Product Manual A

WARN INDUSTRIES
13
FIRST TIME OPERATING INSTRUCTIONS
Step 3 - (Optional) Synthetic Rope
Installation
For synthetic rope models, be sure to fully read
the WARN Synthetic Rope Installation Instruction
manual for detailed synthetic rope installation
instructions.
Step 4 - System Check
1. With clutch engaged, power-in winch rope
while making sure drum is turning in the
proper direction.
2. Once you have confirmed winch rope is
winding on the drum in the correct direction,
continue to power-in the rest of the winch
rope.
11. Installation complete. Move on to First Time
Operating Instructions.
Step 5 - First Time Operating
Instructions
In this section, we’ll show you the first
time operating instructions for effective basic
winch ing. For complete winch operation and
techniques read the Basic Guide to Winching
Techniques found online at http://www.warn.
com/corporate/literaturerequest.shtml.
Remote Control
The winch is controlled by the hand held
remote control. The remote control provides
control of the power-out (forward) or power-in
(reverse) rotation of the spooling drum.
Do not leave the remote plugged into the
winch when not in use. Leaving the remote
plugged in, may result in a dangerous condition
and/or battery drain.
Clutch Operation:
WARNING
Never engage or disengage clutch if winch is
under load, winch rope is in tension or drum is moving.
When the clutch is engaged, the gear train
is coupled to the winch drum and power can
be transferred from the winch motor. When the
clutch is disengaged the drum is in the freespool
position and the gear train and winch rope drum
are uncoupled allowing the drum to rotate freely.
The clutch lever, located on the winch housing
opposite the motor, controls the clutch position.
To prevent damage, always fully engage or fully
disengage the clutch lever.
Spooling Out
WARNING
Never operate winch with less than 5 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.
WARNING
Always keep hands clear of winch rope,
hook loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
WARNING
Always wear heavy leather gloves when
handling winch rope.
Freespooling is generally the quickest and
easiest way to spool out winch rope. Before
freespooling winch rope out from the winch,
power out enough rope to remove any tension
the winch rope might be under. Disengage the
clutch. Then freespool by manually spooling out
enough winch rope for the winching operation.
See The Basic Guide to Winching Techniques for
more information.
NOTICE
Do NOT power out more than 30ft without allowing
the winch to cool for 20 minutes before powering rope back in.
Instead, place the clutch in freespool and pull the rope out by hand.
WARNING
Always use supplied hook strap whenever
spooling winch rope in or out, during installation or
operation to avoid injury to hands and  ngers.
Power Out
Power In
Standard remote control switch
DISENGAGED
ENGAGED
WARN INDUSTRIES
14
FIRST TIME OPERATING INSTRUCTIONS
Spooling In Under Load
WARNING
Never exceed winch’s rated line pull.
Power-in the winch rope evenly and tightly on
the drum. This prevents the outer winch wraps
from sinking into the inner wraps, binding, and
damaging the winch rope.
Avoid shock loads when spooling, by pulsing
the control switch to take up winch rope slack.
Shock loads can momentarily far exceed the
winch and rope ratings.
Spooling In Under No Load
WARNING
Never touch winch rope or hook while
someone else is at the control switch or during winching
operation.
Spooling with an Assistant: Have the assistant
hold the hook strap putting as much constant
tension on the winch rope as possible. While
keeping tension, the assistant should walk toward
the winch while you operate the control switch
spooling in the winch rope. Release the switch
when the hook is a minimum of 6 ft. (2m) from
the fairlead opening.
Spool in the remainder for storage as directed
below.
Spooling Alone: Arrange the winch rope to
be spooled so it will not kink or tangle when
spooled. Be sure any winch rope on the drum is
tightly and evenly layered. Spool enough winch
rope to complete the next full layer on the drum.
Tighten and straighten the layer. Repeat process
until the hook is a minimum of 6 ft. (2 m) from the
fairlead opening.
Spool in the remainder for storage as directed
below.
Spooling Remainder for Storage
When the hook is within 6 ft. (2 m) of the fairlead,
disconnect the hook from the anchor or load.
Hold onto the supplied hook strap and hold
tension on the winch rope. Slowly power-in the
winch by “pulsing” the power-in switch 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.
NOTICE
Do not power the hook into the fairlead. This could
cause 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 switch on
the remote control until there is minimal slack in
the winch rope.
Overloading/Overheating
This winch is rated for intermittent duty.
When the motor approaches stall speed, very
rapid heat buildup occurs which may cause
motor damage.
Double-line rigging (see The Basic Guide to
Winching Techniques) will reduce the amperage
draw, and reduce heat buildup in the motor. This
allows longer continual use.
STRETCHING WINCH ROPE
Stretching (tensioning) the winch rope is
critical to ensure a long product life. Tensioning
the winch rope will prevent outer layers of winch
rope from pinching and deforming the inner
layers.
During its first use, a new winch rope must be
spooled onto its drum under a load of at least
1000 lbs. (454 kgs).
Use the following instructions to properly
stretch the winch rope onto the winch drum.
1. Choose a FLAT AND LEVEL location that is
large enough to run out almost the entire
length of winch rope.
2. Disengage clutch.
WARNING
Always keep hands clear of winch rope,
hook loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
3. Grasp hook strap and spool out the winch
rope to the last 5 wraps on the drum (10
wraps if synthetic rope).
4. Once the winch rope is spooled out, engage
clutch.
5. Attach the hook end of the rope to a suitable
anchor point.
WARNING
Always be certain the anchor you select will
withstand the load and the strap or chain will not slip.
6. Return to your vehicle.
7. Back the vehicle away from the anchor point
until there is very little slack in the winch
rope.
8. Set the parking brake, place the vehicle in
gear or park and turn the vehicle off.
WARNING
Always stand clear of winch rope and load
and keep others away while winching.
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