16.5ti
Warn Industries, Inc.
12900 S.E. Capps Road
Clackamas, OR USA 97015-8903
1-503-722-1200 FAX: 1-503-722-3000
www.warn.com
Customer Service / Service Clients: 1-800-543-9276
International Sales Support / Les Ventes internationales
Soutiennent: 1-503-722-1200
© 2011 Warn Industries, Inc.
WARN®, the WARN logo are registered trade-
marks of Warn Industries, Inc.
WARN® et le logo WARN sont des marques
déposées de Warn Industries, Inc.
Large Frame Ti Winch
INSTALLATION AND OPERATOR’S GUIDE
GUIDE D’INSTALLATION ET OPERATEUR
68735B6
English .......................................................................... 1
Français ......................................................................12
Español .......................................................................23
WARN INDUSTRIES * WINCH
1
ORIGINAL INSTRUCTIONS
Winch Installation and Operator’s
Guide
TABLE OF CONTENTS:
SAFETY
Symbol Index ............................................................................................................... 2
General Safety Precautions .....................................................................................3-5
Safe Working Conditions .............................................................................................6
INSTRUCTIONS
Mounting Winch ........................................................................................................... 7
Electrical Connections ................................................................................................. 8
Operating Instructions ............................................................................................9-10
Stretching Wire Rope ..........................................................................................10-11
Warn Industries Inc.
12900 SE Capps Road
Clackamas, OR 97015
USA
Customer Service: (800) 543-WARN
(9276)
International: (503) 722-1200
Fax: (503) 722-3000
www.warn.com
Every winching situation has the potential for personal injury. In order to minimize that
risk, it is important to read this guide and The Basic Guide to Winching Techniques
carefully. Please familiarize yourself with the operation of your winch before using it, and
be constantly safety oriented. In this guide, we will set forth many of the basic rules of
safe winch operation. Please read The Basic Guide to Winching Techniques for more
information on your winch and proper rigging techniques. Remember, because every
winching situation is different, your constant good judgment and consistent focus on
safety are of great importance.
WARN® and the WARN logo are registered trademarks of Warn Industries, Inc.
© 2011 Warn Industries, Inc.
WARN INDUSTRIES * WINCH
2
SYMBOL INDEX
SYMBOL EXPLANATION
Read the Instruction
Manual
Always Wear Hearing
and Eye Protection
Never Use Winch as a
Hoist
Properly Seat Load in
Throat of Hook
Wind Rope on Bottom
of Drum
Finger/Fairlead Crushing
Hazard
Hand Piercing/Cutting
Hazard
Explosion/Bursting
Hazard
Sharp Edge Hazard
Use hook larger than
1/2” (13mm)
SYMBOL EXPLANATION
Always Wear Leather
Gloves
Do Not Move People
Always Use Supplied
Hook Strap
Never Apply Load to
Hook Tip or Latch
Never Wind Rope Over
Top of Drum
Fairlead Pinch Point
Hot Surface Hazard
Fire and Burn Hazard
Moving Parts Hazard
WARN INDUSTRIES * WINCH
3
GENERAL SAFETY PRECAUTIONS
As you read these instructions, you will see
WARNINGS, CAUTIONS, NOTICES and NOTES.
Each message has a specifi c purpose. WARNINGS
are safety messages that indicate a potentially
hazardous situation, which, if not avoided could result
in serious injury or death. CAUTIONS are safety
messages that indicate a potentially hazardous
situation which, if not avoided, could result in minor
or moderate injury. A CAUTION may also be used
to alert against unsafe practice. CAUTIONS and
WARNINGS identify the hazard, indicate how to avoid
the hazard, and advise of the probable consequence
of not avoiding the hazard. NOTICES are messages
to avoid property damage. NOTES are additional
information to help you complete a procedure.
PLEASE WORK SAFELY!
Warnings and Cautions
WARNING
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could
lead to serious injury or death.
• Always use a hook marked 1/2” (13 mm) or larger
with the M15000 and 16.5ti fairlead.
• Always ensure hook latch is closed and not
supporting load.
• Never apply load to hook tip or latch. Apply load
only to the center of hook.
• Never use a hook whose throat opening has
increased, or whose tip is bent or twisted.
• Always use a hook with a latch.
• Always keep wired remote control lead and
power cord clear of the drum, rope, and rigging.
Inspect for cracks, pinches, frayed wires or loose
connections. Damaged components must be
replaced before operation.
WARNING
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could
lead to serious injury or death.
General Safety:
• 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.
• Never exceed winch or winch rope rated capacity.
Double line using a snatch block to reduce winch
load.
• Always wear heavy leather gloves when handling
winch rope.
• Never use winch or winch rope for towing. Shock
loads can damage, overload and break rope.
• Never use a winch to secure a load.
• Never operate this winch when under the infl uence
of drugs, alcohol or medication.
