R-Series Manual - 109550.A0

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

R Winch Operator’s Manual

INSTALLATION AND OPERATOR’S GUIDE GUIDE D’INSTALLATION ET OPERATEUR

109550A0

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

Français....................................................................................... 20

Español....................................................................................... 39

Deutsch. ..................................................................................... 58

Svenska....................................................................................... 77

Italiano........................................................................................ 96

Nederlands..............................................................................115

Português................................................................................134

Suomi........................................................................................153

ORIGINAL INSTRUCTIONS

SYMBOL INDEX

SYMBOL

EXPLANATION Read All Product Literature

SYMBOL

EXPLANATION

Always Wear Leather Gloves

Winch Operator’s Manual

Always Wear Hearing and Eye Protection

Do Not Move People

This manual provides important safety information and instructions on how to operate your winch. It is important to read ALL instructions and safety information BEFORE installing and operating your winch. As you read these instructions, you will see WARNINGS , CAUTIONS , NOTICES and NOTES . Failure to observe these instructions could lead to serious injury or death. 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. 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!

Always Use Supplied Hook Strap

Never Use Winch as a Hoist

Never Apply Load to Hook Tip or Latch

Properly Seat Load in Throat of Hook

Never Wind Winch Rope Over Top of Drum

Wind Winch Rope on Bottom of Drum

SAVE THIS MANUAL 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.

Fairlead Pinch Point

Finger/Fairlead Crushing Hazard

Hot Surface Hazard

Hand Piercing/Cutting Hazard

TABLE OF CONTENTS: Symbol Index .................................................................................................................................................... 2 General Safety Precautions ..................................................................................................................... 3-5 Know Your Winch............................................................................................................................................ 6 Winch accessories ........................................................................................................................................... 7 Mounting...................................................................................................................................................... 8-10 Electrical Connections ........................................................................................................................... 11-12 Operating Instructions ......................................................................................................................... 13-16 Rigging techniques ...................................................................................................................................... 17 Synthetic Rope Care..................................................................................................................................... 18 Maintenance & Final Analysis .................................................................................................................. 19

Fire and Burn Hazard

Explosion/Bursting Hazard

Never Hook Back on Winch rope

GENERAL SAFETY PRECAUTIONS

Warnings and Cautions

WARNING

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!

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.

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.

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. Complete installation and hook attachment before wiring. • Never operate winch with less than 5 wraps of wire winch rope or 10 wraps of synthetic winch 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 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 specified 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

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

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.

GENERAL SAFETY PRECAUTIONS

KNOW YOUR WINCH Before you begin, you should familiarize yourself with your winch and each of its components:

CAUTION

Winch Drum

Clutch Dial

CUT AND BURN HAZARD Failure to observe these instructions could lead to minor or moderate injury. • Never let winch rope slip through your hands.

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.

Motor

Winch Rope

NOTICE

Motor :

The winch motor is powered by the vehicle’s battery. The motor provides power to the gear mechanism, which turns the winch drum and winds the winch rope. The winch drum is the cylinder onto which the winch rope feeds. The drum is driven by the motor and drive train. The winch rope’s diameter and length are determined by the winch’s load capacity and design. Wrapped around the winch drum and fed through the fairlead, the winch rope is looped at the end to accept the hook’s clevis pin. Synthetic winch rope is constructed of a unique ultra high molecular weight polyethylene material and offers tremendous tensile strength. It is coated with a high temperature urethane and equipped with a temperature resistant sleeve on the first layer for added protection. The synthetic rope’s high flexibility and low weight make it much easier to handle out in the field. The clutch allows the operator to manually disengage the spooling drum from the gear train, enabling the drum to rotate freely (known as “freespooling”). Engaging the clutch “locks” the winch drum back onto the gear train. Using electrical power from the vehicle’s battery, the contactor switches power to the motor, enabling the operator to change the direction of the winch drum rotation. Remote controls come in many forms. All enable the operator to start, stop and change the direction of the winch drum rotation, , as well as stand clear of the winch rope while operating the winch.

