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ORIGINAL INSTRUCTIONS
PowerPlant
Winch
Installation Guide
Every winching situation has the potential for personal injury. In order to minimize that risk, it is important to read this guide and The Basic Guide to
Winching Techniques carefully. Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented. In this
guide we provide important safety information and instructions on how to install your winch. Please read the Basic Guide to Winching Techniques
for information on how to properly use your winch and proper rigging techniques.
Please keep this manual and other product literature found in this kit for future reference. In this kit you will find the following pieces of literature:
Winch Installation Guide, Basic Guide to Winching Techniques, Specification and Performance Data, Product Warranty, Replacement Parts List and
other product literature specific to some products.
SYMBOL INDEX
SYMBOL
EXPLANATION
Read All Product
Literature
Always Wear Hearing and
Eye Protection
Never Use Winch as a
Hoist
Properly Seat Load in
Throat of Hook
Wind Rope on Bottom of
Drum
Finger/Fairlead Crushing
Hazard
Hand Piercing/Cutting
Hazard
Explosion/Bursting
Hazard
Never Route Electrical
Cables through Sharp
Edges Hazard
Avoid Installing Electrical
Cables around Pinch and
Wear/Abrasion Points
SYMBOL
EXPLANATION
Always Wear Leather
Gloves
Do Not Move People
Always Use Supplied
Hook Strap
Never Apply Load to
Hook Tip or Latch
Never Wind Rope Over
Top of Drum
Fairlead Pinch Point
Hot Surface Hazard
Fire and Burn Hazard
Never Route Electrical
Cables through or near
Moving Parts Hazard
Exposed Wiring Hazard,
Insulate Exposed Wiring
and Terminals
Never Hook Back on
Rope
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Table of Contents
Summary of Contents for Warn 91800
- Page 1 ORIGINAL INSTRUCTIONS SYMBOL INDEX SYMBOL EXPLANATION SYMBOL EXPLANATION Read All Product Always Wear Leather Literature Gloves PowerPlant Winch Always Wear Hearing and Do Not Move People Eye Protection Installation Guide Never Use Winch as a Always Use Supplied Hoist Hook Strap Every winching situation has the potential for personal injury.
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Page 2: General Safety Precautions
GENERAL SAFETY PRECAUTIONS GENERAL SAFETY PRECAUTIONS Warnings and Cautions WARNING WARNING WARNING As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. Each message has a specifi c MOVING PARTS ENTANGLEMENT HAZARD purpose. WARNINGS are safety messages that indicate MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to a potentially hazardous situation, which, if not avoided... - Page 3 GENERAL SAFETY PRECAUTIONS GENERAL SAFETY PRECAUTIONS WARNING CAUTION WARNING WARNING MOVING PARTS ENTANGLEMENT HAZARD RISK OF EXPLOSIONS OR FIRE RISK OF BURSTING Failure to observe these instructions could lead to Failure to observe these instructions could lead to Failure to observe these instructions could lead to minor or moderate injury.
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Page 4: Safe Working Conditions
KNOW YOUR WINCH This manual provides instructions on how to Know Your Winch Before you begin, you should familiarize yourself with your WARN winch and each of its components: install your WARN winch system and initial operating instructions. Please read the Basic... -
Page 5: Air Intake Connection
Winch mounting kits are available from your compartment. Standard: 10” x 4.5”, 254 mm x 114.3 mm WARN Dealer to satisfy nearly all applications. For 1. Locate air intake kit contents. Place the small information on available kits, contact your WARN hose clamp onto end of the intake hose. -
Page 6: Electrical Connections
ELECTRICAL CONNECTIONS FIRST TIME OPERATING INSTRUCTIONS Step 3 - Install the Wiring Step 5 - First Time Operating Instructions Clutch Operation Step 4 - System Check When the clutch is engaged, the gear train is Perform system check: To prevent serious injury or death. Always WARNING Winch Operation: coupled to the wire rope drum and power can... - Page 7 Air Hose Fitting Spooling with an Assistant: Have the assistant 1. Your WARN air compressor accessory kit hold the hook strap putting as much constant supplies you with everything you need to tension on the winch rope as possible. While...
- Page 8 FIRST TIME OPERATING INSTRUCTIONS FINAL ANALYSIS AND MAINTENANCE Double-line rigging (see The Basic Guide to exit the vehicle with a load on the winch rope. Before fi rst After each Check Every 90 days Winching Techniques) will reduce the amperage Tensioning the winch rope is critical to ensure a operation draw, and reduce heat buildup in the motor.
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