Warn 99963, 99964 User Manual
PAGE 1 99387 Rev. A0
WINCH USER GUIDE
WARN® 5000 Utility Winch
Part Number: 99963, 99964
English ..................................................1
Spanish .............................................. 15
French ................................................ 29
PAGE 2 99387 Rev. A0
Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided
installation and operating instructions and other information on labels and in this guide. This information alerts you to potential hazards
that could hurt you or others. It is not poss ible to warn you about all potential hazard s associated with this product, you must use your
own good judgment.
CARELESS WINCH INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ
AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING
THIS PRODUCT.
This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death.
WARNING and CAUTION are signal words that identify the level of hazard. These signa l words mean:
WARNING signals a hazard that
could
cause serious injury or death, if you do not follow recommendations.
CAUTION signals a hazard that
may
cause minor to moderate injury, if you do not follow recommendations.
This guide uses
NOTICE
to call attention to important mechanical information, and Note: to emphasize general information worthy of
special attention
Product Description: WARN® 5000 Utility Winch
The WARN® 5000 Utility Winch is a powerful pulling tool. Powered by a 12 volt DC power source this
compact winch has a pulling capacity of 5000 pound / 2268 kilos.
The unit has a 12’ remote control for power in and power out operation, 60’ of 1/4” wire rope and clasp hook.
A freespooliong clutch is a standard option.
Introduction
Thank you for choosing WARN® for your utility winch needs. All WARN® products have been designed and
manufactured for many years of problem-free operation. For future reference please record the following
information:
Model/Part Number: Date of Purchase:
Before you begin
Read the instructions completely to familiarize yourself with the installation process.
Review all the notices, cautions and warnings to make sure the kit will be installed correctly and safely.
PAGE 3 99387 Rev. A0
Safety Precautions
The following are general safety precautions that every winch operator should know. Taking precedence over
any specific rule listed here, however, is the most important rule of all—USE COMMON SENSE.
A few minutes spent reading these rules can make an operator aware of dangerous practices to avoid and
precautions to take for his own safety and the safety of others. Frequent examinations and periodic
inspections of the equipment as well as conscientious observance of safety rules may save lives as well as
time and money.
WARNING
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to severe injury or death.
To avoid injury to hands or fingers.
• Always keep hands clear of wire rope, hook loop, hook and fairlead opening during installation, operation and when
spooling in or out.
• Always use extreme caution when handling hook and wire rope during spooling operations.
• Always use supplied hook strap whenever spooling wire rope in or out, during installation or operation to avoid injury
to hands or fingers.
WARNING
FALLING OR CRUSHING HAZARD
Failure to observe these instructions could lead to severe injury or death.
• Never use as an overhead hoist, or to suspend a load.
• Never use to lift or move persons.
PAGE 4 99387 Rev. A0
Safety Precautions - continued
CAUTION
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor to moderate injury.
General Safety:
• Always Know Your Winch: Take time to fully read and understand the included Installation and Operations guide,
and Basic Guide to Winching Techniques, in order to understand your winch and the winching op e r a ti on.
• Never operate this winch if you are under 16 years of age.
• Never operate this winch when unde r the influence of drugs, alcohol or med i ca ti on.
• Never exceed winch or wire rope rated capacity. Double line using a snatch block to reduce winch load.
Installation Safety:
• Always choose a mounting location that is sufficiently str ong to wit hs t a nd t he ma x i mum pulling capacity of your
winch.
• Always use factory approved switches, remote controls, accessories and installation components.
• Always use grade 5 or better hardware, never weld bolts and never use longer bolts than those supplied from
factory.
• Always complete winch mounting and attachment of hook to hook loop before wiring winch during installation.
• Always position fairlead with WARNING label on top.
• Always spool the wire rope onto the drum as indicated by the drum rotation label on the winch.
Required for automatic brake to work (if winch is so equipped) and for correct installation orientation.
• Always prestretch wire rope and respool under load before use. Tightly wound wire rope reduces chances of
"binding", which is wire rope working its way down into a loosely wound wire rope layer, and catching or damaging
itself.
Winching Safety:
• Always inspect winch installation and wire rope and hook condition before operating winch. Frayed, kinked or
damaged wire rope must be replaced immediately. Loose or damaged winch installation must be corrected
immediately.
• Never hook wire rope back onto itself. This damages the wire rope. Always use a choker chain, wire choker rope or
tree trunk protector on the anchor.
• Always prior to winching, remove any element that may interfere with safe winch operation.
• Always take your time when rigging for a winch pull.
• Always be certain the anchor you select will withstand the load, and the strap or chain will not slip.
• Never engage or disengage clutch if winch is under load, wire rope is in tension or wire rope drum is moving
• Always unspool as much wire rope as possible when rigging. Double line or pick distant anchor point.
• Never winch with less than 5 wraps of wire rope around the drum, the wire rope could come loose from the drum.
• Always stand clear of wire rope and load during operation.
• Never touch wire rope or hook while in tension or under load.
• Never touch wire rope or hook while someone else is at the control switch or during winching operation.
