WARN INDUSTRIES
7
KNOW YOUR WINCH
Know Your Winch
Before you begin, you should familiarize yourself with your WARN winch and each of its components:
Motor
:
The winch motor is powered by the vehicle’s battery. The motor provides power to the gear
mechanism, which turns the winch drum and winds the winch rope.
Winch Drum:
The winch drum is the cylinder onto which the winch rope feeds. The drum is driven by the
motor and drive train. Its direction can be changed using the remote control.
Rope*:
The winch rope’s diameter and length are determined by the winch’s load capacity and
design. Wrapped around the winch drum and fed through the fairlead, the winch rope is
looped at the end to accept the hook’s clevis pin.
Gear Train:
The reduction gear converts the winch motor power into a large pulling force. The gear train
design makes it possible for the winch to be lighter and more compact.
Clutch Lever:
The clutch allows the operator to manually disengage the spooling drum from the gear train,
enabling the drum to rotate freely (known as “freespooling”). Engaging the clutch “locks” the
winch drum back onto the gear train.
Remote Socket
:
The remote socket is where the operator plugs in the wired remote control or optional
wireless remote receiver, in order to control the winch.
Control Pack*:
Using electrical power from the vehicle’s battery, the control pack’s contactor switches
power to the motor, enabling the operator to change the direction of the winch drum
rotation.
Remote Control:
The remote control plugs into the winch control pack, via the remote socket, allowing the
operator to control the winch direction, as well as stand well clear of the wire rope while
operating the winch.
Motor
Control Pack
Remote Socket
Clutch Lever
Transmission
(Gear Train)
Rope
Winch Drum
Remote Control
Figure 1
WARN INDUSTRIES
8
MOUNTING
Mounting Orientation and Hardware
Feet down mounting:
• (
4
) 3/8 Lock Washer
• (
4
) 3/8-16 x 1-1/4 Hex Head Bolt
• (
4
) 3/8-16 Square Nut
For feet forward mounting:
• (
2
) 3/8-16 x 1-1/4 Hex Head Bolt
• (2)
3/8 Washer
• (
2
) 3/8-16 x 1-3/4 Hex Head Bolt
• (
4
) 3/8-16 Square Nut
• (
4
) 3/8 Lock Washer
Step 1 - Mount the Winch
Winch mounting kits are available to satisfy nearly
all applications. For information on available kits,
contact your WARN® product dealer.
NOTICE For optimal performance and the results you expect,
WARN® mounting plates are strongly recommended.
CAUTION
To prevent accidental activation of the winch
and serious injury, complete the winch installation and attach
the hook before installing the wiring.
WARNING
Always choose a mounting location that is
suffi
ciently strong enough to withstand the maximum pulling
capacity of your winch.
WARNING
Never use bolts that are too long.
WARNING
Always spool the winch rope onto the drum
in the direction specifi ed by the drum rotation labels on the
winch and/or in the documentation. This is required for the
automatic brake (if so equipped) to function properly.
WARNING
Always wind the winch rope on the bottom
(mount side) of the drum.
This winch should always be mounted in a
horizontal orientation with the rope winding on
and off the drum on the mount side (bottom) of the
drum.
Correct rotation is required for the automatic
brake to function properly. Horizontal mounting
helps prevent the rope from piling up on one end of
the drum which can damage the winch.
Always use recommended bolt and washer
combinations torqued to recommended levels.
Specifications listed below. Mounting system will
dictate bolt length.
Mounting Bolt Pattern:
Standard: 10”x 4.5” (54 mm x 114.3 mm)
Smooth and fl at mounting surface, minimum
thickness = 1/4” (6.4 mm)
(4) 3/8-16
Square Nut
(4) 3/8-16 x 1-1/4
Hex Head Bolt
(4) 3/8 Lock
Washer
(4) 3/8 Lock
Washer
(2) 3/8-16 x 1-3/4
Hex Head Bolt
(4) 3/8-16
Square Nut
(2) 3/8 Washer
(2) 3/8-16 x 1-1/4
Hex Head Bolt
97003A0
97003A0