• Never operate this winch if you are under 16 years
of age.
• Always ensure the operator and bystandnders are
aware of the stability of the vehicle and/or load.
• Always pass remote lead thru window when used
in vehicle.
Installation Safety:
• Always choose a mounting location that is
suffi ciently strong to withstand the maximum pulling
capacity of your winch.
• Always use grade 5 (grade 8.8 metric) or better
hardware.
• Never weld mounting bolts.
• Always use factory approved mounting hardware,
components, and accessories.
• Never use bolts that are too long.
• Always complete the winch installation and hook
attachment before installing the wiring.
• Always keep hands clear of winch rope, hook
loop, hook and fairlead opening during installation,
operation, and when spooling in or out.
• Always position fairlead with warning readily visible
on top.
• Always prestretch rope and respool under load
before use. Tightly wound rope reduces chances of
“binding”, which can damage the rope.
WARN INDUSTRIES * WINCH
4
GENERAL SAFETY PRECAUTIONS
WARNING
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could
lead to serious injury or death.
Winching Safety:
• Always inspect winch rope, hook, and slings
before operating winch. Frayed, kinked
or damaged winch rope must be replaced
immediately. Damaged components must be
replaced before operation. Protect parts from
damage.
• Always remove any element or obstacle that may
interfere with safe operation of the winch.
• Always be certain the anchor you select will
withstand the load and the strap or chain will not
slip.
• Always use supplied hook strap whenever
spooling winch rope in or out, during installation
and during operation.
• Always require operators and bystanders to be
aware of vehicle and or load.
• Always be aware of stability of vehicle and load
during winching, keep others away. Alert all
bystanders of an unstable condition.
• Always unspool as much wire rope as possible
when rigging. Double line or pick distant anchor
point.
• Always take time to use appropriate rigging
techniques for a winch pull.
• Never touch winch rope or hook while someone
else is at the control switch or during winching
operation.
• Never engage or disengage clutch if winch is
under load, winch rope is in tension or drum is
moving.
• Never touch winch rope or hook while under
tension or under load.
• Always stand clear of winch rope and load and
keep others away while winching.
• Never use vehicle to pull load on winch rope.
Combined load or shock load can damage,
overload and break rope.
• Never wrap winch rope back onto itself. Use a
choker chain or tree trunk protector on the anchor.
WARNING
FALLING OR CRUSHING HAZARD
Failure to observe these instructions could
lead to serious injury or death.
• Always stand clear, keep hands clear, keep others
away.
• 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.
• Never use winch as a hoist or to suspend a load.
• Always be certain anchor will withstand load, use
appropriate rigging and take time to rig correctly.
• Never use winch to lift or move persons.
• Never use excessive effort to freespool winch rope.
• Always use proper posture/lifting technique or
get lifting assistance while handling and installing
product.
• Always spool the rope onto the drum in the
direction specifi ed by the winch warning label on
the winch and/or documentation. This is required
for the automatic brake (if so equipped) to function
properly.
• Always spool the winch rope onto the drum as
indicated by the drum rotation label.
WARNING
CUT AND BURN HAZARD
Failure to observe these instructions could
lead to serious injury or death.
To avoid injury to hands and fi ngers:
• Always wear heavy leather gloves when handling
winch rope.
• Always be aware of possible hot surfaces at winch
motor, drum or rope during or after winch use.
WARN INDUSTRIES * WINCH
5
GENERAL SAFETY PRECAUTIONS
AVOID WINCH AND EQUIPMENT
DAMAGE
• Always avoid side pulls which can pile up wire
rope at one end of the drum. This can damage
wire rope or winch.
• Always ensure the clutch is fully engaged or
disengaged.
• Always use care to not damage the vehicle frame
when anchoring to a vehicle during a winching
operation.
• Never submerge winch in water.
• Always store the remote control in a protected,
clean, dry area.
NOTICE
CAUTION
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could
lead to minor or moderate injury.
To avoid injury to hands or fi ngers:
• Never leave remote control where it can be
activated during free spooling, rigging, or when the
winch is not being used.
• Never leave the winch remote control plugged in
when installing, freespooling, rigging, servicing or
when the winch is not being used.
WARNING
CHEMICAL AND FIRE HAZARD
Failure to observe these instructions could
lead to serious injury or death.
• Always remove jewelry and wear eye protection.
• Never route electrical cables across sharp edges.
• Never route electrical cables near parts that get
hot.
• Never route electrical cables through or near
moving parts.
• Always place the supplied terminal boots on
wires and terminals as directed by the installation
instructions.
• Never lean over battery while making
connections.
• Never route electrical cables over battery
terminals.
• Never short battery terminals with metal objects.
• Always verify area is clear of fuel lines, fuel tank,
brake lines, electrical wires, etc., when drilling.
