75282.D2 - Industrial XL Winch Install and Op guide (Eng)

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

INDUSTRIAL XL WINCH

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

75282D2

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

ORIGINAL INSTRUCTIONS

Winch Installation Guide

TABLE OF CONTENTS: SAFETY

Symbol Index .............................................................................................................................................................................2 General Safety Precautions ............................................................................................................................................... 3-5 INSTRUCTIONS Know Your Winch ..................................................................................................................................................................... 6 Mounting .................................................................................................................................................................................7-9 Hydraulic Connections ........................................................................................................................................................ 10 First Time Operation Instructions.............................................................................................................................. 11-14 Final Analysis and Maintenance .....................................................................................................................................15 Trouble Shooting............................................................................................................................................................. 16-17

Warn Industries Inc. 12900 SE Capps Road Clackamas, OR 97015 USA

Customer Service: (800) 543-9276 International Fax: (503) 722-3005 Fax: (503) 722-3000 www.warn.com

WARN INDUSTRIES 1

SYMBOL INDEX

SYMBOL

EXPLANATION

SYMBOL

EXPLANATION

Always Wear Leather Gloves

Read All Product Literature Some literature available only online at www.warn.com.

Do Not Move People

Always Wear Hearing and Eye Protection

Always Use 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 Rope Over Top of Drum

Wind Rope on Bottom of Drum

Fairlead Pinch Point

Finger/Fairlead Crushing Hazard

Hot Surface Hazard

Hand Piercing/Cutting Hazard

Fire and Burn Hazard

Explosion/Bursting Hazard

Never Route Electrical Cables through or Near Moving Parts

Never Route Electrical Cables Across Sharp Edges

Exposed Wiring Hazard, Insulate Exposed Wiring and Terminals

Avoid Installing Electrical Cables around Pinch and Wear/Abrasion Points

Never Hook Back on Rope

Use hook larger than 1/2” (13mm)

WARN INDUSTRIES 2

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. 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 www.warn.com. • 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. Installation Safety: • Always choose a mounting location that is sufficiently strong to withstand the maximum pulling capacity of your winch. • Always use class 8.8 metric (grade 5) or better hardware. • Never weld mounting bolts. • Always use factory approved mounting hardware, components, and accessories. • Never use bolts that are too long. • Always confirm required bolt length to ensure proper thread engagement. • 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.

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. • Never hook back on rope.

WARN INDUSTRIES 3

GENERAL SAFETY PRECAUTIONS

TROUBLESHOOTING

Problem Possible cause

Corrective action

WARNING

Hydraulic fluid pressure too low or flow rate too low

Check fluid level, filter, valves, and other components. Consult a hydraulic specialist.

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 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.

Remount the winch following specifications and procedures in this manual. Be sure mounting surface is flat to within .020 inch. Use shims if necessary. Be sure mounting bolts are tight. Verify that clutch lever rotates freely. Verify that clutch lever is turned to the correct posi- tion. Verify that air pressure to the clutch is 0 psi (air clutch only).

Drum binds, because im- proper mounting causes winch to twist

FALLING OR CRUSHING HAZARD Failure to observe these instructions could lead to serious injury or death. • Always stand clear, keep hands clear, keep others away. • Never operate winch with less than 5 wraps of rope around the drum. Rope could come loose from the drum, as the rope attachment to the drum is not designed to hold a load. • Never use winch as a hoist or to suspend a load. • Always be certain anchor will withstand load, use appropriate rigging and take time to rig correctly. • Never use winch to lift or move persons. • Never use excessive 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.

Freespool clutch is not engaged

Remove drum. Inspect bushings and replace if necessary.

Worn drum bushings

Winch lacks power, pulls slowly, stalls or will not run at all.

Disassemble winch gearbox. Inspect for damaged components, free rotation of planet gears, binding, or contamination. Replace damaged components and lubricate with EP grease.

Gearbox wear, binding, or internal damage

Hydraulic motor is dam- aged

Replace hydraulic motor.

