Installation Manual

WARN INDUSTRIES
9 87968A2
SPOOLING INSTRUCTIONS
rope is winding off the top you have powered
the winch “out” instead of “in” on the remote
control)
5. If there is still rope laying on the ground, back
the vehicle away until the rope is off of the
ground.
WARNING
Never touch winch rope or hook while
someone else is at the control switch or during
winching operation.
WARNING
Never touch winch rope or hook while
under tension or under load.
WARNING
Always stand clear of winch rope and
load and keep others away while winching.
6. 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.
7. Use care to evenly wrap each layer to prevent
damage to the 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.
8. 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. (2 m), 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.
9. Once you are convinced the rope is winding
on the winch properly, repeat step 6 until the
vehicle is within 6 ft. (2 m) of the winch anchor.
Once within 6 ft. (2 m), slowly let up off of
Rope Spooling Instructions:
THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT
PRECISELY FOLLOWED THE LIFE OF THE WINCH AND ROPE
MAY BE COMPROMISED.
WARNING
Always keep hands clear of winch rope,
hook loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
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.
WARNING
Always wear heavy leather gloves when
handling winch rope.
WARNING
Always wind the winch rope on the bottom
(mount side) of the drum.
1. It is now necessary to spool the remaining
rope onto the winch drum. Choose a FLAT AND
LEVEL location that is large enough to run out
the entire length of rope.
2. Ensure the rope is completely spooled out
except for at least 10 wraps on the drum.
Then turn the clutch lever on the winch to the
“Engaged” position.
WARNING
Always use supplied hook strap whenever
spooling winch rope in or out, during installation and
during operation.
3. 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.
(2 m) 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.
4. Connect the remote control to the winch.
Standing approximately 8 ft. (2.5 m) away from
the winch, power-in the winch until all of the
slack is wound onto the winch drum. WARNING!
Always wind the winch rope on the bottom (mount side)
of the 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
WARN INDUSTRIES
87968A2 10
SPOOLING INSTRUCTIONS
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 in gear and turn the vehicle off.
Exit the vehicle and inspect the winch rope
is being evenly wound onto the winch drum.
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. (1
m) 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.
Proceed to the “Maintenance and Care
Instructions” in this booklet.