SYMBOL INDEX
ORIGINAL INSTRUCTIONS
SYMBOL
EXPLANATION
SYMBOL
EXPLANATION
Read the Instruction
Manual
Always Wear Leather
Gloves
Always Wear Hearing
and Eye Protection
Always Use Supplied
Hook Strap
Wind Rope on Bottom
of Drum
Never Wind Rope Over
Top of Drum
Finger/Fairlead Crushing
Hazard
Fairlead Pinch Point
Explosion/Bursting
Hazard
Fire and Burn Hazard
Fairlead 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 will set forth many of the basic rules of
safe winch operation. Please read The Basic Guide to Winching Techniques for more
information on your winch and proper rigging techniques. Remember, because every
winching situation is different, your constant good judgment and consistent focus on
safety are of great importance.
TABLE OF CONTENTS:
SAFETY
Symbol Index ............................................................................................................... 2
General Safety Precautions ..................................................................................... 3-5
FAIRLEAD INSTALLATION INSTRUCTIONS
Series Large Frame Winches: ..................................................................................... 6
Series XL Frame Winches: .......................................................................................... 8
Large Frame Winches (M12000, M15000, 16.5Ti): ....................................................11
Mid-Frame Winches: ................................................................................................. 12
Warn Industries Inc.
12900 SE Capps Road
Clackamas, OR 97015
USA
Customer Service: (800) 543-WARN
(9276)
International: (503) 722-3008
Fax: (503) 722-3000
WARN® and the WARN logo are registered trademarks of Warn Industries, Inc.
© 2012 Warn Industries, Inc.
WARN INDUSTRIES * WINCH
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www.warn.com
WARN INDUSTRIES * WINCH
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GENERAL SAFETY PRECAUTIONS
Warnings and Cautions
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!
WARNING
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 use excessive effort to freespool winch rope.
• Always use proper posture/lifting technique or
get lifting assistance while handling and installing
product.
• Always spool the rope onto the drum in the
direction specified by the winch warning label on
the winch and/or documentation. This is required
for the automatic brake (if so equipped) to function
properly.
• Always spool the winch rope onto the drum as
indicated by the drum rotation label.
WARNING
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.
• Always wear heavy leather gloves when handling
winch rope.
• Always use supplied hook strap whenever spooling
winch rope in or out, during installation and during
operation.
GENERAL SAFETY PRECAUTIONS
CAUTION
WARNING
CHEMICAL AND FIRE HAZARD
Failure to observe these instructions could
lead to serious injury or death.
• Always verify area is clear of fuel lines, fuel tank,
brake lines, electrical wires, etc., when drilling.
MOVING PARTS ENTANGLEMENT
HAZARD
Failure to observe these instructions could
lead to minor or moderate injury.
To avoid injury to hands or fingers:
• Never leave remote control where it can be
activated during free spooling, rigging, or when the
winch is not being used.
• Never leave the winch remote control plugged in
when installing, freespooling, rigging, servicing or
when the winch is not being used.
Installation Safety:
• Always choose a mounting location that is
sufficiently strong to withstand the maximum pulling
capacity of your winch.
• Always use grade 5 (grade 8.8 metric) or better
hardware.
• Never weld mounting bolts.
• Always use factory approved mounting hardware,
components, and accessories.
• Never use bolts that are too long.
• 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.
WARN INDUSTRIES
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WARN INDUSTRIES
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FAIRLEAD INSTALLATION
STEP 1: Install Fairlead such that the wire rope/cable coming out of
the winch is horizontal and passes through the center of the rollers when
spooling on the first layer of rope next to the drum as shown in the images
below.
Proper centering of Rope:
Improper centering of Rope:
FAIRLEAD INSTALLATION
WARNING
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
Series Large Frame Winches:
The following pictures depict the position of the fairlead when the winch is
mounted in a foot-down and foot-forward position.
Foot-Down Mounting:
Foot-Down Fairlead Mounting Instructions:
STEP 1: Install bolts from inside mounting bracket as shown.
Complete fairlead installation with lock washers and nuts.
Improper Fairlead Placement:
STEP 2: Foot Down Winch Mounting: Install winch to mounting
bracket with bolts and lock washers for each mounting hole available as
shown in the figure.
Never attach fairlead to the side
mounting holes of the winch. This will
cause the fairlead to be mounted too
high and will severely reduce rope life.
