Badland ZXR 2500 - User Manual

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Summary

Important Safety Information

Operation Precautions

Safety guidelines and precautions to follow when operating the winch.

Installation and Setup

Mounting the Winch

Instructions and considerations for physically mounting the winch to a vehicle or surface.

Winch Operation

Remote Control Operation

Guidance on using both wired and wireless remote controls for winch operation.

Basic Operation Procedures

Performing Basic Winching

Step-by-step instructions for safe and effective winch operation.

This document is the owner's manual and safety instructions for the BADLAND ZXR2500 ATV/Utility Winch, model 56258. It provides comprehensive information on the winch's function, technical specifications, usage, and maintenance.

Function Description:

The BADLAND ZXR2500 is an ATV/Utility Winch designed for pulling applications. It is intended for intermittent use, not constant duty, and is suitable for tasks such as vehicle recovery or moving objects within its rated capacity. The winch operates on a 12VDC power supply and features both wired and wireless remote control options for operation. Key features include an auto load-holding dynamic brake, a freespool clutch for quick wire rope deployment, and a roller fairlead to guide the wire rope. The manual emphasizes safe operation, including proper rigging techniques like double line rigging to reduce load on the winch and extend its lifespan.

Important Technical Specifications:

Rated Single Line Pull: 2500 lb (1134 kg)
Application: Utility/Shop/ATV
Motor: 12VDC 1 HP Permanent Magnet
Wire Rope Size/Type: Ø5/32" x 50' (Ø4mm x 15.2m), 7 x 19 Galvanized Steel Aircraft Wire Rope, Nominal strength=2,800 lb
Battery: 12VDC, Minimum 12 Ah
Duty Cycle Rating: 5% (45 sec at Max Rated Load; 14 min, 15 sec Rest)
Geartrain: Single-stage Planetary
Gear Ratio: 153:1
Brake: Auto. Load Holding Dynamic
Drum (Dia. x L): 1.25" x 2.8" (32mm x 71mm)
Hook: 1/4" Eye Hook
Fairlead: Roller with nylon bushings
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)

The manual also provides a detailed table for "Rated Line Pull" and "Wire Rope Capacity" across different layers of the drum, indicating that the pulling capacity decreases as more layers of wire rope are spooled onto the drum. The "First Layer of Wire Rope Performance" table further details line pull, line speed (fpm/mpm), and amp draw at 12V for various load conditions on the first layer.

Usage Features:

The winch offers several usage features designed for convenience and safety:

Clutch Operation: A clutch handle allows engagement or release of the clutch. When the pin rests in the groove, the clutch is engaged; when it rests on top of the drum end, the clutch is released, enabling freespool for quick wire rope deployment.
Remote Control: The winch can be operated via a wired remote control or a wireless remote control. The wired remote connects to a socket on the receiver, while the wireless remote is activated by pressing an ON/OFF button for 3 seconds. Both remotes have "IN" (retract) and "OUT" (extend) buttons. The wireless remote automatically powers off after 2 minutes of inactivity.
Safety Precautions: The manual extensively covers safety, including warnings against exceeding load capacity, dynamic loading, operating with a disengaged clutch, and placing fingers near the fairlead or hook. It advises using a strap to hold the hook and keeping clear of the wire rope's direct line of pull.
Kink Prevention: Illustrations demonstrate how kinks form in wire rope and emphasize the importance of keeping the wire rope straight to prevent damage, as a kinked rope is permanently weakened and must be discarded.
Winch Damper/Blanket: The use of a heavy blanket or winch damper is recommended over the wire rope span (6 feet from the hook) to absorb force if the rope breaks, preventing whiplash.
Double Line Rigging: This technique is highly recommended to reduce the load on the winch, utilize higher capacity lower layers of wire rope, and halve the load through pulley action using a snatch block.
Duty Cycle: The winch has a specified duty cycle of 45 seconds of winching at maximum load followed by at least 14 minutes and 15 seconds of rest to prevent overheating and premature failure.
Underwind Orientation: The winch and fairlead must be installed in an underwind orientation, meaning the wire rope enters and exits the winch at the bottom of the drum.
Minimum Wire Rope Turns: At least 5 full turns of wire rope must remain on the drum, as the connection to the drum is not designed to sustain a load without the friction support from these turns.
Wire Rope Tensioning: The wire rope must be wrapped under at least 500 lb. of tension before use to prevent binding.

Maintenance Features:

The manual outlines essential maintenance procedures to ensure the winch's longevity and safe operation:

Pre-Use Inspection: Before each use, inspect the winch for loose hardware, misalignment, binding of moving parts, cracked or broken parts, damaged electrical wiring, corroded or loose terminals, and any other condition affecting safe operation. The wire rope must be examined for fraying, kinking, or damage.
Post-Use Cleaning: After each use, wipe external surfaces of the winch with a clean cloth.
Lubrication: The wire rope should be lubricated occasionally with a light oil. The winch's internal mechanism is permanently lubricated and should not be opened by the user. If submerged, it should be opened, dried, and re-lubricated by a qualified technician.
Wire Rope Replacement: Instructions are provided for replacing the wire rope, emphasizing the use of wire rope rated to the same or better specifications as the original. The process involves moving the clutch handle to freespool, extending the old wire rope, noting its connection, removing it, attaching the new assembly, and then retracting the new wire rope carefully under tension.
Wireless Remote Control Battery Replacement: Steps are provided for replacing the batteries in the wireless remote control, including removing the battery cover, replacing used batteries with new ones of the same type, ensuring correct polarity, and securing the cover.
Troubleshooting: A troubleshooting guide helps identify and resolve common issues such as motor overheating, motor not turning on, drum not turning, slow operation, or operation in only one direction. It provides possible causes and likely solutions.

The manual stresses that any procedures not specifically explained should only be performed by a qualified technician and that all safety precautions, including disconnecting battery cables, must be followed during maintenance.