Installation Manual

WARN INDUSTRIES
7 87968A2
INSTALLATION INSTRUCTIONS
WARNING
When upgrading from wire to synthetic
winch rope, a WARN Hawse Fairlead is necessary and you
must use the 5/16” anchor puck supplied in your synthetic
rope kit (sizes vary).
NOTICE
Any wire rope damage on drum may be smoothed
with fi ne emery paper.
Zeon 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
• Zip Tie
• 5/16” Anchor Puck
• Gloves
• 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 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.
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.
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 abrasion sleeve over the rope from the
end opposite the hook. Slide the sleeve back to
the hook end of the rope.
3. Insert the synthetic rope through the fairlead
and around the winch drum from the bottom.
4. Before installing the synthetic rope, a loop must
be made using the supplied zip tie.
5. Use the cable tie to pull the synthetic rope
through the rope anchor pocket.
6. Once the rope has been pulled through, cut and
discard the zip tie while being careful not to
harm the rope.
7. Install the 5/16” rope puck in the center of the
rope eyelet.
WARN INDUSTRIES
87968A2 8
INSTALLATION INSTRUCTIONS
8. Keep the puck in place while slowly pulling
the rope away from the drum. Once the puck
is seated against the rope on all sides, pull
the rope way from the drum until the puck
lodges with the rope into position.
9. Ensure the loop does not protrude from the
drum surface and that the rope is held into
place tightly.
10. 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.
11. Turn the clutch lever on the winch to the
“Engaged” position.
12. Wind 10 wraps of rope onto the drum while
applying light tension on the rope.
Proceed to the ‘Rope Spooling Instructions’
section of this document.