WARN INDUSTRIES
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WARN INDUSTRIES
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FAIRLEAD INSTALLATION
FAIRLEAD INSTALLATION
Foot-Forward Fairlead/Winch Mounting Instructions:
STEP 1: Front mounting holes must be used in foot forward
mounting. Use a bolt and lock washer for each mounting hole available as
shown.
Only winches with eight (8) threaded mounting holes in the drum supports
may be mounted foot-down. IMPORTANT: All eight (8) bolts must be
used for foot-down mounting.
STEP 2: Bottom mounting holes must be used in foot forward
mounting. This will reduce deformation of the mounting plate. Use a bolt
and lock washers for each mounting hole as shown.
Foot-Forward Mounting:
WARNING
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
Series XL Frame Winches:
The following pictures depict the position of the fairlead when the winch is
mounted in a foot-down and foot-forward position.
WARNING
Foot-Down Mounting:
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
WARN INDUSTRIES
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WARN INDUSTRIES
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FAIRLEAD INSTALLATION
FAIRLEAD INSTALLATION
Foot-Down Fairlead/Winch Mounting Instructions:
Foot-Forward Rope Down Fairlead/Winch Mounting Instructions:
STEP 1: Mount fairlead to mounting bracket with bolts, lock washers
and nuts for each available mounting hole as shown.
STEP 1: Mount winch to foot forward mounting bracket with a
mounting bolt and lock washer at each available mounting hole.
STEP 2: Mount the fairlead bracket so the cutout is aligned with the
cutout on the winch mounting bracket.
STEP 3: Mount fairlead to fairlead mounting bracket with a bolt, lock
washer and nut at each available mounting hole as shown.
STEP 2: Mount winch to mounting plate with a mounting bolt and
lock washer at each available mounting hole as shown.
Foot-Forward Mounting Rope Up:
WARNING
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
NOTE: Cable must spool off the bottom of the drum when mounted Foot
Down
Foot-Forward Mounting Rope Down:
WARNING
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
WARN INDUSTRIES
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Foot-Forward Rope Up Fairlead/Winch Mounting Instructions:
STEP 1: Mount winch to foot forward mounting bracket with a
mounting bolt and lock washer at each available mounting hole.
STEP 2: Mount the fairlead bracket so the cutout is aligned with the
cutout on the winch mounting bracket.
WARN INDUSTRIES
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FAIRLEAD INSTALLATION
FAIRLEAD INSTALLATION
Foot-Forward Fairlead/Winch Mounting:
STEP 3: Mount fairlead to fairlead mounting bracket with a bolt, lock
washer and nut at each available mounting hole as shown.
STEP 1: Front mounting holes must be used in foot forward
mounting. Use a bolt and lock washer for each mounting hole available
as shown.
STEP 2: Bottom mounting holes must be used in foot forward
mounting. This will reduce deformation of the mounting plate. Use a bolt
and lock washers for each mounting hole as shown. NOTE: Use flat
washers as spacers between bottom of winch and top of mounting
plate to fill any gaps.
Large Frame Winches (M12000, M15000, 16.5Ti):
The following pictures depict the position of the fairlead when the winch is
mounted in a foot-forward position.
Mid-Frame Winches:
Foot-Forward Mounting:
The following pictures depict the position of the fairlead when the winch is
mounted in a foot-down and foot-forward position.
WARNING
Foot-Down Mounting:
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
Foot-Down Fairlead/Winch Mounting Instructions:
STEP 1: Mount fairlead to mounting bracket with bolts, lock washers
and nuts for each available mounting hole as shown.
WARN INDUSTRIES
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WARN INDUSTRIES
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FAIRLEAD INSTALLATION
FAIRLEAD INSTALLATION
Foot-Forward Fairlead/Winch Mounting Instructions:
STEP 1: Front mounting holes must be used in foot forward
mounting. Use a bolt, lock washer, and square nut for each mounting hole
available as shown.
STEP 2: Mount winch to mounting plate with a mounting bolt, lock
washer, and square nut at each available mounting hole as shown.
Foot-Forward Fairlead/Winch Mounting Instructions:
WARNING
Always install
rope in the
direction
specified on the
drum rotation
label, or
brake will not
function.
WARN INDUSTRIES
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WARN INDUSTRIES
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