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Item 59408 

        

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13. Operate the Wired Remote Control briefly to ensure 

it works properly, see Figure L.  If operation is 

reversed, the power cables may be connected 

backwards.  Correct any such issue before use.

Figure L:  Wire Remote Controls

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

the Wired Remote Control to retract the wire rope, 

and winch the as desired.  

Do not power the hook 

all the way into the fairlead to prevent damage.

15. 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.

45°

45°

15°

15°

FiGuRE B: ROLLER FAiRLEAD 

MAXiMuM WinCHinG AnGLES

16. 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 AnCHORinG

17. 

CAuTiOn! 

Stop the winch and release tension 

on the wire rope before moving the whiplash 

dampening blanket or winch 2 (sold separately) on it.

18. Do not continue use of the winch until 

the battery is completely run down.

19. You may wish to keep the engine running while 

using this winch, to continually recharge the battery. 

However, exercise extreme caution when 

working around a running vehicle and ONLY 

operate a vehicle in an outdoor area.

nOTiCE:

  

Do not use the winch in a 

constant duty application, it is designed for 

inTERMiTTEnT uSE OnLy.  Keep the duration 

of the pulling job as short as possible.  if the 

motor becomes very hot to the touch, stop and 

let it cool down for several minutes.  Do not pull 

for more than one minute at or near the rated 

load.  Do not maintain power to the Winch if 

the motor stalls.  Double Line Rigging will help 

prevent overloading and should be used whenever 

practical, see Double Line Rigging on page 11.

20. When finished pulling the load, reverse the direction 

of the winch just enough to release tension on 

the Wire Rope so that you can unfasten the 

Hook from the load and reel in the Wire Rope.

Summary of Contents for ZXR 9500

Page 1: ...n 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 2022 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 manual may not be ...

Page 2: ...tch Sound Rating 85 dB Wire Rope Size Type Ø0 33 X 65 Ø8 3mm X 19 8m Nominal strength 14 000 lb 7 X 19 Galvanized Steel Aircraft Wire Rope Battery 12VDC Minimum 650 CCA Battery Cables 2 5 gauge 6 1 8m long Mounting Bolt Pattern 10 x 4 5 254mm x 114 3mm Mounting Hardware Winch 4x Gr8 8 M10 1 50 x 30mm 32 ft lb 43 4 Nm Fairlead 2x Gr8 8 M12 1 75 x 25mm 55 ft lb 74 5 Nm Control Box 4x G8 ST M5 x 14mm...

Page 3: ...on resistant leather gloves Wear ANSI approved safety glasses Cut or sever hazard Roller entanglement hazard Hot surface burn hazard Fire hazard Caustic chemical hazard from battery acid 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 Propert...

Page 4: ... 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 o...

Page 5: ... Do not use vehicle to pull on the Wire Rope and assist the winch 13 Use as intended only Do not lift items vertically or use for aircraft purposes 14 Prevent entanglement 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 15 Disconnect Wired Remote Control before working near the Wire Rop...

Page 6: ...e rope under tension wire rope might break under this load and recoil back striking the person pushing against it or a bystander 27 If wire rope begins to get entangled stop winch immediately and release wire rope using switch 28 Do not submerge winch in water If winch gets submerged accidentally it needs to be immediately disassembled cleaned dried and re lubricated by a qualified technician to p...

Page 7: ...service 3 Use supplied power cords wire rope or cables listed in manual only Do not use thinner longer cables or link multiple cables together 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...

Page 8: ...ng depending on the mounting location 4 Drill holes appropriate for the hardware at the marked locations Note Depending on the vehicle application it may be beneficial to install the wiring before mounting the wench Check all terminal access before mounting the winch 5 Install the winch using hardware specified on the specification chart Tighten fasteners to the listed torque values 21 57 in 548mm...

Page 9: ...o install a rubber grommet in the hole to prevent fraying of the wires at that point 3 Route the Cables from the Control Box to the battery and from the Control Box to the Winch following the precautions discussed above See Figure E Control Box Black Yellow Winch Red Black Red Disconnect Switch Figure E Wiring Connections 4 Attach the Red Black and Yellow Cap Cables to the terminals on the Winch T...

Page 10: ... supposed to be moved engage the emergency brake and block the wheels using wheel chocks sold separately 6 To pull out the wire rope move the Clutch Handle to the Released position shown in Figure F slide the loop of the Hook Strap over the hook then pull on the Hook Strap to pull out the wire rope CAUTION Leave at least five full turns of wire rope on the drum Figure F Clutch released 7 Hook onto...

Page 11: ... 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 snatch block action b Connect the wire rope for a double line system as shown in Figure J below Use a snatch block sold separately properly rated for the load to be pulled and designed t...

Page 12: ...ire Rope pull straight FIGURE C SNATCH BLOCK ANCHORING 17 CAUTION Stop the winch and release tension on the wire rope before moving the whiplash dampening blanket or winch 2 sold separately on it 18 Do not continue use of the winch until the battery is completely run down 19 You may wish to keep the engine running while using this winch to continually recharge the battery However exercise extreme ...

Page 13: ...oblem corrected before further use Cleaning Maintenance and Lubrication 1 BEFORE EACH USE inspect the general condition of the winch Check for loose hardware misalignment or binding of moving parts cracked or broken parts damaged electrical wiring corroded or loose terminals and any other condition that may affect its safe operation Examine the wire rope Do not use the winch if the wire rope is fr...

Page 14: ...ble 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 Defective Switch Assembly 1 Tap solenoid to loosen contacts Repair or replace solenoid 2 Replace Switch Assembly Follow all safety precautions whenever diagnosing or servicing...

Page 15: ...se 1 15 Hex Screw M4x16 8 16 Iron Bushing 2 17 O Ring 62x3 8 2 18 Sealing Ring 2 19 Washer 2 Part Description Qty 20 Drum Assembly 1 21 Control Box Mounting Screw 4 22 Transmission Shaft 1 23 Brake Assembly 1 24 Spline Bushing 1 25 Tie Plate Assembly 1 26 Control Box Assembly 1 27 Motor Assembly 1 28 Winch Mounting Hardware 4 29 Wire Rope 1 30 Fairlead Mounting Hardware 2 31 Roller Fairlead 1 32 C...

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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