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Page 7

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

Item 56258 

        

SAF

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A

INT

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4.  Have the winch serviced by a qualified repair person 

using only identical replacement parts.  This will 

ensure that the safety of the winch is maintained.

5.  Maintain labels and nameplates on the winch.  

These carry important safety information.  

If unreadable or missing, contact 

Harbor Freight Tools for a replacement.

6.  Receiver and Wireless Remote contain 

no user-servicable parts except the 

Remote’s batteries.  Other than for battery 

replacement, do not open their housing.

 SAVE THESE INSTRUCTIONS.

Installation and Setup

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual 

including all text under subheadings therein before set up or use of this product.

Mounting the Winch

1.  The plate must be rated to at least 

the Winch’s capacity.

2.  Align the Winch perpendicular to center line of 

the vehicle at the desired location, and mark the 

locations of the Winch base holes.  Compare the 

dimensions of the marked holes to Figure D.

3.  Before drilling, 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 for the hardware 

at the marked locations.

5.  Install the Winch using hardware 

described under 

Specifications

.

2.83 in.

72

mm

4.13 

in

.

/

105

mm

1.25  in.

32

mm

2*Ø0.33 in.

/

8.5

mm

3.15 

in

.

80

mm

3.94 

in

.

/

100

mm

2 in.

51

mm

8.31 in.

/

211

mm

11.25 in.

/

286

mm

Figure D:  Winch Dimensions

Mounting Winch Components

 

1.  Mount Receiver in proper location so that:

a.  Winch components are close enough to each 

other to allow wires to be routed properly.

b.  Vehicle component operation 

is not interfered with.

c.  Vehicle components are not damaged 

by drilling or driving screws.

d.  Winch components will not be damaged by 

stresses caused by vehicle operation.

2.  Mark the locations where the screw holes will be.

3.  Verify that the installation surface has no 

hidden components or structural pieces 

that will be damaged before drilling.

4.  Drill pilot holes for the mounting screws.

5.  Secure in place with mounting screws.

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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