Installation Instructions - Warn 9.0Rc Manual

GENERAL SAFETY PRECAUTIONS
C AU T I O N
CUT AND BURN HAZARD
Failure to observe these instructions
could lead to minor or moderate
injury.
To avoid injury to hands or fingers:
• Always wear heavy leather gloves when
handling a rope.
• Never let rope slip through your hands.
To avoid injury to hands or fingers:
• Always be aware of possible hot surface at
winch motor, drum or rope during or after
winch use.
N OT I C E
AVOID WINCH AND EQUIPMENT
DAMAGE
• Always avoid continuous "Power Out". Heat
build up from continous power out may
damage the rope.
• Never expose the rope to harsh detergents,
fuels, oils, or Anti-freeze.
• Always use a chafe protector on all sharp
edges to protect rope.
• Never allow the rope to contact sharp
objects. Severe damage may result.
• Always respool rope in even wraps following
any angled winching activities.
• Always avoid continuous side pulls which can
pile up rope at one end of the drum. This can
damage your rope or winch.
• Always ensure the clutch is fully engaged or
disengaged.
• Never use winch to tow other vehicles. Shock
loads can momentarily exceed capacity of rope
and winch.
• Always use care to not damage your frame
when anchoring your vehicle during a winching
operation.
• Never "jog" rope under load. Shock loads can
momentarily exceed capacity of rope and
winch.
• Never use winch to secure a load during
transport.
• Never submerge winch in water.
• Always store the remote control in a
protected, clean, dry area.
4

INSTALLATION INSTRUCTIONS

Winch Mounting
• Choose a mounting location that is sufficiently
strong enough to withstand the loads you intend
to winch.
• Find the diagrams of your winch on the
following pages. Refer to them for
proper orientation. Only the mounting
orientation shown is possible for safe winching
operation. All others are improper and
inappropriate.
• The rope must always spool onto the drum as
indicated by the drum rotation decal.
• The use of recommended bolt and lock washer
combinations torqued to recommended levels will
prevent vibration during operation.
Find the diagrams of your winch on the
following pages. Refer to them for
proper torque levels.
WA R N I N G
To avoid serious injury or death from
electrical fire:
• Never route electrical
cables:
-Across any sharp edges.
-Through or near moving
parts.
-Near parts that become
hot.
• Always insulate and protect
all exposed wiring and
electrical terminals.
• Always install terminal boots
as directed in installation
instructions.
Electrical Connections
• Make sure to use the insulating boots on the
exposed connections to prevent electrical
shorting. Route battery connection cables in areas
which will not cause them to chafe or cut through
the insulation causing a potential short circuit.
• Upon completion of installation, check winch for
proper operation.
Refer to the electrical circuit diagram
below and the diagrams for your winch
on the following pages.
ELECTRICAL CIRCUIT DIAGRAM
2
1
ARMATURE
FIELD
3
4
WHITE
2
RED
6
GREEN
4
BROWN
1
+ 12V
BLACK
3
SCHEMATIC DIAGRAM
Solenoid Pack Installation
• Mount the control pack according to the
instructions included in the WARN mounting
system kit. Use the bracket included in the kit.
• To mount the control pack directly to the winch,
order control pack bracket part number 26368.
• The control pack mounting fasteners may also be
moved to the unused holes in the control pack
base plate for additional mounting flexibility.
5
REMOTE
CONTROL
SWITCH