Truck, Jeep & SUV
Basic Guide to Winching
Techniques, safety precautions, rigging methods, and step-by-step recovery guidance.
1
Introduction
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Every winching situation has the potential for personal injury. In order to minimize that risk, it is important to read this guide carefully. Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented.
Note
Some images shown in this manual may not necessarily represent your actual product. It is the customer's responsibility to review the specific product operator's manual and other literature specific to your product for complete operation details.
This guide covers winching techniques for Truck & SUV applications. For Powersports winching techniques, refer to the separate Powersports guide.
Video Resources
Watch these companion videos before heading out on the trail.
Basic Guide to Truck Winching
Basic Guide to Winching Techniques
2
Symbol Index
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The following symbols appear throughout this guide. Learn them before operating your winch.
Read All Product Literature
Literature available online at warn.com.
Literature available online at warn.com.
Finger / Fairlead Crushing Hazard
Always Wear Hearing & Eye Protection
Never Use Winch as a Hoist
Properly Seat Load in Throat of Hook
Wind Winch Rope on Bottom of Drum
Always Wear Leather Gloves
Do Not Move People
Always Use Supplied Hook Strap
Never Apply Load to Hook Tip or Latch
Never Wind Winch Rope Over Top of Drum
Never Hook Back on Winch Rope
Hand Piercing / Cutting Hazard
Explosion / Bursting Hazard
Fairlead Pinch Point
Hot Surface Hazard
Fire and Burn Hazard
Never Route Electrical Cables across Sharp Edges
Avoid Electrical Cables around Pinch and Wear Points
Never Route Electrical Cables through or near Moving Parts
3
General Safety Precautions
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As you read these instructions, you will see WARNINGS, CAUTIONS, NOTICES and NOTES. WARNINGS indicate a potentially hazardous situation which could result in serious injury or death. CAUTIONS indicate a potentially hazardous situation which could result in minor or moderate injury.
Never Apply Load to Hook Tip or LatchAlways Use Supplied Hook StrapNever Hook Back on Winch RopeFinger / Fairlead Crushing HazardFairlead Pinch PointAlways Wear Leather GlovesProperly Seat Load in Throat of HookMoving Parts Entanglement Hazard
Failure to observe these instructions could lead to serious injury or death.
General Safety:
- ▸Always Know Your Winch. Take time to fully read the Instructions and/or Operations Guide in order to understand your winch and its operations.
- ▸Never exceed winch or winch rope rated capacity. Double line using a snatch block to reduce winch load.
- ▸Always wear heavy leather gloves when handling winch rope.
- ▸Never use winch or winch rope for towing. Shock loads can damage, overload and break rope.
- ▸Never use a winch to secure a load.
- ▸Never operate this winch when under the influence of drugs, alcohol or medication.
- ▸Never operate this winch if you are under 16 years of age.
Installation Safety:
- ▸Always ensure hook latch is closed and not supporting load.
- ▸Never apply load to hook tip or latch — apply load only to the center of hook.
- ▸Never use a hook whose throat opening has increased, or whose tip is bent or twisted.
- ▸Always keep wired remote control lead and power cord clear of the drum, rope, and rigging.
- ▸Always pass remote lead through window when used in vehicle.
- ▸Never hook back on rope.
Never Wind Rope Over Top of DrumWind Rope on Bottom of DrumProperly Seat Load in Throat of HookNever Use Winch as a HoistDo Not Move PeopleAlways Wear Hearing & Eye ProtectionMoving Parts Entanglement Hazard — Winching Safety
Failure to observe these instructions could lead to serious injury or death.
- ▸Always inspect winch rope, hook, and slings before operating. Frayed, kinked or damaged winch rope must be replaced immediately.
- ▸Always be certain the anchor you select will withstand the load and the strap or chain will not slip.
- ▸Always use supplied hook strap whenever spooling winch rope in or out.
- ▸Always unspool as much winch rope as possible when rigging. Double line or pick distant anchor point.
- ▸Never touch winch rope or hook while someone else is at the control switch or during winching operation.
- ▸Never engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving.
- ▸Never touch winch rope or hook while under tension or under load.
- ▸Always stand clear of winch rope and load and keep others away while winching.
- ▸Never use vehicle to pull load on winch rope — combined load or shock load can damage, overload and break rope.
- ▸Never wrap winch rope back onto itself. Use a choker chain or tree trunk protector on the anchor.
Fire and Burn HazardExplosion / Bursting HazardNo Cables across Sharp EdgesNo Cables through Moving PartsAvoid Cable Pinch / Wear PointsChemical and Fire Hazard
Failure to observe these instructions could lead to serious injury or death.