Verify that hydraulic pressure is applied to disc brake during winch operation. Replace brake if necessary. NOTE: Entire brake as- sembly must be replaced. Replace hydraulic manifold. NOTE: Entire manifold assembly must be replaced. DO NOT attempt to adjust or remove the coun- terbalance valves.

Disc brake is not released

WARNING

Damage or contamina- tion of hydraulic manifold

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.

Ambient temperature too low

Temperature must be above -6º F for the hydraulic system to function properly.

WARN INDUSTRIES 4

WARN INDUSTRIES 17

GENERAL SAFETY PRECAUTIONS

TROUBLESHOOTING Trouble Shooting: Note: These trouble shooting tips apply to both electrical and hydraulic winches except where notes.

WARNING

CAUTION

Problem Possible cause

Corrective action

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

Refer to the product data sheet for the correct line pull rating for your winch.

Load exceeds winch rating

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. Failure to observe these instructions could lead to property damage, severe injury, or death • Never exceed the maximum recommended hydraulic pressure or flow for any of the components used. • Always use a tandem-center type control valve ( A & B work ports blocked) to insure proper brake operation. • Always make sure all hydraulic system components are functioning correctly. • Never use a standard motor valve. • Never use a relief valve that exceeds the hydraulic motor pressure rating. Use of this valve can overload the winch. WARNING

Winch does not hold load when stopped

Brake is badly worn or broken

Replace brake. NOTE: Entire brake assembly must be replaced.

Verify that the hydraulic control valve is an “open- center” type spring return valve and that all hydraulic pressure to the winch is released in the OFF position.

Incorrect hydraulic control valve installed

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. NOTICE

Rotate drum and inspect for bent flanges. Bent drum must be removed and repaired. Remove drum. Inspect bushings and replace if neces- sary. Verify that clutch lever rotates freely. Verify that clutch lever is turned to the release position. Verify that air pressure to the clutch is 50-120 psi (air clutch only). Disassemble winch and verify that driveshaft moves freely and that the driveshaft spring is not damaged. Verify that piston O-ring is not damaged (air clutch only). Connect the winch to a load and alternately power-in and power-out. The rope will usually work itself free. Inspect the rope for damage and replace if necessary. USE EXTREME CAUTION. Remount the winch following specifications and procedures in this manual. Be sure mounting surface is flat to within .020 inch. Use shims if necessary. Be sure mounting bolts are tight.

Bent flange on drum

Worn drum bushings

Freespool clutch is not fully disengaged

Clutch is damaged

Difficulty unspooling rope

Rope is bound up on drum

Drum binds, because improper mounting causes winch to twist

Ambient temperature too low

Run the winch for several minutes to warm the gearbox to operating temperature.

WARN INDUSTRIES 16

WARN INDUSTRIES 5

KNOW YOUR WINCH Know Your Winch Before you begin, you should familiarize yourself with your WARN winch and each of its components. Hydraulic For hydraulic winching applications, no product performs better than a WARN Industrial winch. Powerful hydraulic motors allow for extended duty. Hardened steel, two-stage planetary gear trains deliver efficient and reliable operation plus fast line speeds. Like their electric cousins, these products comply with world-wide quality and safety standards. The pressure rating of the winch motor is determined by (a) the maximum allowable pressure at the motor inlet port and (b) the maximum allowable pressure drop across the

FINAL ANALYSIS AND MAINTENANCE

• Keep winch free of dirt, oil, grease, water and other substances. Remove any overflow grease from bearings. • Check all mounting bolts and make sure they are tightened to proper torque. Replace any damaged fasteners. • Periodically check all hydraulic connections to be sure they are tight and free of corrosion. Periodic Preventive Maintenance

• Check rope for visible damage every time winch is operated. Examples of damage are: cuts, knots, mashed or frayed portions, and broken strands. Replace rope immediately if damaged. Failure to replace a damaged rope could result in breakage. • If winch drum continues to turn after controls are released, brake may need to be replaced.

