Warn Winch Basic Diagnostics. The following Trouble Shooting Tips are a collection of the most frequent problems that we encounter with Warn Winches. Most of these are simple electrical problems and are easily solved. We are here to answer questions and schedule Warn winch service Monday - Friday 8:00AM - 5:30PM EST. Toll Free 1-800-257-4294.

WARN INDUSTRIES * WINCH 7 MOUNTING WINCH MOUNTING WINCH Choose a mounting location that is suffi ciently strong enough to withstand the loads you intend to winch. Only the mounting orientations 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. Refer to the following diagrams for proper mounting orientation.

WARNING Never use bolts that are too long. Mounting Details: (1) Smooth and fl at, thickness = 5/16” (8 mm) (2) 7/16” (11.1 mm) lockwasher X 4 (3) 7/16-14 X 1 1/2” long, grade 5 bolt X 4 Torque 50-55 ft. Hyt tc 365 programming software download. (68-75Nm) (4) 7/16” (11.1 mm) fl atwasher X 6 (5) 7/16-14 X 1 3/4” long, grade 5 bolt X 2 Torque 50-55 ft. (68-75Nm) Control Pack Installation Mount the control pack according to the instructions included in the WARN mounting system kit. Use the bracket included in the kit.

The control pack mounting fasteners may also be moved to the unused holes in the control pack base plate for additional mounting fl exibility. Mounting Bolt Pattern: 10” x 4.5”, 254 mm x 114.3 mm WARNING Always choose a mounting location that is suffi ciently strong to withstand the maximum pulling capacity of your winch. WARNING Always complete the winch installation and attach the hook before installing the wiring.

Plate Thickness Bolt Length 5/16” (8 mm) 1.5” (40 mm) 3/8” (10 mm) 1.5” (40 mm) 1/2” (13 mm) 1.75” (45 mm) WARN INDUSTRIES * WINCH 8 ELECTRICAL CONNECTIONS Electrical Diagrams: 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. WARNING Never route electrical cables across sharp edges. WARNING Never route electrical cables near parts that get hot.

WARNING Never route electrical cables through or near moving parts. WARNING Always place the supplied terminal boots on wires and terminals as directed by the installation instructions. Battery Recommendations A fully charged battery and good connections are essential to the proper operation of your winch. The minimum requirement for a 12 volt DC battery is 650 Cold Cranking Amps. WARNING Always insulate and protect all exposed wiring and electrical terminals. Pin # Color 1 Brown 2 White 3 Black 4 Green 5 6 Red 1 2 3 6 5 4 Black Red White Brown Green A F1 F2.

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