Warn Industries MID-FRAME series Installation And Operator's Manual

MID-FRAME WINCH

WITH SYNTHETIC ROPE

INSTALLATION AND OPERATOR’S GUIDE

GUIDE D’INSTALLATION ET OPERATEUR

87970A2

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

English...........................................................................1

Français.......................................................................17

Español........................................................................33

Deutsch ....................................................................... 49

Svenska ......................................................................65

87970A2

WARN INDUSTRIES * WINCH

Every winching situation has the potential for personal injury. In order to minimize that risk, it is important to read ALL instructions and safety information regarding your product. Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented. These instructions provide important safety information and instructions on how to

install and operate your winch.

In this kit you will find the following pieces of literature:

• Winch Installation Guide/ First Time Operation Instructions

• Product Warranty

SAVE THIS MA NUAL and other product literature for future reference and review frequently

for continuing safe operation.

Instruct all users of this product to review this manual before operating this product.

Additional Product Literature Available Online

• Basic Guide to Winching Techniqu es

• Provides a basic understanding of the winch and teaches basics of proper winching techniques. It is a valuable resource to help winch safely and efficiently.

• Product Specification and Performance Data

• Provides product specifications, performance data and replacement parts information.

• Other product literature specific to some products

Go to

www.warn.com/corporate/literaturerequest.shtml

for additional or replacement

product literature available to view/download.

WARN INDUSTRIES * WINCH

ORIGI NAL INSTRUC TIONS

Winch Installation and Operator’s Guide

TABLE OF CONTENTS:

SAFETY

Symbol Index .......................................................................................................................................................3

General Safety Precautions ......................................................................................................................... 4-7

Safe Working Conditions .................................................................................................................................8

INSTRUCTIONS

Mounting Winch ................................................................................................................................................. 9

Electrical Connections ....................................................................................................................................10

Operating Instructions ............................................................................................................................ 11-12

Installing the Rope ....................................................................................................................................12-14

Rope Inspection ........................................................................................................................................15-16

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

87970A2

WARN INDUSTRIES * WINCH

SYMBOL INDEX

SYMBOL EXPLANATION

Read All Product Literature

Some literature available only online at www.warn.com/ corporate/literaturerequest.shtml.

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 Across Sharp Edges

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

Exposed Wiring Hazard, Insulate Exposed Wiring and Terminals

Never Hook Back on Rope

WARN INDUSTRIES * WINCH

GENERAL SAFETY PRECAUTIONS

As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. Each message has a speci 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.

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, found online at http://www.warn.com/ corporate/literaturerequest.shtml.

• 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 in 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 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.

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

87970A2

WARN INDUSTRIES * WINCH

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 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 10 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 eﬀ ort 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

speci 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  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

GENERAL SAFETY PRECAUTIONS

WARNING

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to serious injury or death.

To avoid injury to hands and  ngers:

• Always know the Working Load Limit (WLL) of your rope.

• Always determine the suitability of a rope for a speci c

application.

• Never use the included rope on a winch with a rated line pull

greater than 10,000 lbs (4536 kg).

• Never use a rope if worn, damaged, abused, overloaded,

improperly maintained or over 1 year old.

• Never stand within the recoil (snapback) area.

• Never use rope over a rough surface without Chafe

Protection.

• Never bend rope around unprotected, sharp corners.

• Never leave clutch disengaged when not freespooling rope.

The automatic brake will not operate when clutch lever is in freespool.

• Never exceed the load rating of 10,000lbs (4536 kg).

• Always replace rope every 12 months.

• Always use a WARN fairlead that is recommended for

synthetic rope.

• Always replace the WARN hawse fairlead if damaged or

abused with a WARN fairlead that is recommended for synthetic rope.

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.

87970A2

WARN INDUSTRIES * WINCH

GENERAL SAFETY PRECAUTIONS

AVOID WINCH AND EQUIPMENT DAMAGE

• Always avoid side pulls which can pile up rope at one end of

the drum. This can damage 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.

• Always avoid continuous “Power-Out”. Heat build up from

continuous power out may damage the rope.

• Never expose the rope to harsh detergents, fuels, oils, or

Anti-freeze.

• Always use a chafe protector on all sharp edges to protect

rope.

• Never allow the rope to contact sharp objects. Severe

damage may result.

• Always respool rope in even wraps following any angled

winching activities.

