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Item 56258 

        

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Wiring

TO PREVENT SERIOUS INJURY FROM EXPLOSION  

DUE TO SPARKING AT THE BATTERY CONNECTION: 

Disconnect the Battery Cables before making other wiring connections.

TO PREVENT SERIOUS INJURY FROM LEAKING BATTERY ACID: 

Do not use a dirty, corroded or leaking battery.   

Only use a 12V automotive (or equivalent) battery, in good condition.

1.  Plan a route for the wiring from the point of the 

vehicle where the Winch will be mounted, or 

used, to the battery.  This route must be secure, 

out of the way of moving parts, road debris, or 

any possibility of being damaged by operation 

or maintenance of the vehicle.  For example, 

you may wish to route the wires under the vehicle, 

attaching it to the frame using suitable fasteners.  

Do not attach the wires to the exhaust system, 

drive shaft, emergency brake cable, fuel line, or any 

other components which may damage the wiring 

through heat or motion, or create a fire hazard.

2.  If you drill through the bumper or any part 

of the body to route the wires, be sure 

to install 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.

6.  Attach the long black cable from the 

Receiver directly to the negative terminal 

of the battery.  Refer to Figure E.

 

Circuit 

Breaker

Receiver

Winch

Wired 

Remote

Wired Remote 

Control Socket

Black

Black

Red

Red

Figure E:  Wiring Connections

Note:

 The attachment of the Motor Cables to the 

terminals on the Winch determines the operation of 

the Remote’s button.  After the unit is mounted and 

powered, check the direction of the Power In and Power 

Out on the Remote button.  To change the direction 

on the Remote, disconnect the battery cables from the 

battery, switch the Motor Cable connections on the 

Motor Assembly, then reconnect the battery cables.

Preparing the Wire Rope

1.  The Wire Rope must be properly coiled under 

tension to be able to support a load without damage.

2.  Uncoil the Wire Rope, except for 5 full wraps.

3.  Recoil the Wire Rope back into the Winch 

under at least 500 lb. of tension.

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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