- ▸Always remove jewelry and wear eye protection.
- ▸Never route electrical cables across sharp edges, near parts that get hot, or through/near moving parts.
- ▸Never lean over battery while making connections.
- ▸Never short battery terminals with metal objects.
- ▸Always verify area is clear of fuel lines, fuel tank, brake lines, and electrical wires when drilling.
- ▸Always insulate and protect all exposed wiring and electrical terminals.
Never Wind Rope Over Top of DrumWind Rope on Bottom of DrumNever Use Winch as a HoistDo Not Move PeopleFalling or Crushing Hazard
Failure to observe these instructions could lead to serious injury or death.
- ▸Always stand clear, keep hands clear, keep others away. Complete installation and hook attachment before winching.
- ▸Never operate winch with less than 5 wraps of steel rope (10 wraps synthetic) on the drum — rope could come loose from the drum.
- ▸Never use winch as a hoist or to suspend a load.
- ▸Always be certain anchor will withstand the load. Use appropriate rigging and take time to rig correctly.
- ▸Never use winch to lift or move persons.
- ▸Never use excessive effort to freespool winch rope.
- ▸Always wind the winch rope on bottom (mountside) of drum.
- ▸Never wind rope over top of drum.
- ▸Never apply a side load to the drum. Always spool rope directly onto the drum.
- ▸Never stand under a suspended load.
Hot Surface HazardHand Piercing / Cutting HazardAlways Wear Leather GlovesCut and Burn Hazard
Failure to observe these instructions could lead to serious injury or death.
- ▸Always wear heavy leather gloves when handling winch rope.
- ▸Never allow the winch rope to slide through your hands or run over bare skin during a winching operation.
- ▸Always be aware of possible hot surfaces at winch motor, drum or rope during or after winch use.
Fairlead Pinch PointFinger / Fairlead Crushing HazardMoving Parts Entanglement Hazard — Remote Control
Failure to observe these instructions could lead to minor or moderate injury.
- ▸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.
Notice — Avoid Winch and Equipment Damage
Always avoid side pulls which can pile up winch rope at one end of the drum — this can damage winch rope or winch. Always ensure the clutch is fully engaged or disengaged. Always use care not to damage the vehicle frame when anchoring to a vehicle during a winching operation. Never submerge winch in water. Always store the remote control in a protected, clean, dry area.
4
Winch Basics
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You have your WARN winch and you're ready to get out on the trails. This guide provides a basic understanding of your winch and the basics of proper winching techniques. Because no two situations are alike, it would be nearly impossible to review them all. We can, however, provide you with the general principles and techniques.
AlwaysTake time to fully understand your winch and the winching operation by reviewing this guide and the Operator's Guide included with your winch.
Winch Components
1
Motor
Typically powered by the vehicle's battery. Provides power to the gear mechanism, which turns the winch drum and winds the winch rope.
2
Winch Drum
The cylinder onto which the winch rope feeds. Driven by the motor and drive train. Its direction can be changed using the remote control.
3
Winch Rope
Diameter and length determined by the winch's load capacity and design. Wrapped around the winch drum and fed through the fairlead, looped at the end to accept the hook's clevis pin.
4
Fairlead
When using the winch at an angle, guides the winch rope onto the spooling drum. Minimizes damage to the winch rope.
5
Gear Train
The reduction gear converts winch motor power into a large pulling force. Makes it possible for the winch to be lighter and more compact.
6
Braking System
Automatically applied to the winch drum when the winch motor is stopped and there is load on the rope. Prevents the winch from paying out line.
7
Clutch
Allows the operator to disengage the drum from the gear train, enabling free spooling. Engaging the clutch "locks" the winch drum back onto the gear train.
8
Control Pack
Using electrical power from the vehicle's battery, the control box solenoids switch power to the motor, enabling the operator to change the direction of the winch drum rotation.
9
Remote Control
Allows the operator to control the winch direction, as well as stand clear of the winch rope while operating the winch.
WarningNever engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving.
5
How the Winch Works
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Winch Mechanics
The major advantage of an electric-powered winch is that it can provide reliable service for intermittent utility and recreational use even while the vehicle's engine is stalled — assuming sufficient battery current is available.
The longer the pull, the more heat that is created. Prolonged winching without cooling the winch motor will damage the motor. Also, if the engine is idling during winching, the battery may drain faster than it is charging. Pay close attention to your voltage gauge.
Control of Your Winch
The winch is controlled by the hand held remote control to allow the operator to stand clear while controlling the winching process. The remote control provides control of the forward or reverse rotation of the spooling drum.