• Never “jog” rope under load. Shock loads can momentarily

exceed capacity of rope and winch.

• Never install more than 100’ (CTI) / 80’ (XDC) of 3/8”

synthetic rope. Damage to the winch may result.

NOTICE

CAUTION

MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to minor or moderate injury.

To avoid injury to hands or  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.

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

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 rope, (2) Inside the vehicle with the hood up (if winch is mounted on front of vehicle). These safe positions will help prevent the rope from striking the operator if the 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 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

Use low pressure water to clean synthetic rope. Do not use any chemicals.

Do not direct high pressure water (pressure washers, car washes, etc.) between the drum support and drum  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  nish.

Thoroughly clean salt residue from the winch as soon as possible to minimize corrosion.

Maintenance

Replace rope every 12 months with WARN rope.

No lubrication is required for the life of the winch unless the winch has been submerged in water. If this occurs, a quali 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 rope before and after each winching operation. When damaged, replace with the size speci ed in the Replacement Parts List, or go to the Warn website at www.warn.com.

The 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.

87970A2

WARN INDUSTRIES * 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.

Mounting Details: (1) Smooth and  at, 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)

(4) 1/2-13 Locknut (5) 1/2 Flat washer (6) 3/8-16 Sq. nut (7) 1/2-13x2” button head bolt (8) Aluminum Fairlead

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.

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.

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)

WARN INDUSTRIES * WINCH

ELECTRICAL CONNECTIONS

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 White 3 Black 4 Green 5 6 Red

87970A2

WARN INDUSTRIES * WINCH

OPERATING INSTRUCTIONS

WARNING

Never engage or

disengage clutch if winch is under load, winch rope is in tension or drum is moving.

WARNING

Never operate

winch with less than 10 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.

NOTICE

Do Not power-out rope more than 30 ft. without allowing the winch to cool for 20 minutes before powering rope back in. Instead, place the clutch in freespool and pull the rope oﬀ by hand.

FIRST TIME OPERATING INSTRU CTIONS

In this section, we’ll show you the first time operating instructions for effective basic winch ing. For complete winch operation and techniques read the Basic Guide to Winching Techniques found online at

http://www.warn.com/

corporate/literaturerequest.shtml. Remote Control Switch

The winch is co ntrolled by the hand held remote contr ol. The remote control provides control of the power-out (forward) or power-in (reve rse) rotation of the spooling drum

Do not leave the remote plugged into the winch when not in use. Leaving the remote plugged in, may result in a dangerous condition and/or battery drain.

Clutch Operation:

When the clutch is engaged, the gear train is coupled to the winch drum and power can be transferred from the winch

Disengaged:

Engaged:

Vertical/Horizontal Remote:

motor. When the clutch is disengaged the drum is in the freespool position and the gear train and winch rope drum are uncoupled allowing the drum to rotate freely.

The clutch lever, located on the winch housing opposite the motor, controls the clutch position. To prevent damage, always fully engage or fully disengage the clutch lever.

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 might be under. Disengage the clutch. Then freespool by manually spooling out enough wire rope for the winching operation. See

The Basic

Guide to Winching Techniques

for more

information.

Always leave at least 5 wraps of rope on the drum.

Spooling In Under Load

Never exceed winch’s rated line pull.

Power-in the wire rope evenly and tightly on the drum. This prevents the outer wire wraps from sinking into the inner wraps, binding, and damaging the wire rope.

Avoid shock loads when spooling, by pulsing the control switch to take up wire rope slack. Shock loads can momentarily far exceed the winch and rope ratings.

Spooling In Under No Load

Spooling with an As sistant:

Have the assistant hold 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 6 ft. (2 m) from the fairlead opening.

Spool in the remainder for storage

as directed below.

OUT

WARN INDUSTRIES * WINCH

OPERATING INSTRUCTIONS

Spooling Out

Freespooling is generally the quickest and easiest way to spool out rope. Before freespooling rope out from the winch, power out enough rope to remove any tension the rope might be under. Disengage the clutch. Then freespool by manually spooling out enough rope for the winching operation. See

The Basic Guide to Winching

Techniques

for more information.

Always leave at least 10 wraps of rope on the drum.

Spooling In Under Load

Never exceed winch’s rated line pull.

Power-in the rope evenly and tightly on the drum. This prevents the outer wraps from sinking into the inner wraps, binding, and damaging the rope.