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.

Winch Drum:

Winch Rope:

Clutch Dial:

Contactor (not shown) :

Remote Control (not shown) :

WINCH ACCESSORIES

MOUNTING

Alone, the winch is not much more than a simple tool. But when used with certain accessories and enhancements, your winch can become a versatile and productive tool. In this section, we’ll review several of these items. Some are vital to the safe operation of your winch, while others offer added versatility and convenience. Gloves Winch rope, through use, will develop “barbs” which can slice skin. It is extremely important to wear protective gloves while operating the winch or handling the winch rope. Avoid loose fitting clothes or anything that could become entangled in the winch rope and other moving parts. Hook Strap Use to hold the hook and keep fingers away from the fairlead as the winch rope is being spooled in. Winches develop tremendous pulling forces and can easily remove fingers and limbs that are placed in pinch points. Put the hook into the loop and hold the strap between the thumb and forefingers. WARNING Always use supplied hook strap whenever spooling winch rope in or out, during installation and during operation. Snatch Block Used properly, the multi- purpose snatch block allows you to: (1) increase your winch’s pulling power; and (2) change your pulling direction without damaging the winch rope. Proper use of the snatch block is covered in “Before You Pull”. Clevis/D-Shackles The D-Shackle is a safe means for connecting the looped ends of cables, straps and snatch blocks. The shackle’s pin is threaded to allow easy removal. Tree Trunk Protector Typically made of tough, high-quality nylon, it provides the operator an attachment point for the winch rope to a wide variety of anchor points and objects, as well as protect living trees. WARNING Never use a strap for winching. WARNING Never use a strap for towing. The strap can be easily cut or abraded.

MOUNT YOUR WINCH

WARNING Never use “bungie” straps that develop tremendous and potentially dangerous amounts of force when stretched. Recovery Strap Never use a recovery strap in a winching operation. Because it is designed to stretch, it stores energy and could react like a rubber band should your rigging fail. Use the recovery strap to “snatch” out a stuck vehicle. Shovels & Hand Tools Quite often during winching activities, you’ll find yourself in need of some additional help. You may want to stow equipment such as a shovel, an axe and a Hi-Lift jack for additional assistance when needed. Backup Parts Important backup parts to carry for back country travel should include an extra screw-pin shackle, snatch block and remote control. For severe and continued winch use, consider including an extra winch rope and winch hook. Toolbox Items to bring along include hand wrenches, screwdrivers, pliers, and tools to change winch rope.

WARNING Always choose a mounting location that is sufficiently strong to withstand the maximum pulling capacity of your winch. WARNING Always position fairlead with warning readily visible on top. WARNING Always use class 8.8 metric (grade 5) or better hardware.

WARNING Never weld mounting bolts. WARNING Always confirm required bolt length to ensure proper thread engagement. WARNING Always complete the winch installation and hook attachment before installing the wiring.

R25 / R35

R45 / R60

76.2

78.9

31.5

Plate Thickness

Bolt Length

3/16”

25 mm 25 mm 30 mm 30 mm

1/4”

5/16”

3/8”

3/16”

25mm

30mm 3/16” 3/16”

MOUNTING

MOUNT YOUR REMOTE EQUIPMENT

WARNING Always confirm required bolt length to ensure proper thread engagement.

1. Disconnect the vehicle battery cables, negative terminal first. All work with electrical wires and cables must be completed with the battery completely disconnected from the vehicle wiring.

WARNING TO AVOID INJURY AND PROPERTY DAMAGE: Use caution if moving or repositioning the vehicle controls so as to not compromise the safe operation of the vehicle. Select a mounting position that will provide clearance for all vehicle controls. Before securing the switch cable with tie wraps, make sure that the handlebars have full range of motion.