NoteWARN® offers a variety of remote control options. See your specific winch operator's guide for details on your particular remote control operation.
How the Winch Reacts to Load
WARN winches are rated by pulling capacity. The maximum pulling capacity occurs on the first layer of winch rope on the drum. As the layers increase, the pulling power decreases. Exceeding the winch capacity could cause the winch to fail or the winch rope to break.
Capacity FormulaCalculate the gross weight of what you intend to pull, multiply by 1.5, then do not exceed the rating of your winch or winch rope.
6
Winch Accessories
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Alone, the winch is not much more than a simple tool. But when used with certain accessories, your WARN winch can become a versatile and productive tool. Some are vital to safe operation, while others offer added versatility and convenience.
Tow Hooks
Secured properly to your vehicle's frame, tow hooks provide an attachment point for winch lines, straps, and chains.
Gloves
Winch rope, through use, will develop "barbs" which can slice skin. Always wear protective gloves while operating the winch or handling the winch rope. Avoid loose fitting clothes.
Hook Straps
Used to hold the hook and keep fingers away from the fairlead as the winch rope is spooled in. Put the hook into the loop and hold the strap between the thumb and forefingers.
Snatch Block
Allows you to (1) increase your winch's pulling power and (2) change your pulling direction without damaging the winch rope.
Clevis / D-Shackles
A safe means for connecting the looped ends of cables, straps and snatch blocks. The shackle's pin is threaded to allow easy removal.
Tree Trunk Protector
Typically made of tough, high-quality nylon. Provides an attachment point for the winch rope to a wide variety of anchor points and protects living trees.
WARN Winch Damper
Helps prevent rope recoil in the event of a rope failure. Place it on the winch rope midway between the winch and the anchor point, before the winch rope is put under tension.
Recovery Strap
Never use a recovery strap in a winching operation. Because it is designed to stretch, it stores energy. Use the recovery strap only to "snatch" out a stuck vehicle.
Shovels & Hand Tools
Stow equipment such as a shovel, an axe and a Hi-Lift jack for additional assistance when needed.
Booster Cables
Many roadside emergencies stem from a dead battery. Include battery booster cables and the WARN quick-connect cable system.
WarningNever use a strap for winching. Never use "bungie" straps that develop tremendous and potentially dangerous amounts of force when stretched.
Battery RecommendationA fully charged conventional automotive battery with a minimum rating of 650 cold cranking amps is recommended to obtain peak performance from your winch.
7
Before You Pull
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Stretching Rope Before First Use
During its first use, a new winch rope must be spooled onto its drum under a load of at least 1,000 lbs. (454 kgs). Use the following instructions to properly stretch the winch rope onto the winch drum.
1
Choose Location
Choose a flat and level location that is large enough to run out almost the entire length of winch rope.
2
Disengage Clutch
See your product's specific operation manual for detailed clutch operation.
3
Spool Out Rope
Grasp hook strap and spool out the winch rope to the last 5 wraps on the drum (10 wraps if synthetic rope).
4
Engage Clutch & Attach to Anchor
Once the winch rope is spooled out, engage clutch. Attach the hook end of the rope to a suitable anchor point.
5
Position Vehicle
Return to your vehicle. Back the vehicle away from the anchor point until there is very little slack in the winch rope.
6
Set Brake & Turn Off
Set the parking brake, place the vehicle in gear or park and turn the vehicle off.
WarningAlways keep hands clear of winch rope, hook loop, hook and fairlead opening. Always stand clear of winch rope and load and keep others away while winching. Never touch winch rope or hook while under tension or under load.
7
Exit & Power In
Exit vehicle. Never exit with a load on the winch rope. Standing approx. 8 ft. (2.44 m) away, power-in the winch until all slack is wound onto the drum.
8
Guide the Rope
With gloves on, hold tension on the rope with one hand; carefully push the rope to the side of the drum it's attached to so there are no gaps between each coil.
9
Check Winding Direction
Rope must wind off the bottom of the drum or the automatic load-holding brake will not function. If it winds off the top, you are powering out — reverse direction.
10
Two-Person Safety Check
These steps are safest with two people. If alone, set the parking brake and turn the vehicle off every time you exit to inspect. Use care to evenly wrap each layer.
WarningNever use the remote when the vehicle is not in the operator's line of sight. Always wind the winch rope on the bottom (mountside) of the drum.
11
Driver Operates Winch
The driver operates the winch. Instruct your assistant to stand to the side and away from the rope — they should signal if the rope is winding correctly across the fairlead.
