MOUNTING
ELECTRICAL CONNECTIONS
5. Thread the hook loop end of the rope through the opening of mounting bracket and fairlead.
1. Plan the routing path. 2. Loosely secure power cables along path. 3. Confirm power cables are protected from sharp edges, heat and moving parts. Consider chassis flex and vibration which might damage cable. 4. Carefully inspect electrical cable routing. Zip tie and secure electrical cables. Zip ties should be snug, but not cutting into wire insulation. Use electrical tape, pieces of rubber hose or electrical conduit to protect electrical cables and wire harness where needed to avoid electrical cable insulation wear or abrasion. 5. FIRST, attach the winch power (red) cable to the positive (+) battery terminal. SECOND, attach the ground (black) cable to the negative (-) battery terminal. WARNING Always connect red (+) power cable ONLY to the positive (+) terminal of the battery. WARNING Always connect black ground (-) power cable ONLY to the negative (-) terminal of the battery. Step 3 - System Check Perform system check: 1. Check fasteners and make sure they are tight and to proper torque 2. Verify the wireless control activation switch light turns ON. A flashing green light appears in the switch. If light does not turn on, immediately check to ensure power cables are correctly connected to the battery, red to (+) and black to (-). If not, disconnect and reconnect as instructed. 3. Verify all electrical wiring to all components is correct and be certain that all connections are tight. 4. Verify there is no exposed/bare wiring, terminals or cable insulation damage. 5. Read The Basic Guide to Winching Techniques completely before operating your winch. 6. Charge remote. Once you have performed a system check, you are ready to perform “First Time Operating Instructions”.
Step 2 - Install the Wiring WARNING To prevent serious injury or death. Always place the supplied terminal boots on wires and terminals as directed by the installation instructions. WARNING To prevent serious injury or death from electrical öre: Never route electrical cables across sharp edges.
Mount Winch: 1. Choose a mounting location that is sufficiently strong enough to withstand the maximum pulling capacity of your winch. 2. Install your mounting bracket per your specific mounting kit instructions. 3. Fasten fairlead to mounting bracket using the (2) bolts specified above for your specific mounting orientation. See the Mounting
NOTE: Do not remove plastic wrap from remaining rope on drum at this time.
6. Set winch in mount. 7. See table below to confirm required bolt length.
Plate Thickness
Bolt Length
Never route electrical cables near parts that get hot.
7 mm (1/4”)
32 mm
Never route electrical cables through or near moving parts.
10 mm (3/8”)
40 mm
13 mm (1/2”)
40 mm
Avoid pinch and wear/abrasion points when installing all electrical cables. WARNING Always insulate and protect all exposed wiring and electrical terminals. NOTICE 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. Route battery connection cables in areas which will not cause them to chafe or cut through the insulation causing a potential short circuit. The winch power wire must be routed to the battery. A direct battery connection of the power (red) and ground (black) cable is required. Do not connect ground to vehicle chassis. Routing the battery connection cables may require removal of vehicle facia or body parts. Always route battery cables along a path that allows the cables to be secured with zip ties. WARNING Loose or unsecured power cables can cause serious injury or death. Always protect power cables from sharp edges, areas that get too hot to touch with your hand and any moving parts.
8. Review mounting orientation on page 10 for bolt sizing. 9. Install bolts and tighten to 41 to 47 Nm (30-35 ft. lbs.). WARNING Always conörm required bolt length to ensure proper thread engagement. 10. Attach hook to winch rope loop.
Orientation section for hardware specifics .
4. Set the (4) flanged nuts into pockets of winch feet.
11. Attach hook strap to hook. 12. Remove plastic wrap from remaining rope on drum. 13. Mounting your winch is now complete. Check all hardware to be sure it is tight and to torque. You can now move on to Install the Wiring. NOTE OPTIONAL SYNTHETIC ROPE INSTALLATION For synthetic rope models, be sure to fully read these instructions to familiarize yourself completely with the Advanced Wireless Remote Control operation before you attempt to install the optional synthetic rope. See your WARN® Synthetic Rope Installation Instruction Manual for detailed synthetic rope installation instructions.
Wireless Control Activation Switch
Ground (black) Cable
Control Pack Ground Wire
Power (red) Cable
WARN INDUSTRIES 13
WARN INDUSTRIES 14
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