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This manual provides instructions on how to
install your WARN winch system and initial
operating instructions. Please read the Basic
Guide To Winching Techniques for complete
operational instructions for your WARN winch
system.
Safety
When installing your WARN winch system, read
and follow all mounting and safety instructions.
The operator should always operate the
winch from a safe position when pulling a load.
The safe areas are: (1) Perpendicular to the wire
rope, (2) Inside the vehicle with the hood up (if
winch is mounted on front of vehicle). These safe
positions will help prevent the wire rope from
striking the operator if the wire rope fails when
under load.
Operate winch from the fully extended remote
control cord length whenever possible. The
operator must always be at least 8 ft. (2.44 m)
from the winch while operating. This will prevent
entanglement with the fairlead and keep the
operator out of harms way during winch load
pulling.
Never work around the wire rope while under
load.
Always use caution when working with electricity
and remember to verify that no exposed electrical
connections exist before energizing your winch
circuit.
For specifications and performance data, refer to
the specification sheet supplied with your winch.
Sound Emissions
The winch is designed so that the sound
emissions do not exceed 70 dBa from the
operator's station. The operator must be at least
8 ft. (2.44 m) from the winch while operating.
If the winch is exceeding 70 dBa from the
operator's station, have the winch inspected at an
authorized service center.
SAFE WORKING CONDITIONS
WARN INDUSTRIES
7
KNOW YOUR WINCH
Know Your Winch
Before you begin, you should familiarize yourself with your WARN winch and each of its components:
Remote Socket
Contactor
Motor
Remote Control
Motor:
The winch motor is powered by the vehicle's battery. The motor provides power to the gear
mechanism, which turns the winch drum and winds the winch rope.
Mode Selector:
The mode selector allows the user to switch between winching and compressor operation.
Rope:
The winch rope's diameter and length are determined by the winch's load capacity and
design. Wrapped around the winch drum and fed through the fairlead, the winch rope is
looped at the end to accept the hook's clevis pin.
Winch Drum:
The winch drum is the cylinder onto which the winch rope feeds. The drum is driven by the
motor and gear train. Its direction can be changed using the remote control.
Gear Train:
The reduction gear converts the winch motor power into a large pulling force. The gear train
design makes it possible for the winch to be lighter and more compact.
Clutch Lever:
The clutch allows the operator to manually disengage the spooling drum from the gear train,
enabling the drum to rotate freely (known as "freespooling"). Engaging the clutch "locks" the
winch drum back onto the gear train.
Air Access Door:
The rubber door marked "AIR" on the geartrain side of the PowerPlant can be pulled out to
gain access to the quick-connect air fitting.
Remote Socket:
The remote socket is where the operator plugs in the wired remote control or optional
wireless remote receiver, in order to control the winch.
Contactor:
Using electrical power from the vehicle's battery, the contactor switches power to the motor,
enabling the operator to change the direction of the winch drum rotation.
Remote Control:
The remote control plugs into the winch, via the remote socket, allowing the operator to
control the winch direction, as well as stand well clear of the wire rope while operating the
winch. The remote also has a switch to turn the compressor on and off.
Air Accessory Kit:
Comes with hose, tire chuck, tire gauge and a quick disconnect coupling for all your air
supply and inflation needs.
Air Intake Hose Kit: Once installed on winch, it provides clean air to the compressor from within the engine
compartment.
73203B0
73203B0
Rope
Winch Drum
Mode Selector
Air Intake Hose Kit
WARN INDUSTRIES
8
Air Access Door
Clutch Lever
Transmission
(Gear Train)
Air Accessory Kit
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