WARN POWERPLANT 9.5 - Manual (Page 8)

WARN INDUSTRIES
11 73203B0
ELECTRICAL CONNECTIONS
Step 3 - Install the Wiring
WARNING To prevent serious injury or death. Always
place the supplied terminal boots on wires and terminals as
directed by the installation instructions.
WARNING To prevent serious injury or death from
electrical fi re:
Never route electrical cables across sharp edges.
Never route electrical cables near parts that get
hot.
Never route electrical cables through or near
moving parts.
Avoid pinch and wear/abrasion points when
installing all electrical cables.
WARNING Always insulate and protect all exposed wiring
and electrical terminals.
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.
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.
Electrical Diagram
Red Cable 72” (183cm)
Black Cable 72” (183cm)
Step 4 - System Check
Perform system check:
• Check fasteners and make sure they are tight and
to proper torque.
• Verify wiring to all components is correct and
be certain that all connections are tight.
• Verify there is no exposed/bare wiring,
terminals or cable insulation damage.
• Check motor rotation: Winch should power in
and rotate the direction indicated by the drum
rotation label. If winch rotates in opposite
direction, recheck electrical connections.
• Check rope direction: Always wind winch rope
on bottom (mountside) of drum.
Once you have performed a system check, you
are ready to confi rm winch function. Proceed
to First Time Winch Operation Instructions, Air
Compressor Operation Instructions and Final
Analysis and Maintenance sections in this booklet.
WARN INDUSTRIES
73203B0 12
FIRST TIME OPERATING INSTRUCTIONS
Step 5 - First Time Operating Instructions
Winch Operation:
WARNING Always understand your winch and the
winching operation by reviewing The Basic Guide to Winching
Techniques included with your winch.
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.
Winch Control Switch
The large rocker switch on the remote control
handle controls the spooling in and spooling out
functions of the winch. This switch is operable only
when the Mode Selector is in the “Winch” symbol
position.
Motor Temperature Indicator and Cutoff
With heavy usage, over a short period of time,
the motor will heat up considerably. To prevent
any damage to the motor due to high heat, there
is a thermal protection device on the motor.
When the factory programed high
temperature point is reached, this device will shut
off the motor and cause the indicator light in the
remote control to blink.
The winch spooling in function and the
compressor will not operate, but the winch
spooling out function will still operate in case it
is necessary to release a load. After the motor is
allowed to cool, normal operation will resume.
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
engagement. To prevent damage, always fully
engage or fully disengage the clutch lever.
Air Compressor Operation:
WARNING Always turn the compressor off and bleed pressure
from the air hose and intercooler before attempting maintenance,
attaching tools, or accessories.
WARNING Never point any nozzle or sprayer toward any part of
the body or at other people or animals.
WARNING Always wear ANSI Z87.1 approved safety glasses
with side shields when using the air compressor.
WARNING Never reach around protective shrouds or attempt
maintenance until unit has been allowed to cool.
WARNING Never touch any exposed metal parts on compressor
during or immediately after operation.
Select the Compressor Mode
Turn the mode selector knob to the “Air
Compressor” symbol. Remove the Air Access
Door and connect an air hose to the quick-
connect fitting.
Air Access Door
The rubber door marked “AIR” on the geartrain
side of the PowerPlant can be pulled out to gain
access to the quick-connect air fitting. Before
operating the compressor, an air hose should be
connected to the fitting. During any winching
OUT
IN
Winch Control Switch
Disengaged Engaged