Avoid shock loads when spooling, by pulsing the control switch to take up rope slack. Shock loads can momentarily far exceed the winch and rope ratings.

Spooling In Under No Load

Spooling with an Assistant:

Have the assistant hold the hook strap putting as much constant tension on the rope as possible. While keeping tension, the assistant should walk toward the winch while you operate the control switch spooling in the rope. Release the switch when the hook is a minimum of 6 ft. (2 m) from the fairlead opening.

Spool in the remainder for storage

as directed below.

Spooling Alone:

Arrange the rope to be spooled so it will not kink or tangle when spooled. Be sure any rope on the drum is tightly and evenly layered. Spool enough rope to complete the next full layer on the drum. Tighten and straighten the layer.

Repeat process until the hook is a minimum of 6 ft. (2 m) from the fairlead opening.

Spool in the remainder for storage as directed below.

Spooling Remainder for Storage

When the hook is within 6 ft. (2 m) of the fairlead, disconnect the hook from the anchor or load. Hold onto the supplied

WARNING

Always keep hands

clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out.

WARNING

Always use

supplied hook strap whenever spooling winch rope in or out, during installation or operation to avoid injury to hands and  ngers.

WARNING

Always wear heavy

leather gloves when handling winch rope.

WARNING

Never touch winch

rope or hook while someone else is at the control switch or during winching operation.

hook strap and hold tension on the winch rope. Slowly power-in the winch by “pulsing” the power-in switch on the remote control until the hook is within 3 ft. (1 m) of the fairlead. Stop winching in and attach the hook to a suitable anchor point on the vehicle.

DO NOT POWER THE HOOK INTO THE FAIRLEAD. This could cause damage to the fairlead. Once the hook is suitably attached to the vehicle, power-in the remaining slack in the winch rope by “pulsing” the power-in switch on the remote control until there is minimal slack in the winch rope.

Overloading/Overheating

This winch is rated for intermittent duty. When the motor approaches stall speed, very rapid heat buildup occurs which may cause motor damage.

Double-line rigging (see

The Basic

Guide to Winching Techniques

) will reduce the amperage draw, and reduce heat buildup in the motor. This allows longer continual use.

87970A2

WARN INDUSTRIES * WINCH

OPERATING INSTRUCTIONS

WARNING

Always prestretch

rope and respool under load before use. Tightly wound rope reduces chances of “binding”, which can damage the rope.

WARNING

Never touch rope or

hook while someone else is at the control switch or during winching operation.

Spooling

THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT PRECISELY FOLLOWED THE LIFE OF THE WINCH AND ROPE MAY BE COMPROMISED.

1. Mount the Warn Aluminum Hawse Fairlead to the winch mount using the supplied hardware. Always mount the fairlead with the labels in the upright position (labels on top and clearly visible). Insert a 7/16” x 1 1/4” bolt through each of the two fairlead mounting holes and through the winch mount. Place a 7/16”  at washer onto each bolt. Install a 7/16” lock nut onto each bolt and tighten to 35 ft. lbs.

6. It is now necessary to spool the remaining rope onto the winch drum. Choose a FLAT location that is large enough to run out the entire length of rope. Attach the hook end of the rope to a suitable anchor point and back the vehicle away from the anchor point leaving approximately 6 ft of slack rope lying on the ground. Before getting out of the vehicle, set the parking brake, place the vehicle in gear or park and turn the vehicle oﬀ .

7. Connect the remote control to the winch. Standing approximately 8 ft away from the winch, power in the winch until there is 10 wraps onto the winch drum. Disconnect the remote control from the winch. Hold tension on the rope with one hand; carefully push the rope to the side of the drum the rope is attached to so there are no gaps between each coil on the drum. Be sure to check that the rope is winding oﬀ of the bottom of the drum, not the top, or the automatic load holding brake will not function properly. (If the rope is winding oﬀ the top you have powered the winch “out” instead of “in” on the remote control)

8. If there is still rope laying on the ground, back the vehicle away until the rope is oﬀ of the ground.

9. The following steps should be done using two people for proper safety. If you attempt to tension your rope alone be sure to always engage the parking brake, place the transmission in gear and turn the vehicle oﬀ every time you exit the vehicle to inspect the winch rope. Never exit the vehicle with a load on the winch rope. Tensioning the rope is critical to ensure a long product life. Tensioning the rope prevents the rope from sinking into the lower layers under load.