Item Qty

Description

A 2 M10 - 1.5 x 20 *AA 2 M10 - 1.5 x 30 B 2 M10 - 1.5 C & D 2 M10 E

4 M8 - 1.25 x 25mm

HANDLEBAR SWITCH MOUNTING

F & G 8 M8

* Use with hawse fairlead only

24.5 Nm (18 ft. lbs.)

REMOTE SOCKET MOUNTING

WARNING Always confirm required bolt length to ensure proper thread engagement.

Item Qty

Description

A 2 M10 - 1.5 x 20 *AA 2 M10 - 1.5 x 30 B 2 M10 - 1.5 C & D 2 M10 E

4 M8 - 1.25 x 30mm

F & G 8 M8 * Use with hawse fairlead only

DASH SWITCH MOUNTING

36.8mm (1.45in.)

21.1mm (.83in.)

24.5 Nm (18 ft. lbs.)

Not to scale. Do NOT use as a template!

ELECTRICAL CONNECTIONS

MOUNT YOUR CONTACTOR

3500

WARNING Never mount contactor with electrical terminals touching metal objects.

WARNING Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc., when drilling.

Red

CONTACTOR MOUNTING

Blue

Black

Yellow

Brown

Green

/N MCJO 3,6-3,9 Nm 32-34,5 lb-in

Black

(1) Green

(2) Red

WIRING YOUR EQUIPMENT

WARNING Always remove jewelry and wear eye protection when making battery connections. WARNING Never route electrical cables through or near moving parts. WARNING Always insulate and protect all exposed wiring and electrical terminals.

WARNING Always place the supplied terminal boots on wires and terminals. WARNING Never route electrical cables across sharp edges. WARNING Never route electrical cables near parts that get hot. WARNING Never route electrical cables over battery terminals.

Red

(3) Black

4500/ 6000

2500

Red

Blue

Yellow

Black

Blue

Yellow

Brown

Black

Brown

/N MCJO 3.6-3.9 Nm 32-34.5 lb-in

(1) Green

Green

Black

/N MCJO 3,6-3,9 Nm 32-34,5 lb-in

Green

(2) Red

1 2 3

Black

Remote Socket (optional)

(3) Black

Red

OPERATING INSTRUCTIONS

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

Operating Instructions

Spooling In Under Load WARNING Never exceed winch or winch rope rated capacity. WARNING Always know the Working Load Limit (WLL) of your rope. WARNING Never exceed the WLL of rope or shock load this rope. Power-in the winch rope evenly and tightly on the drum. This prevents the outer winch wraps from sinking into the inner wraps, binding, and damaging the winch rope. Avoid shock loads when spooling by pulsing the control switch to take up winch rope slack. Shock loads can momentarily far exceed the winch and rope ratings. Spooling In Under No Load WARNING Never touch winch rope or hook while someone else is at the control switch, when winch rope is under load or during winching operation. Spooling with an Assistant : Have the assistant hold the hook strap putting as much constant tension on the winch rope as possible. While keeping tension, the assistant should walk toward the winch while you operate the control switch spooling in the winch 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 winch rope to be spooled so it will not kink or tangle when spooled. Be sure any winch rope on the drum is tightly and evenly layered. Spool enough winch 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. 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 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.

