Warn XD9000i User Manual download pdf (Page 7)

WARN INDUSTRIES

OPERATING INSTRUCTIONS

Remote Control Switch

Do not leave the remote

plugged into the winch when not in

use. Leaving the remote plugged

in, may result in a dangerous

condition and/or battery drain.

Clutch Operation

When the clutch is engaged,

the gear train is coupled to the

wire rope drum and power can be

transferred from the winch motor.

When the clutch is disengaged it

is in the freespool position and the

gear train and wire rope drum are

uncoupled allowing the drum to

rotate freely.

The clutch lever, located on

the winch housing opposite the

motor, controls the clutch position.

To prevent damage, always fully

engage or fully disengage the clutch

lever.

Vertical/Horizontal Remote:

Disengaged:

Engaged:

WARNING

Never engage or

disengage clutch

if winch is under

load, winch rope

is in tension or

drum is moving.

Spooling Out

Freespooling is generally the

quickest and easiest way to spool

out wire rope. Before freespooling

wire rope out from the winch,

power out enough rope to remove

any tension the wire rope might be

under. Disengage the clutch. Then

freespool by manually spooling out

enough wire rope for the winching

operation. See The Basic Guide

to Winching Techniques for more

information.

Always leave at least 5 wraps

of rope on the drum.

Spooling In Under Load

Never exceed winch’s rated

line pull.

Power-in the wire rope evenly

and tightly on the drum. This

prevents the outer wire wraps

from sinking into the inner wraps,

binding, and damaging the wire

rope.

Avoid shock loads when

spooling, by pulsing the control

switch to take up wire rope slack.

Shock loads can momentarily far

exceed the winch and rope ratings.

Spooling In Under No Load

Spooling with an Assistant: Have

the assistant hold the hook strap

putting as much constant tension

on the wire rope as possible. While

keeping tension, the assistant

should walk toward the winch while

you operate the control switch

spooling in the wire rope. Release

the switch when the hook is a

minimum of 6 ft. (2 m) from the

fairlead opening.

Spool in the remainder for

storage as directed below.

Spooling Alone: Arrange the wire

rope to be spooled so it will not

kink or tangle when spooled. Be

sure any wire rope on the drum is

tightly and evenly layered. Spool

enough wire rope to complete the

next full layer on the drum.

Tighten and straighten the layer.

WARNING

Never operate

winch with less

than 5 wraps

of rope around

the drum. Rope

could come

loose from the

drum, as the

rope attachment

to the drum is

not designed to

hold a load.

WARNING

Always

take time to

fully understand

your winch and

the winching

operation by

reviewing The

Basic Guide

to Winching

Techniques

included with

your winch.

NOTICE

Do Not power-

out rope more

than 30 ft.

without allowing

the winch to cool

for 20 minutes

before powering

rope back in.

Instead, place

the clutch in

freespool and

pull the rope off

by hand.

WARN INDUSTRIES

OPERATING INSTRUCTIONS & STRETCHING WIRE ROPE

OPERATING INSTRUCTIONS

Cont.

Repeat process until the hook is a

minimum of 6 ft. (2 m) from the

fairlead opening.

Spool in the remainder for

storage as directed below.

Spooling Remainder for Storage

When the hook is within 6 ft. (2 m)

of the fairlead, disconnect the hook

from the anchor or load. Hold onto

the supplied hook strap and hold

tension on the winch rope. Slowly

power-in the winch by “pulsing”

the power-in switch on the remote

control until the hook is within

3 ft. (1 m) of the fairlead. Stop

winching in and attach the hook

to a suitable anchor point on the

vehicle.

DO NOT POWER THE

HOOK INTO THE FAIRLEAD.

This could cause damage to the

fairlead. Once the hook is suitably

attached to the vehicle, power-in

the remaining slack in the winch

rope by “pulsing” the power-in

switch on the remote control until

there is minimal slack in the winch

wire rope.

Overloading/Overheating

This winch is rated for

intermittent duty. When the motor

approaches stall speed, very rapid

heat buildup occurs which may

cause motor damage.

Double-line rigging (see

The Basic Guide to Winching

Techniques) will reduce the

amperage draw, and reduce heat

buildup in the motor. This allows

longer continual use.

STRETCHING WIRE ROPE

The life of a wire rope is

directly related to the use and care

it receives. During its ﬁ rst use, a

new wire rope must be spooled

onto its drum under a load of at

least 1000 lbs. (454 kgs). Use the

following instructions to properly

stretch the wire rope onto the

winch drum.

1) Choose a FLAT AND LEVEL

location that is large enough to run

out the entire length of wire rope.

2) Turn the clutch lever on the

winch to the “Free Spool” position.

Spool out the wire rope to the last

5 wraps on the drum. Once the

wire rope is spooled out, turn the

clutch lever on the winch to the

“Engaged” position.

3) Attach the hook end of the rope

to a suitable anchor point and back

the vehicle away from the anchor

point until there is very little slack in

the wire rope. Before getting out of

the vehicle, set the parking brake,

place the vehicle in gear or park

and turn the vehicle off.

4) Connect the remote control to

the winch. Standing approximately

8 ft. (2.44 m) away from the

winch, power-in the winch until

all of the slack is wound onto

the winch drum. Disconnect the

remote control from the winch.

Hold tension on the wire rope with

one hand; carefully push the wire

rope to the side of the drum the

wire rope is attached to so there

are no gaps between each coil

on the drum. Be sure to check

that the wire rope is winding off

of the bottom of the drum, not the

top, or the automatic load holding

brake will not function properly.

(If the wire rope is winding off the

top you have powered the winch

“out” instead of “in” on the remote

control).

WARNING

Always keep

hands clear

of winch rope,

hook loop, hook

and fairlead

opening during

installation,

operation, and

when spooling in

or out.

WARNING

Always use

supplied hook

strap whenever

spooling winch

rope in or

out, during

installation or

operation to

avoid injury

to hands and

ﬁ ngers.

WARNING

Always wear

heavy leather

gloves when

handling winch

rope.

WARNING

Never touch

winch rope

or hook while

someone else

is at the control

switch or

during winching

operation.

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Warn XD9000i User Manual Page 7

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