10. Use care to evenly wrap each layer to prevent damage to the rope.

2. Slide the abrasion sleeve over the rope from the end opposite the hook. Slide the sleeve back to the hook end of the rope.

3. Apply Lock Tite 271 or equivalent product to the supplied 1/4”-20 x 1/2” long button head fastener.

4. Install the new synthetic rope using the button head fastener supplied and the machined rope washer. Insert the synthetic rope through the aluminum fairlead and around the winch drum from the bottom. Insert the button head bolt into the machined rope washer and place the synthetic rope on the machined rope washer. Install the button head bolt in the 1/4-20 hole in the side of the winch drum. See Figure for detail.

5. Tighten the 1/4-20 button head bolt to 8 ft. lbs. Turn the winch clutch level to the “engaged” position.

NOTICE

Never install more than 100’ (CTI) / 80’ (XDC) of 3/8” synthetic rope. Damage to the winch may result.

Rope

Rope Washer

1/4-20 x 1/2” Button Head Bolt

WARN INDUSTRIES * WINCH

INSTALLING ROPE

WARNING

Never operate

winch with less than 10 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.

11. Pass the remote control through the driver’s window for the driver of the vehicle to operate. Instruct your assistant to stand to the side of the vehicle and away from the winch rope. Your assistant should signal you if the rope is winding correctly by watching it move across the fairlead as the rope is powered in. Start the vehicle and place the transmission in neutral. Release the parking brake while applying moderate brake pedal pressure. Power the winch remote in. After winching in for approximately 6 ft, stop winching. Slowly let up oﬀ of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch rope. Then place the transmission in park or gear and turn the vehicle oﬀ . Exit the vehicle and inspect the winch rope is being evenly wound onto the winch drum and not sinking into the lower layer. If the rope is sinking, power the rope out and repeat this step from the beginning with more brake pedal pressure.

12. Once you are convinced the rope is winding on the winch properly, return to the vehicle. Pass the remote control through the driver’s window for the driver of the vehicle to operate. Start the vehicle and place the transmission in neutral. Release the parking brake while applying moderate brake pedal pressure. Power the winch remote in. After winching in for approximately 6 ft, stop winching. Slowly let up oﬀ of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch rope. Then place the transmission in park or gear and turn the vehicle oﬀ . Exit the vehicle and inspect the winch rope is being evenly wound onto the winch drum and not sinking into the lower layer. If the rope is sinking, power the rope out and repeat this step from the beginning with more brake pedal pressure.

INSTALLING THE ROPE Cont.

13. Repeat step 12 until the vehicle is within 6 ft of the winch anchor. Once within 6 ft, slowly let up oﬀ of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch rope. Then place the transmission in park or gear and turn the vehicle oﬀ . Exit the vehicle. Disconnect the hook from the anchor. While holding onto the supplied hook strap, hold tension on the winch rope and slowly power-in the winch by “pulsing” the power-in on the remote control until the hook is within 3 ft. of the fairlead. Stop winching in and attach the hook to a suitable anchor point on the vehicle. DO NOT POWER THE HOOK INTO THE FAIRLEAD. This would cause irreparable damage to the fairlead. Once the hook is suitably attached to the vehicle, power in the remaining slack in the winch rope by “pulsing” the power-in on the remote until there is minimal slack in the winch rope.

Rigging

For complete rigging fundamentals, Read the Basic Guide to Winching Techniques, found online at

http:// www.warn.com/corporate/ literaturerequest.shtml.

WARNING

Always spool the

rope onto the drum in the direction speci 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.

WARNING

Always use

supplied hook strap whenever spooling winch rope in or out, during installation and during operation.

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WARN INDUSTRIES * WINCH

ROPE INSPECTION

When rope is  rst used, the outer  laments of the rope will quickly fuzz up. This is the result of these  laments breaking and this roughened surface will actually protect the  bers underneath. The condition should stabilize, not progress. If the surface roughness increases, excessive abrasion is taking place and strength is being lost. Look closely at both the inner and outer  bers. When either is worn the rope is obviously weakened. Open the strands and look for powdered  ber—this is a sign of internal wear.

Rope should be replaced when:

• Rope bulk anywhere along the

length is reduced by 10% or

more by abrasion.

• Two or more adjacent strands

are cut.

• Flat areas or lumps are found

that are not eliminated by

 exing rope.

• Excessive fused or melted  bers

are found. Any such areas will

be stiﬀ and the rope will have a

glazed appearance.