Now that you’ve familiarized yourself with your winch and its components, we can begin reviewing how it works. The major advantage of an electric-powered winch is that it can provide reliable service for intermittent utility and recreational use even while the vehicle’s engine is stalled — assuming, of course, that sufficient battery current is available. Your winch can operate at high current loads, and, for this reason, uses a high current switch system to safely handle the current flow. It is important to understand that the longer the pull, the more heat that is created, just like a hot plate. Powering out the rope also generates heat and drains the electrical system. Whenever possible, unwind rope by “freespooling.” Prolonged winching without cooling the winch motor will damage the motor. Also, even if the engine is idling during winching, the battery may drain faster than it is charging. So pay close attention to make sure you aren’t draining your battery too low to start your vehicle. Control Of Your Winch The winch is controlled by a switch mechanism that provides control of the forward or reverse rotation of the spooling drum. How the Winch Reacts to Load Winches are rated by pulling capacity. The maximum pulling capacity occurs on the first layer of rope on the drum. As the layers increase, the pulling power decreases. It’s the mathematics of winching. Exceeding the winch capacity could cause the winch to fail or the rope to break. Thinking through how you intend to use your winch now, could save you a big headache later. In addition, you’ll also want to make sure that your winch’s mounting system and your vehicle’s frame can accommodate the rated load of your winch.

WARNING Never use winch as a hoist or to

suspend a load.

WARNING Never use winch to lift or move

persons.

Remote Control: WARNING 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. WARNING Never leave remote control where it can be unintentionally activated. WARNING Never leave the winch remote control plugged in when installing, freespooling, rigging, servicing or when the winch is not being used. The remote control provides control of the power-out (forward) or power-in (reverse) 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 accidental activation and/or battery drain.

ENGAGED/LOCK

DISENGAGED/UNLOCK

Spooling Out WARNING Never operate winch with less than 5 wraps of wire rope or 10 wraps of synthetic rope around the drum. Rope could come loose from the drum. 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 wear heavy gloves when handling winch rope. Freespooling is generally the quickest and easiest way to spool out winch rope. Before freespooling winch rope out from the winch power-out enough rope to remove any tension on the winch rope. Disengage the clutch. Then manually spool out enough winch rope for the winching operation. NOTICE Do NOT power out 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 out by hand. WARNING Always use supplied hook strap whenever spooling winch rope in or out.

OUT

Clutch Operation: WARNING Never engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving. NOTICE Always ensure the clutch is fully engaged or disengaged when operating winch. The clutch dial is located on the winch housing opposite the motor and controls the clutch position. To prevent damage, always fully engage or fully disengage the clutch lever.

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS 10. Exit vehicle. WARNING! Never exit the vehicle with a load on the winch rope. While standing approximately 8 ft. (2.44 m) away from the winch, power-in the winch until all of the slack is wound onto the winch drum. WARNING Never touch winch rope or hook while someone else is at the control switch, when winch rope is under load or during winching operation. WARNING Never let winch rope slip through your hands. 11. With gloves on, hold tension on the winch rope with one hand, carefully push the winch rope to the side of the drum the winch rope is attached to so there are no gaps between each coil on the drum. 12. The following steps should be done using two people for proper safety. If you attempt to tension your winch rope alone be sure to always set the parking brake, place the transmission in gear or park and turn the vehicle off every time you exit the vehicle to inspect the winch rope. NOTICE Use care to evenly wrap each layer to prevent damage to the rope. WARNING Never use remote when vehicle is not in line of sight of operator. 13. The driver of the vehicle should operate the winch. 14. Instruct your assistant to stand to the side of the vehicle and away from the winch rope. NOTE: Your assistant should signal you if the winch rope is winding correctly or incorrectly by watching it move across the fairlead as the winch rope is powered in. 15. Start the vehicle and place the transmission in neutral. Then release the parking brake while applying moderate brake pedal pressure. 16. Power-in the winch rope to start winching in. 17. After winching in for approximately 6 ft. (2 m), stop winching. 18. 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. 19. Place the transmission in park or in gear and turn the vehicle off.

