INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
3. Insert the synthetic rope through the fairlead and around the winch drum from the bottom.
WARNING When upgrading from wire to synthetic winch rope, a WARN Hawse Fairlead is necessary. NOTICE Any wire rope damage on drum may be smoothed with öne emery paper. Standard Duty, Heavyweight, Ultra Performance & Premium Series Synthetic Winch Rope Installation: THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT PRECISELY FOLLOWED THE LIFE OF THE WINCH AND WINCH ROPE MAY BE COMPROMISED. Things You Will Need: • WARN® Synthetic Winch Rope • Abrasion Sleeve • Rope Washer • Button Head Bolt • Gloves • Loctite 271 or equivalent • WARN® Hawse Fairlead (if replacing wire rope) WARNING MOVING PARTS ENTANGLEMENT HAZARD. Failure to observe these instructions could lead to serious injury or death. WARNING Always position fairlead with warning readily visible on top. CAUTION Always wear heavy leather gloves when handling winch rope. WARNING Always replace the WARN Fairlead if damaged or abused. WARNING Always keep hands clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out. For synthetic winch rope applications, you must have a Hawse Fairlead mounted to your winch. For optimal performance, a WARN Hawse Fairlead is strongly recommended. If you need to purchase a new WARN Hawse Fairlead, contact your WARN product dealer. 1. Disconnect the negative cable from the battery that is used to power the winch. WARNING Never bend rope around unprotected, sharp corners. WARNING Never use rope over a rough surface without abrasion protection. 2. Slide the black abrasion sleeve over the rope from the end opposite of the hook. Slide the sleeve towards the hook end of the rope. 3. Insert the synthetic rope through the fairlead and around the winch drum from the bottom.
WARNING When upgrading from wire to synthetic winch rope, a WARN Hawse Fairlead is necessary and you must use the 5/16” anchor puck supplied in your synthetic rope kit (sizes vary). NOTICE Any wire rope damage on drum may be smoothed with öne emery paper. Zeon Synthetic Series Rope Installation: THE FOLLOWING STEPS ARE VERY IMPORTANT AND IF NOT PRECISELY FOLLOWED THE LIFE OF THE WINCH AND WINCH ROPE MAY BE COMPROMISED. Things You Will Need: • WARN® Synthetic Winch Rope • Abrasion Sleeve • Installation wire • 5/16” Anchor Puck • Gloves • WARN® Hawse Fairlead ( if replacing wire rope ) WARNING MOVING PARTS ENTANGLEMENT HAZARD. Failure to observe these instructions could lead to serious injury or death. WARNING 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. WARNING Always position fairlead with warning readily visible on top. CAUTION Always wear heavy leather gloves when handling winch rope. WARNING Always replace the WARN Fairlead if damaged or abused. For synthetic winch rope applications, you must have a Hawse Fairlead mounted to your winch. For optimal performance, a WARN Hawse Fairlead is strongly recommended. If you need to purchase a new WARN Hawse Fairlead, contact your WARN product dealer. 1. Disconnect the negative cable from the battery that is used to power the winch. WARNING Never bend rope around unprotected, sharp corners. WARNING Never use rope over a rough surface without abrasion protection. 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.
4. Apply Loctite 271 or equivalent product to the supplied button head fastener. 5. Insert the button head fastener supplied and the machined rope washer. Before tightening the bolt, install the rope eyelet on the machined rope washer. Tighten button head bolt. 6. Reconnect negative cable to the battery that is used to power the winch.
4. Before installing the synthetic rope, thread the installation wire through the loop of the rope and ease the rope loop through the rope anchor pocket.
Rope
Rope Washer
Button Head Bolt
WARNING Always wind the winch rope on bottom (mount side) of drum. WARNING Never operate winch with less than 10 wraps of winch rope around the drum. Rope could come loose from the drum, as the winch rope attachment to the drum is not designed to hold a load. WARNING Never touch winch rope or hook while someone else is at the control switch or during winching operation. 7. Turn the clutch lever on the winch to the “Engaged” position. NOTE: If you own a Zeon Platinum Winch, you will use your wireless remote control to engage your winch. 8. Power in and wind 10 wraps of winch rope onto the drum while applying tension on the winch rope.
5. Once the rope has been partially pulled through pocket, wrap the wire ends around the head of pliers to complete pulling rope loop through pocket.
Proceed to the ‘Rope Spooling Instructions’ section of this document.
WARN INDUSTRIES 7
WARN INDUSTRIES 8
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