Rope Storage and Care

To ensure safety and performance, the inspection and maintenance of winching rope should be among every user’s primary concerns.

1. Inspect your winch rope for breaks, cuts, abrasion and melted or fused  bers before each use.

2. Wash rope periodically to remove dirt and grit. Simply rinse rope with a garden hose, and allow it to air-dry.

DO NOT use solvents, bleach or harsh detergents when washing rope, and never apply a heat source to speed drying.

3. Coil rope loosely, for storage, being sure to remove any excess twists. To maximize rope life, always store rope line in a dark, dry place. Before using any rope, refer to the following guide.

WARNING

Never operate

winch with less than 10 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.

If the rope is damaged, remove it from service immediately, and replace it with undamaged rope. Broken or cut strands reduce the rope’s strength throughout its length — not just in the area of damage. As a general rule, retire your 12 strand rope when more than 3 broken or cut strands are visible, or if two adjacent strands are compromised.

4. Replace your rope every 12 months with only WARN rope.

Normal Wear

When small surface  bers break on a rope, they create a fuzzy texture. Known as “mild abrasion,” this is considered good wear, and will not aﬀ ect the performance of the rope. The nubby surface actually protects the underlying  ber from further wear.

Excessive Wear–RETIRE THE ROPE

When  bers are melted or fused, it is generally the result of rope abuse. Melted or fused polyester  bers result from bringing the rope’s surface to a temperature in excess of 430° F. Caused by excessive load weights or powering out, these damaged  bers can compromise strength, and should signal the rope’s retirement.

Chemical Attack–RETIRE THE ROPE

(NOT ILLUSTRATED)

Localized discolorations could potentially represent chemical attack by anything from gear oil to battery acid. When doubt exists, retire the line.

WARN INDUSTRIES * WINCH

ROPE INSPECTION

WARNING

Always wear heavy

leather gloves when handling winch rope.

Examples:

Rope with original bulk.

Rope strand showing full volume.

Rope displaying 25% strand volume reduction from abrasion—rope should be

replaced.

Rope strand reduced by 25% abrasion—rope should be

replaced.

Rope displays two adjacent cut strands—rope should be

replaced.

Rope exhibits  ber-set from compression. A slight sheen is visible. This is not a permanent characteristic and can be eliminated by  exing the rope.

ROPE INSPECTION Cont.

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WARN INDUSTRIES * WINCH

Chaque situation de treuillage peut potentiellement occasionner des blessures. Afin de minimiser ce risque, il est important de lire attentivement TOUTES les instructions

et informations de sécurité afférentes à votre produit. Veillez à vous familiariser avec le

maniement du treuil avant de l'utiliser et à vous préoccuper avant tout de la sécurité. Ces

instructions fournissent des informations et des consignes de sécurité importantes concernant

l’installation et l’utilisation du treuil.

Vous trouverez dans ce kit la documentation suivante:

• Guide d’installation du treuil / Instructions relatives à une première utilisation

• Garantie du produit

CONSERVEZ CE MANUEL et tous les autres documents relatifs au produit à titre de référence

et consultez-les fréquemment pour assurer un fonctionnement continu en toute sécurité.

Demandez à tous les utilisateurs de ce produit de lire le présent manuel avant de l'utiliser.

Autres documents relatifs au produit disponibles en ligne

:

• Manuel de base des techniques de treuillage

• Fournit une compréhension globale du treuil et vous enseigne les techniques de treuillage. Il s’agit d’une ressource utile qui favorise l’utilisation efficace et sûre du treuil.

• Caractéristiques du produit et données de performance

• Fournit les caractéristiques du produit, les données de performance et les renseignements concernant les pièces de rechange.

• Autres documents rela tifs à des produits spécifiques

Consultez le site

www.warn.com/corporate/literaturerequest.shtml

pour accéder à d’autres

documents ou à des documents sur les produits de remplacement, disponibles en consultation/

téléchargement.

WARN INDUSTRIES * WINCH

TRADU CTION DE LA NOTICE ORIGIN ALE

Treuil Guide d'installation et manuel del'utilisateur

TABLE DES MATIÈRES:

SÉCURITÉ

Index des symboles .........................................................................................................................................19

Mesures générales de sécurité ............................................................................................................. 20-23

Conditions de travail sûres ............................................................................................................................24

INSTRUCTIONS

Montage du treuil .............................................................................................................................................25

Raccordements électriques ..........................................................................................................................26

Instructions d’ utilisation ......................................................................................................................... 27-28

Installation du câble d’acier ................................................................................................................... 29-30

Inspection du câble d’acier ....................................................................................................................31-32

Warn Industries Inc.

