Installation Manual

WARN INDUSTRIES
5 87968A2
REMOVAL INSTRUCTIONS
WARNING
Always Know Your Winch. Take time to fully
read the Instructions and/or Operations Guide, and/or Basic
Guide to Winching Techniques, in order to understand your
winch and its operations.
Ultra Performance & Premium Series
Synthetic Winch Rope Removal:
NOTE: For Zeon specific winches, skip to Zeon Series
Winch Rope Removal section.
THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT
PRECISELY FOLLOWED THE LIFE OF THE WINCH AND WINCH
ROPE MAY BE COMPROMISED.
Things You Will Need:
• Gloves
• Standard Hex Wrench Set
CAUTION
Always wear heavy leather gloves when
handling winch rope.
1. Disconnect the negative cable from the
battery that is used to power the winch.
2. Disengage the clutch.
3. Using gloves, freespool winch rope off drum.
NOTE: For ease of removal, e nsure there is no tension
on the winch rope prior to attempting removal.
4. Remove the button head fastener and rope
washer securing winch rope. Remove winch
rope completely and discard.
Zeon Synthetic Series Winch Rope
Removal
THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT
PRECISELY FOLLOWED THE LIFE OF THE WINCH AND WINCH
ROPE MAY BE COMPROMISED.
Things You Will Need:
• Gloves
• Standard Flat Head Screwdriver
CAUTION
Always wear heavy leather gloves when
handling winch rope.
1. Disconnect the negative cables from the
battery that are used to power the winch.
2. Disengage the clutch.
3. Using gloves, freespool winch rope off drum.
NOTE: For ease of removal, e nsure there is no tension
on the winch rope prior to attempting removal.
4. Using a flat head screwdriver, find the oblong
hole in the puck. Insert end of flat head
screwdriver in the hole of puck and using
leverage against the drum, dislodge puck.
5. Remove the puck and pull the winch rope
through and out of the rope anchor pocket.
Rope
Rope Washer
1/4-20x1/2” Button
Head Bolt
WARN INDUSTRIES
87968A2 6
INSTALLATION INSTRUCTIONS
WARNING
When upgrading from wire to synthetic
winch rope, a WARN Hawse Fairlead is necessary.
NOTICE
Any wire rope damage on drum may be smoothed
with fi ne emery paper.
Ultra Performance & Premium
Synthetic Series Rope Installation:
THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT
PRECISELY FOLLOWED THE LIFE OF THE WINCH AND WINCH
ROPE MAY BE COMPROMISED.
Things You Will Need:
• WARN® Synthetic Winch Rope
• Abrasion Sleeve
• Rope Washer
• Button Head Bolt
• Gloves
• Loctite 271 or equivalent
• WARN® Hawse Fairlead (if replacing wire rope)
WARNING
MOVING PARTS ENTANGLEMENT HAZARD.
Failure to observe these instructions could lead to serious
injury or death.
WARNING
Always position fairlead with warning
readily visible on top.
CAUTION
Always wear heavy leather gloves when
handling winch rope.
WARNING
Always replace the WARN Fairlead if
damaged or abused.
WARNING
Always keep hands clear of winch rope,
hook loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
For synthetic winch rope applications, you must
have a Hawse Fairlead mounted to your winch. For
optimal performance, a WARN Hawse Fairlead is
strongly recommended. If you need to purchase
a new WARN Hawse Fairlead, contact your WARN
product dealer.
1. Disconnect the negative cable from the battery
that is used to power the winch.
WARNING
Never bend rope around unprotected, sharp
corners.
WARNING
Never use rope over a rough surface without
abrasion protection.
2. Slide the black abrasion sleeve over the rope
from the end opposite of the hook. Slide the
sleeve towards the hook end of the rope.
3. Insert the synthetic rope through the fairlead
and around the winch drum from the bottom.
4. Apply Loctite 271 or equivalent product to
the supplied 1/4”-20 x 1/2” long button head
fastener.
5. Insert the button head fastener supplied and
the machined rope washer. Before tightening
the bolt, install the rope eyelet on the
machined rope washer. Tighten the 1/4-20
button head bolt to 8 ft. lbs.
6. Reconnect negative cable to the battery that is
used to power the winch.
WARNING
Always wind the winch rope on bottom
(mount side) of drum.
WARNING
Never operate winch with less than 10
wraps of winch rope around the drum. Rope could come
loose from the drum, as the winch rope attachment to the
drum is not designed to hold a load.
WARNING
Never touch winch rope or hook while
someone else is at the control switch or during winching
operation.
7. Turn the clutch lever on the winch to the
“Engaged” position.
8. Power in and wind 10 wraps of winch rope onto
the drum while applying tension on the winch
rope.
Proceed to the ‘Rope Spooling Instructions’
section of this document.
Rope
Rope Washer
1/4-20x1/2” Button
Head Bolt