GENERAL SAFETY PRECAUTIONS
TROUBLESHOOTING
Problem Possible cause
Corrective action
WARNING
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
Powered by FlippingBook