Fairlead Installation Guide

Transcription

1 ORIGINAL INSTRUCTIONS SYMBOL INDEX SYMBOL EXPLANATION SYMBOL EXPLANATION Fairlead Installation Guide Read the Instruction Manual Always Wear Hearing and Eye Protection Always Wear Leather Gloves Always Use Supplied Hook Strap 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. Wind Rope on Bottom of Drum Finger/Fairlead Crushing Hazard Never Wind Rope Over Top of Drum Fairlead Pinch Point TABLE OF CONTENTS: SAFETY Symbol Index... 2 General Safety Precautions INSTRUCTIONS Series Large Frame Winches:... 6 Series XL Frame Winches:... 8 Large Frame Winches (M12000, M15000, 16.5Ti):...11 Mid-Frame Winches: Explosion/Bursting Hazard Fire and Burn Hazard Warn Industries Inc SE Capps Road Clackamas, OR USA Customer Service: (800) 543-WARN (9276) International: (503) Fax: (503) WARN and the WARN logo are registered trademarks of Warn Industries, Inc Warn Industries, Inc. * WINCH 1 * WINCH 2

2 GENERAL SAFETY PRECAUTIONS GENERAL SAFETY PRECAUTIONS Warnings and Cautions CAUTION As you read these instructions, you will see S, CAUTIONS, NOTICES and NOTES. Each message has a specifi c purpose. S 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 S 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! FALLING OR CRUSHING HAZARD 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 specifi ed 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 label. MOVING PARTS ENTANGLEMENT HAZARD 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. Installation Safety: Always choose a mounting location that is suffi ciently 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. CHEMICAL AND FIRE HAZARD 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 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. 3 4

3 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 fi rst layer of rope next to the drum as shown in the images below. Proper centering of Rope: Series Large Frame Winches: mounted in a foot-down and foot-forward position. Foot-Down Mounting: Improper centering of Rope: 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 fi gure. 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. 5 6

4 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: Series XL Frame Winches: mounted in a foot-down and foot-forward position. Foot-Down Mounting: 7 8

5 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. Foot-Forward Rope Down 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. 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: NOTE: Cable must spool off the bottom of the drum when mounted Foot Down Foot-Forward Mounting Rope Down: 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. 9 10

6 STEP 3: Mount fairlead to fairlead mounting bracket with a bolt, lock washer and nut at each available mounting hole as shown. Foot-Forward Fairlead/Winch Mounting: 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): mounted in a foot-forward position. Foot-Forward Mounting: Mid-Frame Winches: mounted in a foot-down and foot-forward position. Foot-Down Mounting: 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

7 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: 13 14