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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 Operation
Always prestretch rope and respool under load
WARNING
before use. Tightly wound rope reduces chances of "binding",
which can damage the rope.
Never operate winch with less than 5 wraps of
WARNING
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.
The life of a winch rope is directly related to
the use and care it receives. 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 the entire length of winch
rope.
2) Turn the clutch lever on the winch to the "Free
Spool" position. Spool out the winch rope to the
last 5 wraps on the drum. Once the winch rope is
spooled out, turn the clutch lever on the winch to
the "Engaged" position.
3) Attach the hook end of the rope to a suitable
anchor point and back the vehicle away from the
anchor point until there is very little slack in the
winch rope. 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. (2.44 m) away from
the winch, power-in the winch until all of the
slack is wound onto the winch drum. Disconnect
the remote control from the winch. Hold tension
on the winch rope with one hand; carefully push
the winch rope to the side of the drum the winch
rope is attached to so there are no gaps between
each coil on the drum. Be sure to check that the
winch rope is winding off of the bottom if the
drum, not the top, or the automatic load holding
brake will not function properly. (If the winch
rope is winding off the top you have powered the
winch "out" instead of "in" on the remote control).
5) The following steps should be done using two
people for proper safety. If you attempt to tension
your winch rope alone be sure to always engage
the parking brake, place the transmission in gear
or park and turn the vehicle off every time you
exit the vehicle to inspect the winch rope. Never
FIRST TIME OPERATING INSTRUCTIONS
exit the vehicle with a load on the winch rope.
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.
6) Use care to evenly wrap each layer to prevent
damage to the rope.
7) 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 winch rope is
winding correctly by watching it move across
the fairlead as the winch rope is powered in.
Start the vehicle and place the transmission in
neutral. Release the parking brake while applying
moderate brake pedal pressure.
Press power-in on the remote control switch.
After winching in for approximately 6 ft. (2m),
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 in gear and
turn the vehicle off . Exit the vehicle and inspect
the winch to make sure that the winch rope is
being evenly wound onto the winch drum and
not sinking into the lower layer. If the winch rope
is sinking, power the winch rope out and repeat
this step from the beginning with more brake
pedal pressure.
8) When you are convinced the winch rope is
winding onto the winch drum 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 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. 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 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
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.
WARN INDUSTRIES
15
FINAL ANALYSIS AND MAINTENANCE
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
Check fasteners and make sure they are tight
and to proper torque.
Replace damaged fasteners.
Verify wiring to all components is correct and
be certain that all connections are tight.
Verify there is no exposed/bare wiring,
terminals or cable insulation damage
(chafi ng/cutting).
Cover any exposures with terminal boots.
Repair or replace damaged electrical cable.
Inspect rope for damage.
Replace rope immediately if damaged.
Keep winch, rope and switch control free
from contaminants.
Use a clean rag or towel to remove any
dirt and debris.
To prevent serious injury or death:
WARNING
Always spool the winch rope onto the drum as
indicated by the drum rotation label.
Always Wind Rope on Bottom of Drum.
Never Wind Rope Over Top of Drum.
. This could
73203B0
73203B0
Before fi rst
Check
operation
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X
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Take time to fully understand your winch and
the winching operation by reviewing the Basic
Guide to Winching Techniques included with your
winch.
For further information or any questions
contact:
12900 S.E. Capps Road, Clackamas
OR USA 97015-8903, 1-503-722-1200,
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
WARN INDUSTRIES
16
After each
Every 90 days
use
X
X
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X
WARN INDUSTRIES, INC.
or visit www.warn.com.
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