12900 SE Capps Road Clackamas, OR 97015

États-Unis

Service à la clientèle: (800) 543-WARN

(9276)

International: (503) 722-1200

Fax : (503) 722-3000

www.warn.com

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WARN INDUSTRIES * WINCH

INDEX DES SYMBOLES

SYMBOLE EXPLICATION

Lire tous les documents relatifs au produit.

Certains littérature disponible uniquement online www.warn.com/ corporate/literaturerequest.shtml.

Toujours porter un dispositif de protection auditive et oculaire

Ne jamais utiliser le treuil comme palan

Positionner correctement la charge dans la gorge du crochet

Enrouler le câble sur le dessous du tambour

Danger d’écrasement des doigts dans le guidecâble

Risque de percement/ coupure des mains

Risque d’explosion/ rupture

Ne jamais faire passer les câbles électriques par-dessus des bords tranchants.

Éviter les points de pincement et d’usure/ abrasion lors de l’installation des câbles électriques

SYMBOLE EXPLICATION

Toujours porter des gants de cuir

Ne pas déplacer des personnes

Toujours utiliser la sangle de crochet fournie

Ne jamais appliquer la charge sur l’extrémité ou le loquet du crochet

Ne jamais enrouler le câble sur le dessus du tambour

Point de pincement du guide-câble

Risque de surface chaude

Risque d’incendie et de brûlure

Ne jamais faire passer les câbles électriques à travers des pièces mobiles ou à proximité.

Danger de  ls nus, isoler les  ls nus et les terminaux

Ne jamais accrocher le câble à lui-même

WARN INDUSTRIES * WINCH

MESURES GÉNÉRALES DE SÉCURITÉ

Les directives suivantes comprennent des indications

intitulées AVERTISSEMENT, ATTENTION, AVIS et REMARQUE. Chacune d'entre elles comporte un objectif bien précis: AVERTISSEMENT présente des consignes de sécurité soulignant un danger potentiel qui, s’il n'est pas évité, peut entraîner des blessures graves ou la mort. ATTENTION comprend des consignes de sécurité signalant un danger potentiel qui, s'il n'est pas évité, peut entraîner des blessures légères ou modérées. ATTENTION sert aussi à signaler une utilisation dangereuse. ATTENTION et AVERTISSEMENT identi ent un danger, indiquent comment l'éviter et montrent ses conséquences possibles si on l'ignore. AVISprésente des consignes visant à éviter les dommages matériels. REMARQUE donne des renseignements additionnels qui aident à accomplir une procédure. TRAVAILLEZ

PRUDEMMENT!

Avertissements et mises en garde

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES

Le non-respect des consignes peut entraîner des blessures graves ou la mort. Consignes de sécurité générales:

• Il faut toujours avoir une bonne connaissance du treuil.

Prendre le temps de bien lire le manuel d’utilisation, et/ ou le manuel de base des techniques de treuillage, a n de comprendre le treuil et son fonctionnement, trouvés en ligne à

http://www.warn.com /corporate/literaturerequest.shtml

• Ne jamais excéder la capacité nominale du treuil ou du câble

d'acier. Un câblage double avec poulie ouvrante permet de réduire la charge subie par le treuil.

• Toujours porter des gants de cuir épais durant la

manipulation du câble du treuil.

• Ne jamais utiliser le treuil ou le câble du treuil pour faire du

remorquage. Cela peut endommager, surcharger et casser le câble.

• Ne jamais se servir du treuil pour maintenir une charge.

• Ne jamais faire fonctionner l'appareil sous l'eﬀ et de drogues,

de l'alcool ou de médicaments.

• Ne jamais laisser des personnes âgées de moins de 16 ans

utiliser ce treuil.

Consignes de sécurité se rapportant à l’installation:

• Toujours choisir une surface de montage suﬃ samment

résistante pour supporter la capacité de traction maximale du treuil.

• Toujours utiliser un matériel de montage de catégorie 8,8 ou

supérieure.

• Ne jamais souder les boulons de montage.

• Toujours utiliser un matériel de montage, des composants et

des accessoires homologués par le fabricant.