Semi-annually or after each 25 hours of operation

Before first operation

After each use

Check

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.

motor. Pressure drop is defined as the difference between the inlet pressure (P1) and the outlet pressure (P2) at the winch motor. Exceeding the maximum inlet pressure may damage the motor. Exceeding the maximum pressure drop may cause failure of winch components. HYDRAULIC FLUID: The hydraulic fluid used with the winch must be an extreme pressure, anti-wear hydraulic oil with oxidation and corrosion inhibitors. It must contain a foam suppressant, and have a viscosity rating of 100-300 SSU at 15-45 °C.

Check hydraulic connections

X X

Visual check of winch and control valve Inspect rope for damage. Replace rope immediately if damaged. Keep winch, rope and switch control free from contaminants. Use a clean rag or towel to remove any dirt and debris.

Pre-Install Checklist 1 Check to see that you have received the following: • The winch • The winch mounting hardware 2 Upon removing winch from packaging, check for damage including bent or cracked tie rods, tie bars, or housings. Correct any damage before installing winch. 3 Make sure the environment surrounding winch and control pack is free of : • Combustible vapors • Chemical fumes • Oil vapors • Corrosive material 4 Make sure that the air temperature surrounding the winch and control pack stays within 120° F (49° C) and -20° F (-29° C).

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

5 Make sure that the mounting structure can withstand the full rated pull of the winch.

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.

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

WARN INDUSTRIES 6

WARN INDUSTRIES 15

FIRST TIME OPERATING INSTRUCTIONS Spooling In Under No Load WARNING Never touch winch rope or hook while someone else is at the control switch 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.

MOUNTING

Mounting the Winch

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.

CAUTION To prevent accidental activation of the winch and serious injury, complete the winch installation and attach the hook before installing the wiring. WARNING Always choose a mounting location that is sufficiently strong enough to withstand the maximum pulling capacity of your winch. WARNING Never use bolts that are too long.

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

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. (2m) 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. 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 hook strap and hold tension on the winch rope. Slowly power-in the winch by “pulsing” the power-in switch on the control valve 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. 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 control valve until there is minimal slack in the winch rope. Overloading/Overheating This winch is rated for intermittent duty.

Rigging For complete rigging fundamentals, Read the Basic Guide to Winching Techniques, found online at http://www.warn.com.

Mounting Bolts: Use the supplied fasteners whenever possible or SAE Grade 8 bolts of the same thread size. The tie plates, tensioner bracket, and spacers supplied with the winch should NOT be removed. Mounting brackets (if required) should be added to the tie plates and spacers supplied with the winch. Mounting brackets thicker than ½ inch (12mm) in thickness may require longer mounting bolts to be used. The bolt threads must extend a minimum of ¾ inch (19mm) into the drum supports. Bolts that are too long or too short will fail to anchor the winch securely and may cause a failure of the winch mounting. Mounting Brackets: When foot mounting the winch, the mounting plate should be a minimum of ½ inch thick steel. A thinner mounting plate will not support the winch properly and may cause a failure of the winch mounting. Foot mounting plates thicker than 1/2 inch (12mm) will require longer mounting bolts. When side mounting the winch, brackets must be a minimum of 4 inch (100mm) by 4 inch (100mm) by ½ inch (12mm) thick angle iron or larger. Mounting brackets with inadequate thickness may cause a failure of the winch mounting. Side mounting brackets thicker than 1/2 inch (12mm) will require longer mounting bolts. 1 Make sure that the mounting surface is flat within +/-0.020 in. (0.50 mm). If the surface is not flat, use shim stock as needed to avoid straining the winch. 2 Torque all mounting bolts to the recommended values on the product data sheet. 3 Use the mounting hole locations provided on the product data sheet.

