WARN INDUSTRIES * WINCH
13
OPERATING INSTRUCTIONS
WARNING
Always
prestretch
rope and respool
under load before
use. Tightly wound
rope reduces chances
of “binding”, which
can damage the
rope.
WARNING
Never
touch rope or
hook while someone
else is at the control
switch or during
winching operation.
Spooling
THE FOLLOWING STEPS ARE VERY
IMPORTANT AND IF NOT PRECISELY
FOLLOWED THE LIFE OF THE WINCH
AND ROPE MAY BE COMPROMISED.
1. Mount the Warn Aluminum Hawse
Fairlead to the winch mount using
the supplied hardware. Always
mount the fairlead with the labels in
the upright position (labels on top
and clearly visible). Insert a 7/16” x
1 1/4” bolt through each of the two
fairlead mounting holes and through
the winch mount. Place a 7/16” at
washer onto each bolt. Install a 7/16”
lock nut onto each bolt and tighten to
35 ft. lbs.
6. It is now necessary to spool the
remaining rope onto the winch
drum. Choose a FLAT location that
is large enough to run out the entire
length of rope. Attach the hook end
of the rope to a suitable anchor point
and back the vehicle away from the
anchor point leaving approximately
6 ft of slack rope lying on the ground.
Before getting out of the vehicle, set
the parking brake, place the vehicle in
gear or park and turn the vehicle off .
7. Connect the remote control to the
winch. Standing approximately 8 ft
away from the winch, power in the
winch until there is 10 wraps onto the
winch drum. Disconnect the remote
control from the winch. Hold tension
on the rope with one hand; carefully
push the rope to the side of the drum
the rope is attached to so there are
no gaps between each coil on the
drum. Be sure to check that the rope
is winding off of the bottom of the
drum, not the top, or the automatic
load holding brake will not function
properly. (If the rope is winding off
the top you have powered the winch
“out” instead of “in” on the remote
control)
8. If there is still rope laying on the
ground, back the vehicle away until
the rope is off of the ground.
9. The following steps should be done
using two people for proper safety.
If you attempt to tension your rope
alone be sure to always engage the
parking brake, place the transmission
in gear and turn the vehicle off
every time you exit the vehicle to
inspect the winch rope. Never exit
the vehicle with a load on the winch
rope. Tensioning the rope is critical to
ensure a long product life. Tensioning
the rope prevents the rope from
sinking into the lower layers under
load.
10. Use care to evenly wrap each layer
to prevent damage to the rope.
2. Slide the abrasion sleeve over the
rope from the end opposite the hook.
Slide the sleeve back to the hook end
of the rope.
3. Apply Lock Tite 271 or equivalent
product to the supplied 1/4”-20 x 1/2”
long button head fastener.
4. Install the new synthetic rope using
the button head fastener supplied
and the machined rope washer.
Insert the synthetic rope through
the aluminum fairlead and around
the winch drum from the bottom.
Insert the button head bolt into the
machined rope washer and place the
synthetic rope on the machined rope
washer. Install the button head bolt
in the 1/4-20 hole in the side of the
winch drum. See Figure for detail.
5. Tighten the 1/4-20 button head
bolt to 8 ft. lbs. Turn the winch clutch
level to the “engaged” position.
NOTICE
Never
install more
than 100’ (CTI) /
80’ (XDC) of 3/8”
synthetic rope.
Damage to the winch
may result.
Rope
Rope Washer
1/4-20 x 1/2”
Button Head
Bolt
Rope Washer
Rope
WARN INDUSTRIES * WINCH
14
INSTALLING ROPE
WARNING
Never
operate
winch with less
than 10 wraps of
rope around the
drum. Rope could
come loose from
the drum, as the
rope attachment
to the drum is not
designed to hold
a load.
11. Pass the remote control through
the driver’s window for the driver of
the vehicle to operate. Instruct your
assistant to stand to the side of the
vehicle and away from the winch
rope. Your assistant should signal you
if the rope is winding correctly by
watching it move across the fairlead
as the rope is powered in. Start the
vehicle and place the transmission
in neutral. Release the parking brake
while applying moderate brake pedal
pressure. Power the winch remote in.
After winching in for approximately 6
ft, stop winching. Slowly let up off of
the brake pedal and then apply the
parking brake. This will ensure that
there is no load on the winch rope.
Then place the transmission in park
or gear and turn the vehicle off . Exit
the vehicle and inspect the winch
rope is being evenly wound onto
the winch drum and not sinking into
the lower layer. If the rope is sinking,
power the rope out and repeat this
step from the beginning with more
brake pedal pressure.
12. Once you are convinced the rope
is winding on the winch properly,
return to the vehicle. Pass the remote
control through the driver’s window
for the driver of the vehicle to
operate. Start the vehicle and place
the transmission in neutral. Release
the parking brake while applying
moderate brake pedal pressure.
Power the winch remote in. After
winching in for approximately 6 ft,
stop winching. Slowly let up off of
the brake pedal and then apply the
parking brake. This will ensure that
there is no load on the winch rope.
Then place the transmission in park
or gear and turn the vehicle off . Exit
the vehicle and inspect the winch
rope is being evenly wound onto
the winch drum and not sinking into
the lower layer. If the rope is sinking,
power the rope out and repeat this
step from the beginning with more
brake pedal pressure.
INSTALLING THE ROPE Cont.
13. Repeat step 12 until the vehicle
is within 6 ft of the winch anchor.
Once within 6 ft, slowly let up off of
the brake pedal and then apply the
parking brake. This will ensure that
there is no load on the winch rope.
Then place the transmission in park
or gear and turn the vehicle off . Exit
the vehicle. Disconnect the hook from
the anchor. While holding onto the
supplied hook strap, hold tension on
the winch rope and slowly power-in
the winch by “pulsing” the power-in
on the remote control until the hook
is within 3 ft. of the fairlead. Stop
winching in and attach the hook to a
suitable anchor point on the vehicle.
DO NOT POWER THE HOOK INTO
THE FAIRLEAD. This would cause
irreparable damage to the fairlead.
Once the hook is suitably attached to
the vehicle, power in the remaining
slack in the winch rope by “pulsing”
the power-in on the remote until
there is minimal slack in the winch
rope.
Rigging
For complete rigging fundamentals,
Read the Basic Guide to Winching
Techniques, found online at
http://
www.warn.com/corporate/
literaturerequest.shtml.
WARNING
Always
spool the
rope onto the drum
in the direction
speci ed by the
winch warning label
on the winch and/
or documentation.
This is required for
the automatic brake
(if so equipped) to
function properly.
WARNING
Always
use
supplied hook
strap whenever
spooling winch rope
in or out, during
installation and
during operation.
87970A2
87970A2