20 Exit the vehicle and inspect the winch to make sure that the winch rope is being evenly wound onto the winch drum and not sinking into the lower layer. If the winch rope is sinking, power-out the winch rope by pushing the power-out button on the remote control and repeat this step from the beginning with more brake pedal pressure. 21. When you are convinced the winch rope is winding onto the winch drum properly, repeat steps until the vehicle is within 6 ft. (2 m) of the winch anchor. Once within 6 ft. (2 m), 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 in gear and turn the vehicle off. 22. Exit the vehicle. Disconnect the hook from the anchor. 23. While holding onto the supplied hook strap, hold tension on the winch rope and slowly power-in the winch by “pulsing” the power- in button on your remote control until the hook is within 3 ft. (1 m) of the fairlead. 24. Stop winching in and attach the hook to a suitable storage point on the vehicle. 25. Once the hook is suitably attached to the vehicle, power-in the remaining slack in the winch rope by “pulsing” the power-in button on your remote control until there is minimal slack in the winch rope. NOTICE Do not power the hook into the fairlead. This could cause damage to the fairlead.

Stop winching in and attach the hook to a suitable anchor point on the vehicle. NOTICE 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 WARNING Always be aware of possible hot surfaces at winch motor, drum or rope during or after winch use. 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. STRETCHING WINCH ROPE WARNING Always prestretch rope and respool under load before use. WARNING 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. Stretching (tensioning) the winch rope is critical to ensure a long product life. Tensioning the winch rope will prevent outer layers of winch rope from pinching and deforming the inner layers. During its first use, a new winch rope must be spooled onto its drum under a load of at least 500 lbs. (226 kgs). Use the following instructions to properly stretch the winch rope onto the winch drum. WARNING Always wear heavy gloves when handling winch rope. 1. Choose a FLAT AND LEVEL location that is large enough to run out almost the entire length of winch rope.

2. Disengage clutch. WARNING Always keep hands clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out. 3. Grasp hook strap and spool out the winch rope to the last 5 wraps on the drum (10 wraps if synthetic rope). 4. Be sure to check that the winch rope is winding off of the bottom of the drum or the automatic load holding brake will not function properly. NOTE: If the winch rope is winding off the top of the drum, you have powered the winch “out” instead of “in”. Be sure you are powering in. WARNING Always wind the winch rope on bottom (mountside) of drum. NOTICE For proper function of the winch brake, the winch rope must be spooled onto the drum in the specified direction. *See drum rotation label located on winch. 5. Once the winch rope is spooled out, engage clutch. WARNING Always ensure hook latch is closed. WARNING Always apply load only to the center of hook. WARNING Never apply load to hook tip or use hook that is bent or twisted. 6. Attach the hook end of the rope to a suitable anchor point. WARNING Always remove any obstacle that may interfere with safe operation of the winch. WARNING Never wrap winch rope back onto itself. Use a chain or strap on the anchor. WARNING Always be certain the anchor you select will withstand the load and the strap or chain will not slip. 7. Return to your vehicle. 8. Back the vehicle away from the anchor point until there is very little slack in the winch rope. 9. Set the parking brake, place the vehicle in gear or park and turn the vehicle off. WARNING Always stand clear of winch rope and load and keep others away while winching.

RIGGING TECHNIQUES

SYNTHETIC ROPE CARE

Various winching situations will require application of other winching techniques. These could range from too little distance to achieve maximum pull using straight line rigging, simply increasing pulling power, or maintaining a straight-line pulling situation. You will have to assess what technique is correct for your All winching operations should have a straight line from the winch to the object being pulled. This minimizes the rope collecting on one side of the drum affecting pulling efficiency and damaging rope. A snatch block, secured to a point directly in front of the vehicle, will enable you to change your pulling direction while still allowing the rope to be at 90º to wind properly onto the spooling drum. Increasing pulling power & duration In some cases, you may find yourself needing more pulling power. The use of snatch blocks increases mechanical advantage and that increases your pulling power: situation. Think “safety” at all times. How to change the pulling direction Double line Because pulling power decreases with the number of layers of rope on the winch drum, you can use a snatch block to double line out more rope. This decreases the number of layers of rope on the drum, and increases pulling power. Start by feeding out enough rope to free the winch hook. Attach the hook to your vehicle’s frame and run the rope through a snatch block. Do not attach hook to mounting kit. Disengage the clutch and, using the snatch block, pull out enough wire to reach your anchor point. Secure to the anchor point with a tree trunk protector or choker chain. Attach the clevis/ shackle. Attach the shackle to the two ends of the strap/chain, being careful not to over tighten (tighten and back-off 1/2 turn).