12
Start Vehicle & Begin Winching
Start the vehicle, place transmission in neutral. Release the parking brake while applying moderate brake pedal pressure. Power-in to begin winching.
13
Stop & Inspect
After about 6 ft. (2 m), stop winching. Apply parking brake, place transmission in park/gear, turn off vehicle. Exit and verify the rope is winding evenly without sinking into lower layers.
14
Repeat Until Close
Repeat until the vehicle is within 6 ft. (2 m) of the anchor. Apply the parking brake, place transmission in park and turn the vehicle off.
15
Disconnect & Final Spool
Exit vehicle. Disconnect from anchor. Holding hook strap, pulse-in the winch until the hook is within 3 ft. (1 m) of the fairlead. Attach hook to a vehicle anchor point and pulse in remaining slack. Do not power the hook into the fairlead.
Fundamentals for Winching
Whether you're recovering another vehicle or pulling a stump from the ground, knowing the proper winching techniques can help keep you and others around you safe. Perhaps the most important part of the winching process, regardless of the situation, is what you do before you pull.
1
Always take your time to assess your situation and plan your pull carefully.
2
Always take your time when using a winch.
3
Use the right equipment for your situation.
4
Always wear leather gloves and do not allow the winch rope to slide through your hands.
5
You and only you should handle the winch rope and operate the remote control switch.
6
Think safety at all times.
7
Practice. Practice and practice the steps.
8
Example Pull — Preparing
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The following steps describe how to recover your vehicle by rigging a single line pull. Double or multiple line rigging techniques follow the same basic steps, but use a snatch block to assist the process.
WarningAlways keep hands clear of winch rope, hook loop, hook and fairlead opening during installation, operation, and when spooling in or out. Always wear heavy leather gloves when handling winch rope.
1
Put on Gloves
Always wear heavy leather gloves before handling the winch rope.
2
Disengage Clutch
To allow free spooling of the winch drum. Freespooling conserves battery power. NOTE: WARN® offers multiple clutch control configurations.
3
Free the Winch Hook & Attach Hook Strap
Free the winch hook from its anchor point. Attach hook strap to the hook if not already attached.
4
Pull Winch Rope to Anchor Point
Pull out enough winch rope to reach your anchor point. Keep a certain amount of tension in the wire to prevent it from becoming twisted and overwrapped.
How to Choose an Anchor Point
A secure anchor is critical to winching operations. Natural anchors include trees, stumps, and rocks — hook the cable as low as possible. If no natural anchors are available, your vehicle can become the anchor point — put the transmission in neutral, apply the hand brake and block its wheels.
Choose an anchor point that enables you to pull straight in the direction the vehicle will move. An anchor point as far away as possible provides the greatest pulling power.
5
Secure to Anchor Point
Secure the tree trunk protector or choker chain around the object. Never wrap winch rope back onto itself.
6
Attach Clevis/D-Shackle & Hook Strap
Attach the shackle to the two ends of the strap or chain and through the hook loop, being careful not to over tighten (tighten and back-off ½ turn).
7
Lock the Clutch
Lock the winch drum by rotating the clutch lever on the winch to Engage.
8
Connect Remote Control
Be careful not to let the remote control cord dangle in front of the winch. Always pass the remote through a window. Always disconnect the remote when not in use.
9
Put Winch Rope Under Tension
Using the winch switch, slowly wind the winch rope until no slack remains. Once under tension, stand well clear, and never step over it.
10
Check Your Anchor
Make sure all connections are secured and free of debris before continuing with the winching procedure.
9
Example Pull — Pulling
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Operating your winch properly is so important you should practice these techniques before having to face the distractions and stresses of a real winching situation.
WarningNever use winch as a hoist or to suspend a load. Never use winch or winch rope for towing — shock loads can damage, overload and break rope. Never operate winch with less than 5 wraps of winch rope (10 wraps synthetic) around the drum.
11
Check Winch Rope
The winch rope should be neatly wound around the spooling drum. Improper winding can cause damage to the winch rope.
12
Place Damper
Lay something over the winch rope midway between the winch and the anchor point to absorb energy should the winch rope snap loose.
13
Make Your Intentions Clear
Ensure everyone in the immediate vicinity is aware of your intentions. Declare where spectators should not stand.
14
Begin Winching
With the vehicle's engine on and light tension on the winch rope, begin winching slowly and steadily. Be sure the winch rope is winding evenly and tightly around the spooling drum.
15
Complete Recovery
Continue pulling until the vehicle is on stable ground. If you are able to drive the vehicle, the winching operation is complete.
16
Secure Vehicle
Secure the vehicle's brakes and put the transmission in "park" (automatic) or "low" gear (manual). Release tension in the winch rope.