WARN INDUSTRIES 14

WARN INDUSTRIES 7

MOUNTING Mounting Configurations

FIRST TIME OPERATING INSTRUCTIONS

First Time Operating Instructions In this section, we’ll show you the first time operating instructions for effective basic winching. For complete winch operation and techniques read the Basic Guide to Winching Techniques found online at http://www.warn Clutch Operation: WARNING Never engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving. 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. 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 WARNING Never operate winch with less than 5 wraps of rope around the drum. Rope could come loose from the drum, as the rope attachment to the drum is not designed to hold a load. WARNING Always keep hands clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out. System Check Once you have performed a system check, you are ready to confirm winch function. • Recheck mounting hardware for loose bolts, etc. • Be sure all hydraulic system components and connections are correct • Be sure all connections are tight and secure • Check motor rotation: The drum should rotate counterclockwise when viewed from the motor end when hydraulic fluid is supplied to Port A of the motor. • To ensure maximum hydraulic motor life, the winch should be operated for one hour at no more than 30% of rated load before application of full load.

WARNING Always wear heavy leather 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 the winch rope might be under. Disengage the clutch. Then freespool by manually spooling out enough winch rope for the winching operation. See The Basic Guide to Winching Techniques for more information. WARNING Always use hook strap whenever spooling winch rope in or out, during installation or operation to avoid injury to hands and fingers. Some models may be equipped with a drum retarder to prevent unintended drum rotation during freespool operation. The drum retarder contains a user-adjustable drag setting which improves the spooling of the winch rope and helps maintain the rope’s integrity and life span. Drum Retarder Operation: Set the adjusting screw to provide adequate resistance to the drum rotation during free spooling. Once the desired resistance is reached, cinch down the Jam nut to lock the placement of the adjusting screw.

This section illustrates the recommended mounting configurations for the Series XL winch. This section does not include every possible mounting configuration, but illustrates the correct methods for mounting the winch. Foot Down Mounting Position: DO NOT wind the rope from the top of the drum. DO NOT position the load direction away from the mounting surface.

Foot Down Mounting Position: DO wind the rope from the bottom of the drum.

Jam Nut

Foot Forward Mounting Position: DO wind the rope from the top or bottom of the drum towards the direction of the mounting surface.

Drum Support

Adjusting Screw

Side Mount: DO wind the rope from the top of the drum.

Spooling In Under Load WARNING Never exceed winch’s rated line pull. 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.

WARN INDUSTRIES 8

WARN INDUSTRIES 13

FIRST TIME OPERATING INSTRUCTIONS

MOUNTING

Installing the Winch rope WARNING 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 Never exceed winch or winch rope capacity listed on product data sheet. Double line using a snatch block to reduce winch load. NOTICE Always raise tensioner when installing rope. The winch rope may be spooled on the winch drum in either direction. Always follow the guidelines for pull direction listed under the section “Mounting Configurations”. 1 Insert pry bar between roller tensioner and drum.

Mounting Bolt Patterns

4. Release roller tensioner.

1.50

5 Insert the end of the winch rope into the anchor hole in the drum flange. NOTE: A small piece of tape around the end of the winch rope will make installation much easier. The winch rope must extend to the other end of the hole. Set Screws

7.50

8x . 70 Mounting Hole

Pin Holes

12.00 (18.00)

1.50

6 Torque the set screws to 12-15 lb-ft (16-20 N-m). Do not overtighten as this may cause the screw threads to be damaged. Ensure both (2) set screws secure the winch rope. Ensure both (2) set screws do not protrude from the drum flange. 7. With end of rope securely installed, carefully wind the rope evenly onto the drum. Keep the rope under tension at all times. WARNING Never operate winch with less than 5 wraps of wire rope around the drum. Rope could come loose from the drum. 8. Once five wraps has been spooled onto the drum, use a pry bar to lift roller tensioner and remove the 1/4” pin. Carefully lower the tensioner.

