WARN INDUSTRIES
7 38292D7
MOUNTING
MOUNTING WINCH
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.
Refer to the following diagrams for
proper mounting orientation.
The alignment between the winch
gear housing and the winch drum
support is of prime importance for the
life of your winch. For winches that are
not mounted on a factory mounting
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
with 7/16” square nuts. (Cavities have
been provided in the gear case and
drum support for square nuts.) Any
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
WARNING
Never
use bolts that
are too long.
Mounting Details:
(1)
Smooth and fl at, thickness = 1/4” (6.4 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 45-50 ft. lbs. (61-68Nm)
two soft plugs into fairlead holes with
hammer. This is an anti-theft device.
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.
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
1/4” (7 mm)
1.5” (40 mm)
3/8” (10 mm)
1.5” (40 mm)
1/2” (13 mm)
1.75” (45 mm)
WARN INDUSTRIES
38292D7
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.
Refer to the electrical circuit
diagrams on the following page.
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.
WARNING
Always
insulate and
protect all exposed
wiring and electrical
terminals.
Battery
Red Cable (72”)
To Motor Field #2
To Motor
Armature
Ground Wire
To Motor
Field #1
Winch
Motor
Black Cable
(72”)