• Always consult operator’s manual for proper
wiring details.
• Always insulate and protect all exposed wiring
and electrical terminals.
CAUTION
CUT AND BURN HAZARD
Failure to observe these instructions could
lead to minor or moderate injury.
• Never let winch rope slip through your hands.
WARN INDUSTRIES * WINCH
6
SAFE WORKING CONDITIONS
WARNING
Always stand
clear, keep
hands clear,
keep others
away.
SAFE WORKING CONDITIONS
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.
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.
Cleaning
Do not direct high pressure
water (pressure washers, car
washes, etc.) between the drum
support and drum fl ange or clutch
lever.
Use low pressure water and a
soapy rag or sponge to clean the
winch.
Avoid using chemicals that
may damage the fi nish.
Thoroughly clean salt residue
from the winch as soon as possible
to minimize corrosion.
Maintenance
No lubrication is required for
the life of the winch unless the
winch has been submerged in
water. If this occurs, a qualifi ed
service center must complete
service as soon as possible to
prevent corrosion damage. If the
control pack is submerged, it must
be replaced when the winch is
serviced.
Check battery cables and
electrical connections at 90 day
intervals to be certain they are
clean and tight at all connection
points.
Inspect the wire rope before
and after each winching operation.
When damaged, replace with the
size specifi ed in the Replacement
Parts List, or go to the Warn
website at www.warn.com.
The wire rope must always
spool onto the drum as indicated
by the drum rotation decal on the
winch.
WARNING
Always require
operators and
bystanders to be
aware of vehicle
and or load.
NOTICE
Never submerge
winch in water.
CAUTION
Never leave
remote control
where it can be
activated during
free spooling,
rigging, or when
the winch is not
being used.
WARN INDUSTRIES * WINCH
7
MOUNTING WINCH
MOUNTING WINCH
Choose a mounting location
that is suffi ciently strong enough
to withstand the loads you intend
to winch. Only the mounting
orientations shown are possible for
safe winching operation. All others
are improper and inappropriate.
The use of recommended bolt
and lock washer combinations
torqued to recommended levels will
prevent vibration during operation.
The mounting details indicate the
proper torque levels.
Remember the winch rope
must always spool onto the drum
as indicated by the drum rotation
decal.
Refer to the following
diagrams for proper mounting
orientation.
WARNING
Never use bolts
that are too long.
Control Pack Installation
Mount the control pack
according to the instructions
included in the WARN mounting
system kit. Use the bracket
included in the kit.
The control pack mounting
fasteners may also be moved to
the unused holes in the control
pack base plate for additional
mounting fl exibility.
Mounting Bolt Pattern:
Standard: 10” x 4.5”, 254 mm x 114.3 mm
WARNING
Always choose
a mounting
location that is
suffi ciently strong
to withstand the
maximum pulling
capacity of your
winch.
WARNING
Always complete
the winch
installation and
attach the hook
before installing
the wiring.
Mounting Details:
(1) Smooth and fl at, thickness = 5/16” (8 mm)
(2) 7/16” (11.1 mm) lockwasher X 4
(3) 7/16-14 X 1 1/2” long, grade 5 bolt X 4
Torque 50-55 ft. lbs. (68-75Nm)
(4) 7/16” (11.1 mm) fl atwasher X 6
(5) 7/16-14 X 1 3/4” long, grade 5 bolt X 2
Torque 50-55 ft. lbs. (68-75Nm)
Plate Thickness Bolt Length
5/16” (8 mm) 1.5” (40 mm)
3/8” (10 mm) 1.5” (40 mm)
1/2” (13 mm) 1.75” (45 mm)
WARN INDUSTRIES * WINCH
8
ELECTRICAL CONNECTIONS
1
2
3
6
5
4
Black
Black
Red
Green
Brown
White
Blue
A
F1
F2
Electrical Diagrams:
ELECTRICAL CONNECTIONS
Use the included insulating
boots on exposed connections to
prevent electrical shorting. Route
battery connection cables in areas
which will not cause them to
chafe or cut through the insulation
causing a potential short circuit.
Upon completion of
installation, check winch for proper
operation.
WARNING
Never route
electrical cables
across sharp
edges.
WARNING
Never route
electrical cables
near parts that
get hot.
WARNING
Never route
electrical cables
through or near
moving parts.
WARNING
Always place
the supplied
terminal boots
on wires and
terminals as
directed by
the installation
instructions.
Battery Recommendations
A fully charged battery and
good connections are essential
to the proper operation of your
winch. The minimum requirement
for a 12 volt DC battery is 650 Cold
Cranking Amps.
WARNING
Always insulate
and protect all
exposed wiring
and electrical
terminals.
Pin # Color
1 Brown
2 Green
3 Black
4 White
5 Blue
6 Red
Black
Black
Red
White
Brown
Green
Blue
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