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
© 2013 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.
M8274-50 Winch
INSTALLATION AND OPERATOR’S GUIDE
GUIDE D’INSTALLATION ET OPERATEUR
38292D7
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Español........................................................................ |
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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 di erent, your constant good judgment and consistent focus on safety are of great importance.
TABLE OF CONTENTS: |
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SAFETY |
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Symbol Index ....................................................................................................................................................... |
2 |
General Safety Precautions......................................................................................................................... |
3-5 |
Safe Working Conditions ................................................................................................................................. |
6 |
INSTRUCTIONS |
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Mounting Winch ................................................................................................................................................. |
7 |
Electrical Connections .................................................................................................................................. |
8-9 |
Operating Instructions ............................................................................................................................ |
10-11 |
Stretching Rope ........................................................................................................................................ |
11-12 |
WARN® and the WARN logo are registered trademarks of Warn Industries, Inc. © 2013 Warn Industries, Inc.
Warn Industries Inc.
12900 SE Capps Road
Clackamas, OR 97015
USA
Customer Service: (800) 543-9276
International Fax: (503) 722-3005
Fax: (503) 722-3000
www.warn.com
SYMBOL INDEX
SYMBOL EXPLANATION
Read All Product
Literature
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
Never Route Electrical
Cables through Sharp
Edges Hazard
Avoid Installing Electrical
Cables around Pinch and
Wear/Abrasion Points
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
Never Route Electrical
Cables through or near
Moving Parts Hazard
Exposed Wiring Hazard,
Insulate Exposed Wiring
and Terminals
Never Hook Back on
Rope
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GENERAL SAFETY PRECAUTIONS
Warnings and Cautions
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!
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 bystanders 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.
•Never hook back on rope.
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.
Installation Safety:
•Always choose a mounting location that is su ciently strong to withstand the maximum pulling capacity of your winch.
•Always use class 8.8 metric (grade 5) 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.
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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 winch 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 e ort to freespool winch rope.
•Always use proper posture/lifting technique or get lifting assistance while handling and installing product.
•Always wind the winch rope on bottom (mountside) of drum.
•Never wind rope over top of drum.
•Always spool the winch rope onto the drum in the direction specifi ed by the drum rotation labels on the winch and/or in the documentation. This is required for the automatic brake (if so equipped) to function properly.
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.
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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 winch rope at one end of the drum. This can damage winch 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.
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.
Instructions For Wire Rope Installation
Remove the end cap from the drum support and insert the end of the wire rope through the fairlead and through the hole in the drum. Attach the wire rope clamp and pull tight so clamp returns to inside the drum. Secure the winch as stated in the winch mounting instructions.
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MOUNTING
MOUNTING WINCH
Choose a mounting location that is sufficiently strong enough to withstand the loads you intend to winch. Only the mounting orientation 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.
The alignment between the winch gear housing and the winch drum support is of prime importance for the life of your winch. For winches that are not mounted on a factory mounting plate, it is recommended to use a winch mounting bracket as shown below, applying the illustrated hole pattern, hole diameters and tolerances.
1)Place the winch on the mounting plate, align the upper holes in the gear case and drum end support with the upper holes in the mounting plate. Secure loosely with two 7/16” - 14x1- 1/2” hex head cap screws with lock washers in the upper holes.
2)Align holes in fairlead with holes in mounting plate and winch. Insert two 7/16” - 14x1-1/2” hex head cap screws with lock washers through fairlead and secure loosely to winch with 7/16” square nuts. (Cavities have been provided in the gear case and drum support for square nuts.) Any deviation from this standard mounting will be shown on the mounting kit installation instructions.
NOTE: Drum end support must be tightened first. Lightly tighten gear side and align with end support. Assure that drum rotates freely with clutch disengaged. If drum binds or does not rotate freely, relocate end support and repeat process. On models without clutch, check for binding after electrical connections are made.
3)Tighten the above cap screws to 45-50 ft. lbs. (61-68Nm) torque. Install
two soft plugs into fairlead holes with |
WARNING |
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hammer. This is an anti-theft device. |
Always choose a |
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mounting location |
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that is su ciently |
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strong to withstand |
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the maximum |
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pulling capacity of |
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your winch. |
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winch installation |
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and attach the hook |
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Control Pack Installation |
before installing the |
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Mount the control pack according to |
wiring. |
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the instructions included in the WARN |
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mounting system kit. Use the bracket |
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included in the kit. |
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Mounting Bolt Pattern: |
Never use bolts that |
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are too long. |
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10” x 4.5”, 254 mm x 114.3 mm |
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Plate Thickness |
Bolt Length |
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1/4” (7 mm) |
1.5” (40 mm) |
3/8” (10 mm) |
1.5” (40 mm) |
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1/2” (13 mm) |
1.75” (45 mm) |
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Mounting Details:
(1)Smooth and flat, thickness = 1/4” (6.4 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 45-50 ft. lbs. (61-68Nm)
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ELECTRICAL CONNECTIONS
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.
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.
Refer to the electrical circuit diagrams on the following page.
Electrical Diagrams:
WARNING
Always place the supplied terminal boots on wires and terminals
as directed by Red Cable (72”) the installation
instructions.
WARNING
Always insulate and protect all exposed wiring and electrical terminals.
Battery
To Motor Field #2
To Motor
Armature
To Motor |
Winch |
Field #1 |
Motor |
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Ground Wire |
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Black Cable |
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(72”) |
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