2. Lift roller tensioner until pin holes are aligned.

BOLT PATTERN - SERIES XL FOOT MOUNTING STANDARD DRUM (LONG DRUM)

4x . 70 Mounting Hole

3. Insert a 1/4” pin into the pinholes.

12.00 (18.00)

1.50

BOLT PATTERN - SERIES XL SIDE MOUNTING STANDARD DRUM (LONG DRUM)

9. Always operate winch with a minimum of 5 wraps of wire rope around the drum. Rope could come loose from the drum.

WARN INDUSTRIES 12

WARN INDUSTRIES 9

HYDRAULIC CONNECTIONS Hydraulic Winches: General Information

FIRST TIME OPERATING INSTRUCTIONS

Brake System

Freespool Clutch Operation

WARNING Never exceed the maximum recommended hydraulic pressure or flow for any of the components used. WARNING Always use a tandem-center type control valve ( A & B work ports blocked) to insure proper brake operation. WARNING Always make sure all hydraulic system components are functioning correctly. WARNING Never use a standard motor valve. WARNING Always connect the winch to the hydraulic system as shown in the hydraulic schematic. NOTE: The hydraulic system diagram and component descriptions are provided for general reference. Consult a knowledgeable hydraulics representative for specific recommendations on component selection, interconnection, layout, and best practice. The pressure rating of the winch motor is determined by (a) the maximum allowable pressure at the motor inlet port and (b) the maximum allowable pressure drop across the motor. Pressure drop is defined as the difference between the inlet port pressure and the outlet port pressure at the winch motor. Exceeding the maximum inlet pressure may damage the winch motor. Exceeding the maximum pressure drop may cause failure of winch components.

WARN Series XL winches are equipped with a 2-part hydraulic braking system. 1 Dual counterbalance valves mounted to the winch motor provide dynamic braking to control the load when it is moving (i.e. power out function). 2 A spring applied hydraulically released (SAHR) disc brake prevents movement of the winch drum and load when the winch is stopped (i.e. control valve OFF position).

The recommended operating temperature range of the hydraulic motor is 100°F to 150°F (38°C to 66°C). The maximum operating temperature range is -6°F to 180°F (-21°C to 82°C). Do NOT exceed the flow rating of the hydraulic motor. See the product data sheet for specific hydraulic specifications. HYDRAULIC FLUID: The hydraulic fluid used with the winch must be an extreme pressure, anti-wear hydraulic oil with oxidation and corrosion inhibitors. It must contain a foam suppressant, and have a viscosity rating of 100-300 SUS at 60°F to 115°F (15°C to 46°C). The recommended nominal filtration level is 10 microns or finer.

WARNING Always ensure the clutch is fully engaged before operating the winch. WARNING Never engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving. WARNING Never operate the winch motor for a prolonged period while the clutch is in freespool mode. WARNING Never exceed 120 psi air pressure. WARNING Never use oil or other liquids to operate the air clutch. WARN Series XL winches are equipped with either a manual or air operated freespool clutch depending on the model. The freespool clutch allows the operator to rapidly spool out the winch rope. The freespool clutch disconnects the winch drum from the winch brake. MANUAL CLUTCH OPERATION The manual freespool clutch is operated by depressing the detent latch and turning the clutch lever as indicated on the winch label. AIR CLUTCH OPERATION The air freespool clutch is operated by application of air pressure to the fitting supplied on the winch gearbox housing. The fitting is designed to accept ¼” rigid plastic tubing.

Both braking components are designed to operate in either direction, which allows flexibility in the rope winding direction.

Never attempt to adjust or remove the Counterbalance Valves installed in the winch hydraulic manifold.

In order for the brake system to function properly, the winch must be connected to the proper system Control Valve. The Control Valve must be a 3-position, 4-way, spring return valve as shown in the Hydraulic Schematic. The Control Valve and hydraulic plumbing must allow both motor ports (Port A and Port B) to drain freely to the hydraulic system reservoir in the center (OFF) position. Hydraulic system back pressure (return line pressure) must not exceed 100 psi. Use of the incorrect control valve or plumbing may cause failure of the brake system.

1. To release the clutch (freespool operation): Apply 50-120 psi air pressure to the air fitting.

2. To engage the clutch (winch operation): Remove air pressure (0 psi) from the air f itting.

WARN INDUSTRIES 10

WARN INDUSTRIES 11

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