• Never touch wire rope or hook while remote control is plugged into winch.
• Always stand clear of wire rope and load and keep others away while winching.
• Always require operator and bystanders to be aware of stability during winching of vehicle and/or load.
• Always keep remote control lead clear of the drum, wire rope and rigging. Inspect for cracks, pinches, frayed wires
or loose connections. Replace if damaged.
PAGE 5 99387 Rev. A0
Safety Precautions - continued
CAUTION
CUT AND BURN HAZARD
Failure to observe these instructions could lead to minor to moderate injury.
To avoid injury to hands and fingers:
• Always wear heavy leather gloves when handling a wire rope.
• Never let wire rope slip through your hands.
• Always be aware of possible hot surface at winch motor, drum or wire rope during or after winch use.
CAUTION
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to minor to moderate injury.
•
Never apply load to hook tip or lat ch. A pply load only to t he center of hook.
• Never use a hook whose throat opening has increased, or whose tip is bent or twisted.
NOTICE
AVOID WINCH AND EQUIPMENT DAMAGE
• Always avoid continuous side pulls, which can pile up wire rope at one end of the drum. This can damage your wire
rope or winch.
• Always ensure the clutch is fully engaged or Disengaged.
• Never use winch to tow other vehicles. Shock loads can momentarily exceed capacity of wire rope & winch
• Always use care to not damage your frame when anchoring your vehicle during a winching operation.
• Never "jog" wire rope under load. Shock loads can momentarily exceed capacity of wire rope and winch.
• Never use winch to secure a load during transport.
• Never submerge winch in water.
• Always store the winch in a protected, clean, dry area.
Part number & Cord ends for the WARN® 5000
PART NUMBERS
99964
12v DC 5000# Utility Winch - US
99963
12v DC 5000# Utility Winch - International
PAGE 6 99387 Rev. A0
Parts List
The WARN® 5000 Utility Winch consists of the follo wing main components.
1. WARN 5000 Winch Unit
2. Remote with 12’(3.7 m) Lead
3. Fairlead
4. 2 – 6’ (1.8 m) x 6 gauge cable
5. Latch Hook and Hook Strap
6. Mounting Hardware
1
2
3
4 5 6
PAGE 7 99387 Rev. A0
Specification Data for the WARN® 5000
FEATURES
Pulling Capacity
5000lbs. (2268 kg)
Brake
Dynamic and mechanical br aking
Switch Type
Remote with 12’ (3.7 m)
Lead
Warranty
1 year limited
Motor
Permanent Magnet
Wire Rope
1/4" (6.35 mm) X 60' (18.3 m)
HP
1.9 HP 3.0" Diameter
Drum Diameter
2.5" (6.35 cm)
Power
12 volt DC
Fairlead
Hawse
Gear Train
3-Stage planetary
Hole Pattern
4 holes
Gear Ratio
216:1
Electrical Leads
2 – 6’ (1.8 m) x 6 gauge cable
Clutch
Lever- Multi-directional
Weight
42 lbs. (19.1 kg.)
Performance Data for the WARN® 5000
PERFORMANCE DATA: 5000
Load
Current
Speed
Pulling Power by Wire Rope
Layer
Lbs.
Kg
Amps
Ft/min
M/min
Layer
lbs.
kg
0 0 40
13.8
4.2 1 5000
2268
1000
453.6
81
10.9
3.3 2 4280
1941
2000
907.2
118
9.3
2.8 3 3750
1701
3000
1360.8
152
8.1
2.5 4 3341
1515
4000
1814.4
188
6.8
2.1 5 3020
1369
5000
2268
220
5.4
1.6
Dimensional Data for the WARN® 5000
PAGE 8 99387 Rev. A0
Winch Installation to fixed location
CAUTION
Winch Failure Hazard
Failure to observe these instructions could lead to minor or moderate injury.
Always choose a mounting location that is sufficiently strong to withstand the loads you
intend to winch
The 5000 can be mounted to a fixed location by utilizing the mounting hole pattern for the winch unit.
First, choose a mounting location that is sufficiently strong enough to withstand the loads you intend
to winch.
Next, drill four holes to the dimensions specified in the drawing below.
Mounting Plate Hole Pattern
3/8" [9.52 mm] DIA (4 plcs)
4.5"
[114mm]
4.25"
[107.95
mm]
PAGE 9 99387 Rev. A0
Winch Installation to a fixed location- continued
To secure the winch, alwa ys use:
▫ A flat, secure mounting location at least 3/16 in. (4.8 mm) thick steel.
▫ 3/8 in. lockwasher x 4.
▫ 3/8-16 x 1in. long, hex head capscrew, Grade 5 or better x 4.
▫ Torque mounting bolts to 30-35 ft-lbs (41-47 Nm).
Bolt length may need to be longer than specified above depending upon the thickness of the material the
winch is mounted to.
Wiring Instructions
WARNING
Shock & Fire Hazard
Failure to observe these instructions could lead to severe injury or death.
Never route electrical cables across sharp edges
Never route electrical cables through or near moving parts.
Always read and follow all wiring instructions included in operators guide.
Always insulate and protect all exposed wiring and electrical terminals
Install battery cables with red lead connected to the positive terminal of battery, and black lead to
the negative terminal of battery.
Verify that all wiring connections are clean and tight.
Before using the winch, verify the following:
Wiring to all components is correct.
There are no exposed wiring or terminals, cover any existing exposures with insulator plate,
terminal boots, heat shrink tubing or electrician’s tape.
PAGE 10 99387 Rev. A0
Operating Instructions
USING THE REMOTE CONTROL
The remote pendant control is hard wired to the winch and can be operated in the remo te position away from
the winch unit or with the pendant docked in the carrier plate.
Press the black power-out button to spool wire rope off of the drum, or press the white power-in button to
spool wire rope onto the drum.
POWER-OUT
POWER-IN
PAGE 11 99387 Rev. A0
Operating Instructions - continued
CLUTCH OPERATION
WARNING
Winch Function Hazard
Failure to observe these instructions could lead to injury or property damage
Never engage or disengage the clutch if the winch is underload or wire rope is under tension.
When the clutch is engaged the gear train is coupled to the wire rope drum and power may be transferred
from the winch motor. When the clutch is in freespool the gear train and wire rope drum a re uncoupled
allowing the drum to rotate freely. The clutch lever, located on top of the motor, controls the clutch position.
To prevent damage, always fully engage or fully disengage the clutch lever.
Engaged
Disengage - Freespool
PAGE 12 99387 Rev. A0
Operating Instructions - continued
SPOOLING OUT
Freespooling is generally the quickest and easiest way to spool out wire rope. Before freespooling wire rope
out from the winch, power out enough rope to remove any tension the wire rope may be under before
disengaging the clutch. Now freespool by manually spooling out enough wire rope for the winching
operation.
CAUTION
Personal Injury Hazard
Failure to observe these instructions could lead to minor or moderate injury.
Always wear leather gloves when handling wire rope
Never winch with less than 5 wraps of wire rope around the drum.
STRETCHING THE WIRE ROPE
The life of a wire rope is directly related to the care and use it receives. During its first use, a new wire rope
must be spooled onto its drum under a load of at least 500 lb. (227kg). Spool out the entire wire rope length
leaving 5 wraps on the drum, then power in the wire rope under a load of 500 lb. (227kg) or more. This will
stretch new wire rope and create a good wire wrap around the drum. Failure to do so may result in the outer
wire wraps drawing into the inner wraps, binding, and damaging the wire rope.
WARNING
Moving Parts Entanglement Hazard
Failure to observe these instructions could lead to severe injury or death.
ALWAYS keep hands clear of the wire rope, hook loop, hook and fairlead ope ning
during installation, operation and when spooling in or out.
ALWAYS use supplied hook strap whenever spooling the wire rope in or out, during
installation, or operation to avoid injury to hands or fingers.
PAGE 13 99387 Rev. A0
Operating Instructions - continued
SPOOLING IN UNDER LOAD
The wire rope must al ways spool onto the bottom of the drum as indicated by decal on the winch.
Power in the wire rope evenly and tightly on the drum. This prevents the outer wire wraps from
drawing into the inner wraps, binding and damaging the wire rope.
Avoid shock loads when spooling, by using the control switch intermittently to take up wire rope
slack. Shock loads can momentarily far exceed the winch and wire rope ratings.
SPOOLING IN UNDER NO LOAD
Assisted: Have your assistant hold the hoo k with the hook strap putting as much constant tension
on the wire rope as possible. While keeping tension, the assistant should walk toward the winch
while you operate the control switch spooling in the wire rope. Release the switch when the hook is
a minimum of 4 ft (1.2m) from the fairlead opening. Spool in the remainder for storage.
Unassisted: Arrange the wire rope to be spooled so it will not kink or tangle when spooled. Be sure
any wire rope on the drum is tightly and evenly layered. Spool enough wire rope to complete the next
full layer on the drum. Tighten and straighten the layer. Repeat process until the hook is a minimum
of 4ft (1.2m) from the fairlead. Spool in the remainder for storage.
SPOOLING REMAINDER FOR STORAGE
Keep hands clear of the wir e rope, hook and fairlead opening. Always use the hook strap to hold hook when
spooling under no load. Carefully power in the remaining wire rope, jogging the control switch to take up the
last of the slack. Secure t he hook to a suitable anchor point near the winch. Be careful not to overtighten or
damage may occur to the wire rope or a nchor point
.
RIGGING
Always spool out as much wire rope as possible when preparing rigging. Pick an anchor as far away
as is practical; this provides the winch with its greatest pulling power.
Rigging a double line with a snatch block will reduce the load on the winch to half without significant
loss of spooling speed.
Natural anchors such as trees, stumps and rocks are the handiest when available. Attach the choker
chain, wire choker rope or tree trunk protector on the anchor as low as possible to avoid pulling the
anchor down. If several possible anchors are available but they are not strong enough individually, it
may be practical to attach a wire or chain choker around several anchors to form a strong collective
anchor point.
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