WARNING

ITEMS NEEDED

• 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. • Always wind the winch rope on bottom (mount side) of drum. • Never operate winch with less than 5 wraps of wire rope or 10 wraps of synthetic rope around the drum. Rope could come loose from the drum. • Never bend rope around unprotected, sharp corners. • Never use rope over a rough surface without abrasion protection.

NOTE: For 25s models The steps will be the same, except the rope will thread on motor side of the winch.

ANCHORING WIRE ROPE ON DRUM

≥ 10

≥ 5

R25

4-5Nm (35- 44 in-lbs)

R35 & R45

6-7Nm (53- 62 in-lbs)

INSTRUCTIONS INITIALES

FINAL ANALYSIS AND MAINTENANCE

Before first operation

After each use

Check

Every 90 days

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 Check fasteners and make sure they are tight and to proper torque. Replace damaged fasteners. Verify wiring to all components is correct and be certain that all connections are tight. Verify there is no exposed/bare wiring, terminals or cable insulation damage (chafing/cutting). Cover any exposures with terminal boots. Repair or replace damaged electrical cable. Inspect winch rope, hook, and slings. Frayed, kinked or damaged winch rope must be replaced immediately. Damaged components must be replaced before operation. Keep winch, rope and switch control free from contaminants. Use a clean rag or towel to remove any dirt and debris. If winch is submerged in water: Power winch rope out and back in about 30 feet. Follow the “Stretching Winch Rope” procedure, in order to dry out winch.

Manuel de l'utilisateur du treuil

Ce manuel fournit des informations et des consignes de sécurité importantes concernant l’utilisation du treuil. Il est important de lire attentivement TOUTES les instructions et informations de sécurité afférentes à votre produit AVANT d'installer et d'utiliser le treuil. Les directives suivantes comprennent des indications, intitulées AVERTISSEMENT , ATTENTION , AVIS et REMARQUE . Le non-respect des consignes peut entraîner des blessures graves ou la mort. 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 et AVERTISSEMENT identifient 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 !

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

TABLE DES MATIÈRES : Index des symboles ..................................................................................................................................... 21 Mesures générales de sécurité.......................................................................................................... 22-24 Se familiariser avec le treuil...................................................................................................................... 25 Accessoires de treuillage............................................................................................................................ 26 Montage ....................................................................................................................................................27-29 Raccordements électriques ................................................................................................................. 30-31 Mode d'emploi ........................................................................................................................................ 32-35 Techniques de câblage ............................................................................................................................... 36 Entretien du câble synthétique ............................................................................................................... 37 Entretien et derniers commentaires ..................................................................................................... 38

Take time to fully understand your winch and the winching operation by reviewing the Basic Guide to Winching Techniques found online at: www.warn.com

For further information or any questions contact: WARN INDUSTRIES, INC.

12900 S.E. Capps Road, Clackamas OR USA 97015-8903, 1-503-722-1200, Customer Service: 1-800-543-9276 Dealer Locator Service: 1-800-910-1122 Or visit www.warn.com.

INDEX DES SYMBOLES

MESURES GÉNÉRALES DE SÉCURITÉ

Avertissements et mises en garde

SYMBOLE

EXPLICATION

SYMBOLE

EXPLICATION

AVERTISSEMENT

Lire tous les documents relatifs au produit

Toujours porter des gants de cuir

Toujours porter un dispositif de protection auditive et oculaire

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. Les mises en garde intitulées ATTENTION servent également à signaler une utilisation dangereuse. ATTENTION et AVERTISSEMENT identifient 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 !

