MOUNTING WINCH
two soft plugs into fairlead holes with
hammer. This is an anti-theft device.
Choose a mounting location that is
sufficiently strong enough to withstand
the loads you intend to winch. Only
the mounting orientation shown are
possible for safe winching operation. All
others are improper and inappropriate.
The use of recommended bolt and
lock washer combinations torqued
to recommended levels will prevent
vibration during operation. The
mounting details indicate the proper
torque levels.
Remember the winch rope must
always spool onto the drum as
indicated by the drum rotation decal.
Control Pack Installation
Refer to the following diagrams for
proper mounting orientation.
the instructions included in the WARN
The alignment between the winch
mounting system kit. Use the bracket
gear housing and the winch drum
included in the kit.
support is of prime importance for the
life of your winch. For winches that are
Mounting Bolt Pattern:
not mounted on a factory mounting
10" x 4.5", 254 mm x 114.3 mm
plate, it is recommended to use a winch
mounting bracket as shown below,
applying the illustrated hole pattern,
hole diameters and tolerances.
1) Place the winch on the mounting
plate, align the upper holes in the gear
case and drum end support with the
upper holes in the mounting plate.
Secure loosely with two 7/16" - 14x1-
1/2" hex head cap screws with lock
washers in the upper holes.
2) Align holes in fairlead with holes
in mounting plate and winch. Insert
two 7/16" - 14x1-1/2" hex head cap
screws with lock washers through
fairlead and secure loosely to winch
Mounting Details:
with 7/16" square nuts. (Cavities have
(1) Smooth and fl at, thickness = 1/4" (6.4 mm)
been provided in the gear case and
(2) 7/16" (11.1 mm) lockwasher X 4
drum support for square nuts.) Any
(3) 7/16-14 X 1 1/2" long, grade 5 bolt X 4
deviation from this standard mounting
will be shown on the mounting kit
installation instructions.
NOTE: Drum end support must be
tightened first. Lightly tighten gear
side and align with end support. Assure
that drum rotates freely with clutch
disengaged. If drum binds or does not
rotate freely, relocate end support and
repeat process. On models without
clutch, check for binding after electrical
connections are made.
3) Tighten the above cap screws to
45-50 ft. lbs. (61-68Nm) torque. Install
All manuals and user guides at all-guides.com
MOUNTING
Always choose a
mounting location
that is suffi ciently
strong to withstand
the maximum
pulling capacity of
your winch.
Always complete the
winch installation
and attach the hook
before installing the
wiring.
Mount the control pack according to
Never use bolts that
are too long.
Plate Thickness
Bolt Length
1/4" (7 mm)
1.5" (40 mm)
3/8" (10 mm)
1.5" (40 mm)
1/2" (13 mm)
1.75" (45 mm)
Torque 45-50 ft. lbs. (61-68Nm)
WARN INDUSTRIES
7
ELECTRICAL CONNECTIONS
WARNING
WARNING
Never route
electrical cables
across sharp edges.
WARNING
Never route
electrical cables near
parts that get hot.
WARNING
WARNING
Never route
electrical cables
through or near
moving parts.
WARNING
WARNING
Always place the
supplied terminal
boots on wires
and terminals
as directed by
the installation
instructions.
WARNING
Always insulate and
protect all exposed
wiring and electrical
terminals.
38292D7
38292D7
ELECTRICAL CONNECTIONS
Use the included insulating boots
on 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
diagrams on the following page.
Electrical Diagrams:
Red Cable (72")
Battery
WARN INDUSTRIES
8
To Motor Field #2
To Motor
Armature
To Motor
Winch
Field #1
Motor
Ground Wire
Black Cable
(72")