• Ne jamais utiliser des boulons trop longs.

• Toujours achever le montage du treuil et la  xation du crochet

avant d'eﬀ ectuer le câblage.

• Toujours garder les mains éloignées du câble du treuil,

de la boucle du crochet, du crochet et de l'ouverture du guide-câble durant l'installation et l’utilisation de l'appareil et l'enroulement ou le déroulement du câble.

• Toujours positionner le guide-câble avec l'avertissement

visible sur le dessus.

• Toujours étirer au préalable le câble et l’enrouler sous charge

avant de l’utiliser. Un câble enroulé de manière serrée réduit le risque qu'il coince et soit endommagé.

AVERTISSEMENT

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

•

Toujours

s’assurer que le loquet du crochet est fermé et

qu’il ne soutient aucune charge.

•

Ne jamais

appliquer la charge sur l’extrémité ou le loquet du crochet. Appliquer la charge uniquement au centre du crochet.

•

Ne jamais

utiliser un crochet dont l’ouverture de la gorge a

augmenté ou dont l’extrémité est courbée ou tordue.

•

Toujours

utiliser un crochet avec loquet.

•

Toujours

s’assurer que l’opérateur et les personnes présentes sont conscients de la stabilité du véhicule et/ou de la charge.

•

Toujours

garder le  l de la télécommande et le cordon d’alimentation à l’écart du tambour, du câble et du câblage. S’assurer qu’il n’y a pas de  ssures, de points de pincement, de  ls eﬃ lochés ou de connexions desserrées. Tous les composants endommagés doivent être remplacés avant d’utiliser le produit.

•

Toujours

faire passer la télécommande par la fenêtre, si on l’utilise de l’intérieur d’un véhicule.

•

Ne jamais

accrocher le câble à lui-même

AVERTISSEMENT

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WARN INDUSTRIES * WINCH

MESURES GÉNÉRALES DE SÉCURITÉ

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

Consignes de sécurité concernant le treuillage:

•

Toujours

inspecter le câble du treuil, le crochet et les élingues avant de faire fonctionner le treuil. Tout câble de treuil eﬃ loché, tordu ou endommagé doit être remplacé immédiatement. Tous les composants endommagés doivent être remplacés avant d'utiliser le produit. Protéger toutes les pièces contre le risque de dommages.

•

Toujours

s'assurer que tout objet ou obstacle pouvant gêner la bonne utilisation du treuil est écarté.

•

Toujours

s'assurer que le point d'ancrage choisi peut supporter la charge et que la sangle ou la chaîne ne glisse pas.

•

Toujours

utiliser la sangle de crochet fournie pourenrouler ou dérouler le câble du treuil, durant l'installation ou l'utilisation.

•

Toujours

exiger de l'opérateur et des personnes présentes d’être attentifs au véhicule et à la charge.

•

Toujours

être conscient de la stabilité du véhicule et de la charge durant le treuillage. Veiller à ce que personne ne s'approche. Alerter toutes les personnes alentour en cas d'instabilité.

•

Toujours

dérouler autant de câble que possible avant de procéder au câblage. Utiliser une ligne double ou choisir un point d’ancrage distant.

•

Toujours

prendre le temps d'utiliser des techniques de câblage adaptées avant d'utiliser le treuil pour tirer.

•

Ne jamais

toucher le câble du treuil ou le crochet lorsqu'une autre personne est à l'interrupteur de commande ou durant le fonctionnement du treuil.

•

Ne jamais

essayer d'embrayer ou de débrayer si le treuil est sous charge, si le câble du treuil est entension ou si le tambour est en train de tourner.

•

Ne jamais

toucher le câble ou le crochet lorsque lecâble est tendu ou sous charge.

•

Toujours

se tenir à l'écart du câble du treuil et dela charge

durant l'utilisation et ne jamais laisser personne s'approcher.

•

Ne jamais

se servir d'un véhicule pour tirer une charge sur le câble du treuil. La charge combinée ou un choc peut endommager, surcharger et casser le câble.

•

Ne jamais

replier le câble du treuil sur lui-même. Utiliser toujours une chaîne ou une protection detronc d'arbre sur le point d'ancrage.

DANGER DE CHUTE OU D'ÉCRASEMENT

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

•

Toujours

rester à l'écart, en gardant les mains et les autres

personnes à l'écart également.

