1. Important Safety Information
Read and understand all instructions and warnings before installing, operating, or performing maintenance on this winch. Failure to follow these instructions may result in serious injury or property damage.
- Always wear appropriate personal protective equipment, including gloves and eye protection, when operating the winch.
- Keep hands and clothing clear of the wire rope, fairlead, and drum during operation.
- Never exceed the rated line pull capacity of the winch.
- Ensure the winch is securely mounted to a structure capable of withstanding the maximum rated load.
- Do not use the winch for lifting or moving people.
- Inspect the wire rope, hooks, and all connections before each use. Replace damaged components immediately.
- Maintain a safe distance from the wire rope under tension.
Image: The WARN 5000 DC Series winch showing a prominent warning label on its control box, emphasizing safety precautions.
2. Product Overview and Components
The WARN 99963 5000 DC Series 12V Electric Winch is designed for heavy-duty pulling applications, offering a robust 5,000 lbs (2268 kg) pulling capacity. It features a powerful 1.9 horsepower permanent magnet DC motor and a durable three-stage planetary gear train for reliable performance.
Key Features:
- Pulling Capacity: 5,000 lbs (2268 kg)
- Motor: 1.9 Horsepower Permanent Magnet DC
- Voltage: 12V DC
- Gear Train: Durable Three-Stage Planetary
- Braking: Dynamic and Mechanical for superior control
- Wire Rope: 60 feet (18.3 meters) of high-strength wire rope
Included Components:
- Electric Winch Unit
- Wire Rope (pre-installed)
- Remote Control
- Mounting Hardware (bolts, nuts, washers)
- Fairlead (if included with specific model variant)
Image: The WARN 5000 DC Series electric winch displayed with its included accessories, including power cables, remote control, mounting hardware, and a recovery strap.
Image: A close-up view of the WARN 5000 DC Series winch, highlighting the robust power cables (red and black) connected to the unit.
3. Setup and Installation
Proper installation is critical for the safe and effective operation of your WARN winch. If you are unsure about any step, consult a qualified professional.
3.1 Mounting the Winch
- Select a mounting location that is structurally sound and can support the winch's maximum pulling capacity. This typically involves a winch plate or bumper designed for the purpose.
- Position the winch on the mounting surface, ensuring proper alignment with the fairlead.
- Use the provided mounting hardware to secure the winch. Tighten all bolts to the manufacturer's specified torque settings.
Image: A black metal mounting plate with multiple bolt holes, designed to securely attach the winch to a vehicle or other structure.
3.2 Electrical Connections
Connect the winch to a 12-volt DC power source (e.g., vehicle battery) using heavy-gauge cables. Ensure all connections are clean, tight, and free from corrosion.
- Connect the red positive (+) cable from the winch to the positive (+) terminal of the battery.
- Connect the black negative (-) cable from the winch to the negative (-) terminal of the battery or a suitable chassis ground point.
- Ensure all connections are insulated to prevent short circuits.
3.3 Wire Rope Preparation
Before first use, fully extend the wire rope and then carefully re-spool it onto the drum under a light load (e.g., 500 lbs). This helps to properly layer the rope and prevent damage during heavy pulls.
Image: The WARN 5000 DC Series winch with its wire rope neatly spooled around the drum, ready for operation.
4. Operating Instructions
Familiarize yourself with the winch controls and operating procedures before attempting to pull a load.
4.1 Pre-Operation Checks
- Verify the winch is securely mounted and electrical connections are tight.
- Inspect the wire rope for frays, kinks, or damage.
- Ensure the area around the winch and the load is clear of bystanders and obstructions.
- Confirm the vehicle's engine is running to maintain battery voltage during winching.
4.2 Winching Procedure
- Engage/Disengage Clutch: Locate the clutch lever on the winch. Move it to the 'Free Spool' position to manually pull out the wire rope. Move it to the 'Engaged' position for powered winching.
- Attach Hook: Securely attach the hook to a suitable anchor point (e.g., tree saver strap, recovery point on another vehicle). Ensure the safety latch on the hook is closed.
- Connect Remote Control: Plug the remote control into the winch's control box.
- Operate Winch: Use the remote control to slowly reel in the wire rope. Maintain tension on the rope to ensure even spooling.
- Monitor Operation: Observe the winch, rope, and load throughout the pull. Stop immediately if any unusual noises or movements occur.
- Post-Winching: Once the pull is complete, release tension, disconnect the hook, and carefully re-spool any remaining loose rope. Disconnect the remote control.
Image: The wired remote control for the WARN winch, featuring a toggle switch for 'In' and 'Out' operations.
Image: A close-up of the WARN winch remote control, showing the directional switch for controlling the wire rope movement.
4.3 Winching Applications
Image: A vehicle equipped with a WARN winch engaged in a recovery operation, demonstrating its use in challenging terrain.
Image: An off-road vehicle navigating rocky terrain, showcasing the WARN winch mounted on the front bumper, ready for potential recovery needs.
Image: A WARN winch being used to pull a vehicle onto a flatbed trailer, illustrating its utility for loading and transport tasks.
5. Maintenance
Regular maintenance ensures the longevity and safe operation of your WARN winch.
- Wire Rope Inspection: Regularly inspect the entire length of the wire rope for signs of wear, kinks, broken strands, or corrosion. Replace the rope if any damage is found.
- Electrical Connections: Check all electrical connections for tightness and corrosion. Clean terminals as needed.
- Mounting Hardware: Periodically check all mounting bolts and nuts to ensure they remain tight.
- Cleaning: Keep the winch clean from dirt, mud, and debris. Use a mild detergent and water, then rinse thoroughly. Avoid high-pressure washing directly on electrical components.
- Lubrication: Refer to the specific WARN service manual for any recommended lubrication points and schedules.
6. Troubleshooting
If your winch is not operating correctly, refer to the following common issues and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Winch does not operate | No power to winch; Loose electrical connections; Faulty remote control; Engaged clutch. | Check battery connections and voltage; Tighten all electrical connections; Test remote control; Ensure clutch is disengaged for free spool, engaged for power. |
| Winch operates slowly or with reduced power | Low battery voltage; Overload; Corroded electrical connections; Motor overheating. | Charge battery or run vehicle engine; Reduce load; Clean and tighten connections; Allow motor to cool. |
| Wire rope is tangled or unevenly spooled | Improper re-spooling; Lack of tension during winding. | Carefully unspool and re-spool the rope under a light load to ensure even layering. |
For issues not covered here, contact WARN customer support.
7. Specifications
| Specification | Value |
|---|---|
| Model Number | 99963 |
| Rated Line Pull | 5,000 lbs (2268 kg) |
| Motor | 1.9 HP Permanent Magnet DC, 12V |
| Gear Train | 3-Stage Planetary |
| Braking | Dynamic and Mechanical |
| Wire Rope Length | 60 feet (18.3 meters) |
| Product Dimensions | 19 x 11 x 9 inches (48.26 x 27.94 x 22.86 cm) |
| Item Weight | 1 pound (0.45 kg) (Note: This weight may be a data anomaly for a winch of this capacity.) |
8. Warranty and Support
For warranty information, technical support, or to purchase replacement parts, please contact WARN customer service directly. Keep your purchase receipt and product model number (99963) handy for faster service.
Visit the official WARN website for the most up-to-date information and support resources: www.warn.com