17
Disconnect Winch Rope
Disconnect from the anchor.
18
Rewind Winch Rope
The person handling the winch rope should walk the rope in and not let it slide through the hand, while controlling the winch at all times.
19
Disconnect Remote Control
Disconnect the remote control cord from the control box and store in a clean and dry place. Put the cap on the solenoid plug in.
Notes on Pulling
What to Look for Under Load: The winch rope must always spool onto the drum as indicated by the drum rotation decal. Avoid shock loads by using the control switch intermittently to take up winch rope slack. During side pulls the winch rope tends to stack up at one end of the drum — line up pulls as straight ahead as possible.
How to Spool Under No Load: Arrange the remote control lead so it cannot be caught in the winch. Keep the winch rope under light tension and spool it back onto the winch drum in even layers. Stop frequently to tighten and straighten the layers as necessary.
10
Winching Hand Signals
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In some situations, recovery could involve two people. You and your helper must establish clear and precise hand signals. It should be understood that if the driver controlling the winch cannot see both hands of the assistant, the winch should not be activated.
Signal 1
Direction of Steering
Hold your arms out with thumbs up and tilt your hands in the direction you advise the driver to steer.
Signal 2
Power In the Winch Rope
Hold your forefinger in the air above shoulder height and draw small circles in the air to indicate to wind the winch.
Signal 3
Power Out the Winch Rope
Hold your forefinger pointing down and draw circles in the air at about waist height to indicate feeding more wire from the winch.
Signal 4
Pulse Wind the Winch Rope
Tells the driver to wind the winch in short, quick bursts. Open and close the two fingertips until you want the winch to stop.
Signal 5
Braking
Cross your palms together to tell the driver to apply the foot brake.
Signal 6
Drive Assist
Tells driver to give the tires more drive force to assist the winching process.
Signal 7
Stop the Winch
Clinch fist, palm to driver, held high enough for driver to see and other arm straight out at shoulder height — the signal to stop the winch.
11
Rigging Techniques
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Various Winching Situations
Various winching situations will require application of other winching techniques. You will have to assess what technique is correct for your situation. Think "safety" at all times.
How to Change the Pulling Direction
All winching operations should have a straight line from the winch to the object being pulled. A snatch block, secured to a point directly in front of the vehicle, will enable you to change your pulling direction while still allowing the winch rope to be at 90° to wind properly onto the spooling drum.
Increasing Pulling Power
In some cases, you may find yourself needing more pulling power. The use of snatch blocks increases mechanical advantage and increases your pulling power.
Single Line
Standard rigging — winch rope runs directly from winch drum to anchor point. Maximum capacity is at first layer of rope on drum.
⚡ Standard Power
Double Line
Use a snatch block to double line out more winch rope. This decreases the number of layers of winch rope on the drum, and increases pulling power.
⚡⚡ Increased Power
Triple Line
Use the same techniques as the Double Line. Keep a 90° angle between the winch and run the winch rope through both snatch blocks to the final anchor point.
⚡⚡⚡ Maximum Power
12
Maintenance
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Excessive use of your winch, especially in dusty, muddy and wet conditions can play havoc on the winch's performance. We suggest you contact a WARN Authorized Service Center to perform normal and expected wear service work as well as resolve any warranty issues.
Contact WARNWARN INDUSTRIES, INC. · 12900 S.E. Capps Road, Clackamas, OR USA 97015 · 1-503-722-1200 · Customer Service: 1-800-543-9276 · Dealer Locator: 1-800-910-1122
Recommended Maintenance Schedule
| Task | Before First Use | After Each Use | Every 90 Days |
|---|---|---|---|
| Read Instructions and Operations Guide fully | ✓ | ||
| Check fasteners for tightness and proper torque | ✓ | ✓ | |
| Verify wiring to all components is correct and tight | ✓ | ✓ | |
| Verify no exposed/bare wiring or cable insulation damage | ✓ | ✓ | |
| Inspect rope for damage — replace immediately if damaged | ✓ | ✓ | ✓ |
| Keep winch, rope and switch control free from contaminants | ✓ | ||
| Check battery cables per manufacturer guidelines | ✓ | ||
| Inspect remote control for damage — store in clean dry area | ✓ | ✓ | |
| Lubrication | No lubrication required for the life of the winch | ||
Final NoteThe basic guide to winching techniques cannot cover all the possible situations in which you may need to use a winch. In the final analysis, the decisions you make will determine the final outcome. So think through each situation and each step of use. Always be mindful of your own safety and the safety of others. Pay attention and you'll have fun.
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