•

Ne jamais

utiliser le treuil avec moins de 10 spires de câble enroulées autour du tambour. Le câble pourrait se dérouler du tambour, étant donné que l'ancrage ducâble n'est pas conçu pour retenir une charge.

•

Ne jamais

utiliser le treuil comme palan ou pour suspendre une charge.

•

Toujours

s'assurer que le point d'ancrage peut supporter la charge, et prendre le temps d'employer des techniques de câblage appropriées.

•

Ne jamais

utiliser le treuil pour soulever ou transporter des

personnes.

•

Ne jamais

forcer trop fort pour dérouler le câble du treuil.

•

Toujours

utiliser une posture/technique de levage adéquate ou demander de l'aide lors de la manipulation ou de l'installation du produit.

•

Toujours

enrouler le câble sur le tambour dans le sens spéci é par l’étiquette d'avertissement apposée sur le treuil ou la documentation du treuil. Cela est nécessaire pour que le frein automatique (le cas échéant) fonctionne correctement.

•

Toujours

enrouler le câble du treuil sur le tambour comme indiqué par l’autocollant de rotation du

tambour.

RISQUE DE COUPURE ET DE BRÛLURE

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

Pour éviter de se blesser les mains et les doigts:

•

Toujours

porter des gants de cuir épais durant lamanipulation du

câble du treuil.

•

Toujours

penser aux surfaces chaudes au niveau dumoteur du treuil, du tambour ou du câble durant ouaprès l'utilisation du treuil.

AVERTISSEMENT

WARN INDUSTRIES * WINCH

MESURES GÉNÉRALES DE SÉCURITÉ

DANGER D'IMPACT ET DE HAPPEMENT PAR DES PIÈCES MOBILES

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

Pour éviter de se blesser les mains et les doigts:

• Toujours connaître la limite de charge de service (LCS) de

votre câble.

• Toujours déterminer si le câble est adapté à l'application

envisagée.

• Ne jamais utiliser ce câble sur un treuil avec un eﬀ or t en 1ère

couche supérieur à 4536kg.

• Ne jamais utiliser un câble s'il est usé, endommagé, maltraité,

surchargé, mal entretenu ou s'il a plus d'un an.

• Ne jamais se tenir dans la zone de recul.

• Ne jamais utiliser le câble sur une surface rugueuse sans

protection contre les frottements.

• Ne jamais appuyer le câble sur des coins acérés

nonprotégés.

• Ne jamais laisser l'embrayage débloqué lorsqu'on

n'eﬀ ectue pas de déroulement en roue libre du câble. Le frein automatique ne fonctionnera pas lorsque le levier d'embrayage se trouve en position de déroulement en roue libre.

• Ne jamais dépasser la charge nominale de 4 536 kg.

• Remplacer le câble tous les 12 mois, sans exception.

• Toujours utiliser un guide-câble WARN recommandé pour les

câbles synthétiques.

• S’il a été endommagé ou maltraité, toujours remplacer

le guide-câble écubier WARN par un guide-câble WARN recommandé pour les câbles synthétiques.

RISQUES ASSOCIÉS AUX PRODUITS CHIMIQUES ET RISQUE D'INCENDIE

Le non-respect des consignes peut entraîner des blessures graves ou la mort.

• Toujours retirer les bijoux et porter des lunettes

desécurité.

• Ne jamais faire passer les câbles électriques

par-dessus des bords tranchants.

• Ne jamais faire passer les câbles électriques àproximité de

pièces qui s'échauﬀ ent.

• Ne jamais faire passer les câbles électriques àtravers des

pièces mobiles ou à proximité.

• Toujours placer les capuchons fournis sur les  ls et les bornes,

conformément aux instructions d'installation.

• Ne jamais se pencher au-dessus de la batterie

enprocédant aux connexions.

• Ne jamais faire passer les câbles électriques

par-dessus les bornes de la batterie.

• Ne jamais court-circuiter les bornes de la batterie avec des

objets métalliques.

• Toujours s'assurer que la zone ne contient pas deconduites

de carburant, de réservoir de carburant, de conduites de frein, de câblage électrique, etc., avant de percer.

• Toujours consulter le manuel de l'utilisateur pour

lesinformations correctes de câblage.

• Toujours isoler et protéger tous les  ls et bornes

électriques exposés.

AVERTISSEMENT

87970A2

+ 29 hidden pages

Warn Industries MID-FRAME series Installation And Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual