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: 1-503-722-3008
© 2011 Warn Industries, Inc.
WARN®, the WARN logo are registered trademarks of Warn Industries, Inc.
WARN® et le logo WARN sont des marques déposées de Warn Industries, Inc.
ENDURANCE / 12.0XE WINCH
INSTALLATION AND OPERATOR’S GUIDE
GUIDE D’INSTALLATION ET OPERATEUR
79295A2
English..................................................................... |
1-12 |
Français................................................................. |
13-24 |
Español.................................................................. |
25-36 |
ORIGINAL INSTRUCTIONS
Winch Installation and Operator’s
Guide
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.
TABLE OF CONTENTS: |
|
SAFETY |
|
Symbol Index............................................................................................................... |
2 |
General Safety Precautions ..................................................................................... |
3-5 |
Safe Working Conditions............................................................................................. |
6 |
INSTRUCTIONS |
|
Mounting Winch........................................................................................................... |
7 |
Mounting Cooling Fan ................................................................................................. |
8 |
Electrical Connections................................................................................................. |
9 |
Operating Instructions .......................................................................................... |
10-11 |
Stretching Wire Rope .......................................................................................... |
11-12 |
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 |
WARN® and the WARN logo are registered trademarks of Warn Industries, Inc. |
www.warn.com |
|
© 2011 Warn Industries, Inc. |
|
|
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
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
Sharp Edge Hazard |
Moving Parts Hazard |
WARN INDUSTRIES * WINCH |
WARN INDUSTRIES * WINCH |
1 |
2 |
GENERAL SAFETY PRECAUTIONS
Warnings and Cautions
As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. Each message has a specific 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!
WARNING
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to serious injury or death.
•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 ensure the operator and bystandnders are aware of the stability of the vehicle and/or load.
•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.
•Always pass remote lead thru window when used in vehicle.
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 influence of drugs, alcohol or medication.
•Never operate this winch if you are under 16 years of age.
Installation Safety:
•Always choose a mounting location that is sufficiently 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.
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 specified 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 fingers:
•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 |
WARN INDUSTRIES * WINCH |
3 |
4 |
GENERAL SAFETY PRECAUTIONS
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.
CAUTION
MOVING PARTS ENTANGLEMENT HAZARD
Failure to observe these instructions could lead to minor or moderate injury.
To avoid injury to hands or fingers:
•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.
NOTICE
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.
WARN INDUSTRIES * WINCH 5
SAFE WORKING CONDITIONS
WARNING
Always stand clear, keep hands clear, keep others away.
WARNING
Always require operators and bystanders to be aware of vehicle and or load.
CAUTION
Never leave remote control where it can be activated during free spooling, rigging, or when the winch is not being used.
NOTICE
Never submerge winch in water.
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 flange or clutch lever.
Use low pressure water and a soapy rag or sponge to clean the winch.
Avoid using chemicals that may damage the finish.
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 qualified 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 specified 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.
WARN INDUSTRIES * WINCH 6
MOUNTING WINCH
MOUNTING WINCH
Choose a mounting location that is sufficiently 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.
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 flexibility.
Mounting Bolt Pattern:
Standard: 10” x 4.5”, 254 mm x 114.3 mm
WARNING
Always choose a mounting location that is sufficiently strong to withstand the maximum pulling capacity of your winch.
WARNING
Always complete the winch installation and attach the hook before installing the wiring.
WARNING
Never use bolts that are too long.
|
|
Plate Thickness |
Bolt Length |
|
|
1/4” (7 mm) |
1.25” (32 mm) |
|
|
3/8” (10 mm) |
1.5” (40 mm) |
|
|
1/2” (13 mm) |
1.5” (40 mm) |
Mounting Details: |
|
||
(1) |
Smooth and flat, thickness = 1/4” (6.4 mm) |
|
|
(2) |
3/8” (9.525 mm) lockwasher X 4 |
|
|
(3) |
3/8-16 X 1 1/4” long, grade 5 bolt X 4 |
|
|
|
Torque 30-35 ft. lbs. (41-47Nm) |
|
|
MOUNTING COOLING FAN
COOLING FAN MOUNTING
The fan must be correctly installed to provide the best performance. The fan should be mounted in a location that is as clean, dry, and cool as possible. The mounting location must also provide clearance for the fan’s control cable as well as the outlet hose. When mounting the fan, insure that the inlet is unobstructed and higher than the winch. Also insure that the winch exhaust outlet is not near the fan inlet.
Best locations for the fan will vary depending on the vehicle. Typical location include: near
air intake box and inner fender inside engine compartment. Avoid mounting fan near exhaust manifold, turbocharger, or radiator.
Maximum operating temperature is 175°F (80°C). Avoid sharp edges when routing fan control cable and hose.
If your vehicle is used in extremely dusty conditions you can choose to equip the winch cooling fan with a high performance
filter. Filter part number RC-0790 available from K&N Filters is recommended for this application. The filter can be installed directly to the fan inlet.
Mounting Steps
1.Determine the fan mounting location.
2.Mount fan on a flat surface, mark and drill mounting holes.
3.Loosely attach the fan using WARN supplied 1/4-inch bolts, lock nuts, and washers or sheet metal screws.
4.Tighten fasteners.
5.Attach hose to fan outlet.
6.Route fan outlet hose to winch and tie down with tie wraps. Cut off excess hose.
7.Thread plastic fittings into winch motor end cap. Tighten and align fitting with hose.
8.Connect the fan outlet hose to the plastic fitting positioned above the “W” on the motor end cap.
9.Route fan control cable along fan outlet tubing and attach with tie wraps.
10.Connect fan control cable to plug behind and below winch control pack.
11.Connect the remaining hose to the plastic fitting positioned below the “W” on the motor end cap.
12.Route winch exhaust hose and tie down with tie wraps. Cut off excess hose.
Cooling Fan
The cooling fan is used to cool the winch motor. A
thermostat inside the winch motor automatically controls the fan and turns it on and off according to the winch motor temperature. The fan will not run until the winch motor reaches a predetermined temperature.
There is also a fan override switch in the remote handle that can be used to operate the fan. When properly connected the fan delivers cooling air that flows
through the inlet hose to the winch motor. Hot air from the winch motor is exhausted through the outlet hose.
See the Cooling Fan Mounting Instructions for proper fan, hose, and control cable installation.
Fan Override Switch
WARN INDUSTRIES * WINCH |
WARN INDUSTRIES * WINCH |
7 |
8 |
Loading...