as shown in 

Figure C, to keep the Wire Rope pull straight.

Figure C: Snatch Block

16. 

WARNING!  TO PREVENT SERIOUS 

INJURY: 

Stop the Winch and release 

tension on the Wire Rope before moving the 

blanket or winch damper placed on it.

17. Do not continue use of the Winch until 

the battery is completely run down.

18. When possible, keep the engine running while using 

this Winch, to continually recharge the battery and 

prevent the battery from being drained so much that 

the vehicle cannot start.  However, exercise extreme 

caution when working around a running vehicle 

and ONLY operate a vehicle in an outdoor area.

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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