Ne pas déplacer des personnes

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES Le non-respect des consignes peut entraîner des blessures graves ou la mort. Consignes de sécurité générales : • Toujours se familiariser avec le treuil. Prendre le temps de bien lire le mode d'emploi et/ou le manuel d'utilisation et/ ou le manuel de base des techniques de treuillage, afin de comprendre le treuil et son fonctionnement. • Ne jamais excéder la capacité nominale du treuil ou du câble de treuil. 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 le treuil sous l'effet de drogues, de l'alcool ou de médicaments. • Ne jamais laisser des personnes âgées de moins de 16 ans utiliser ce treuil.

Toujours utiliser la sangle de crochet fournie

Ne jamais utiliser le treuil comme palan

Ne jamais appliquer la charge sur l'extrémité ou le loquet du crochet Ne jamais enrouler le câble du treuil sur le dessus du tambour

Positionner correctement la charge dans la gorge du crochet

Enrouler le câble du treuil sur le dessous du tambour

AVERTISSEMENT

Point de pincement du guide-câble

Danger d'écrasement des doigts dans le guide-câble

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 s'est élargie 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 fil 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 fissures, de points de pincement, de fils effilochés 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.

Risque de surface chaude

Risque de percement/ coupure des mains

Risque d'incendie et de brûlure

Risque d'explosion/rupture

AVERTISSEMENT

Ne jamais accrocher le câble du treuil à lui-même

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 éventuelles au niveau du moteur du treuil, du tambour ou du câble durant ou après l'utilisation du treuil.

MESURES GÉNÉRALES DE SÉCURITÉ

AVERTISSEMENT AVERTISSEMENT

ATTENTION

RISQUE DE COUPURE ET DE BRÛLURE Le non-respect des instructions peut entraîner des blessures mineures ou modérées. • Ne jamais laisser le câble du treuil glisser dans les mains.

DANGER DE HAPPEMENT PAR DES PIÈCES MOBILES Le non-respect des instructions peut entraîner des blessures mineures ou modérées. Pour éviter de se blesser les mains ou les doigts : • Ne jamais laisser la télécommande dans un emplacement où elle peut être activée durant la mise en roue libre, le câblage ou quand le treuil n'est pas utilisé. • Ne jamais laisser la télécommande du treuil branchée durant l'installation, le déroulement en roue libre, le câblage, l'entretien ou quand le treuil n'est pas utilisé.

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 effiloché, 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 un câblage 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 se trouve à l'interrupteur de commande ou durant le fonctionnement du treuil. • Ne jamais essayer d'embrayer ou débrayer si le treuil est sous charge, si le câble du treuil est tendu 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. Utilisez 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. Achever le montage et la fixation du crochet avant d'effectuer le câblage. • Ne jamais utiliser le treuil avec moins de 5 spires de câble ou de câble synthétique 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 du treuil sur le dessous (côté support) du tambour. • Ne jamais enrouler le câble sur le dessus du tambour. • Toujours enrouler le câble du treuil sur le tambour dans le sens spécifié par les étiquettes de rotation du tambour apposées sur le treuil et/ou par la documentation du treuil. Cela est nécessaire pour que le frein automatique (le cas échéant) fonctionne correctement.

AVIS

ÉVITER D’ENDOMMAGER LE TREUIL ET L'ÉQUIPEMENT • Toujours éviter de tirer sur le côté, ce qui a pour effet d'empiler le câble du treuil sur l'une des extrémités du tambour. Cela peut endommager le câble du treuil ou le treuil. • Toujours s’assurer d’avoir complètement embrayé ou complètement débrayé. • Toujours faire attention à ne pas endommager le châssis du véhicule si l'on décide de s'arrimer à un véhicule pour pouvoir travailler avec le treuil. • Ne jamais submerger le treuil dans l’eau. • Toujours ranger la télécommande dans un endroit sûr, propre et sec.

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