WARN AXON 55 Powersports Winch (Model 101155) Instruction Manual
Brand: WARN | Model: 101155
Introduction
The WARN AXON 55 Powersports Winch is engineered for robust performance and reliability in demanding conditions. This manual provides essential information for the safe and effective use of your winch, ensuring optimal functionality and longevity.
The AXON 55 features a massive 5,500 lb capacity with a durable steel wire rope, designed for heavy-duty UTV applications and significant pulling tasks. Its revolutionary Motactor technology integrates the motor and contactor for enhanced performance and simplified installation. Equipped with a dash-mounted control switch, a HUB wireless receiver, a 50' x 1/4" steel rope, roller fairlead, and a black hook, this winch offers advanced digital control for real-time load and temperature feedback. The all-metal construction, black powder-coated finish, and IP68-rated waterproof sealing ensure corrosion resistance and protection against environmental elements. The clutch design is based on WARN's proven 4WD hub lock technology, and the three-stage planetary gear train provides smooth, reliable operation with a load-holding mechanical brake for precise control.
Key Features
- Massive 5,500 lb Capacity: Ideal for large UTVs and demanding pulls.
- Integrated Motactor: Combines motor and contactor for superior performance and simplified installation.
- Digital Control: Provides real-time load and temperature information for enhanced user feedback.
- Durable Construction: All-metal build with black powder-coated finish for corrosion resistance.
- IP68 Waterproof Rating: Ensures protection against water and other elements.
- Advanced Clutch Design: Based on WARN's reliable 4WD hub lock technology.
- Three-Stage Planetary Gear Train: All-metal, smooth, and reliable for consistent operation.
- Load-Holding Mechanical Brake: Offers precise control during winching operations.
- Included Accessories: Dash-mounted control switch, HUB wireless receiver, 50' x 1/4" steel rope, roller fairlead, and black hook.
Setup and Installation
The WARN AXON 55 winch is designed for straightforward installation, thanks to its integrated Motactor technology. Proper installation is crucial for safe and effective operation.
Unboxing and Component Identification
Upon receiving your WARN AXON 55 winch, carefully unbox all components and verify against the packing list. Familiarize yourself with the winch unit, steel rope, fairlead, hook, control switch, and wireless remote.
Mounting the Winch
Mount the winch securely to your vehicle's winch plate or bumper using appropriate hardware. Ensure the mounting surface is strong enough to support the winch's pulling capacity. The compact design of the Motactor simplifies wiring and reduces overall installation time.
Rope Installation
The 1/4" diameter x 50' length steel rope comes pre-installed. If re-spooling or replacing the rope, ensure it is properly secured to the winch drum according to manufacturer guidelines. The roller fairlead should be positioned to guide the rope smoothly and prevent damage.
Electrical Connections
Connect the winch to your vehicle's 12-volt electrical system. The integrated Motactor simplifies wiring by combining the motor and contactor into a single unit. Ensure all connections are secure and properly insulated to prevent shorts and ensure reliable power delivery.
Control System Setup
Install the dash-mounted control switch in a convenient location within reach of the operator. The HUB wireless receiver allows for remote operation, providing flexibility and safety during winching. Refer to the detailed wiring diagrams in the full product manual for specific connection instructions.
Operating Instructions
Operating your WARN AXON 55 winch requires careful attention to safety and proper technique. Always prioritize safety and follow these guidelines.
Pre-Operation Checklist
- Ensure the winch is securely mounted and all electrical connections are tight.
- Inspect the steel rope for any frays, kinks, or damage. Replace if necessary.
- Check the fairlead for obstructions and ensure smooth rope movement.
- Verify the dash-mounted switch and wireless remote are functioning correctly.
- Ensure the vehicle's engine is running to provide adequate power to the winch.
Winching Procedure
- Anchor Point Selection: Choose a strong, stable anchor point capable of withstanding the pulling force. Use a tree trunk protector or similar strap to avoid damaging trees or other objects.
- Rope Deployment: Disengage the clutch (refer to the hub lock clutch dial) and manually pull out the required length of steel rope. Always leave at least five wraps of rope on the drum to maintain maximum pulling capacity.
- Secure the Hook: Attach the hook securely to the anchor point. Ensure the hook's safety latch is closed.
- Engage Clutch: Re-engage the clutch.
- Begin Winching: Use the dash-mounted switch or wireless remote to begin winching. Operate in short, controlled bursts. The digital control provides feedback on load and temperature, helping you manage the winching process effectively.
- Monitor Operation: Continuously monitor the winch, rope, and anchor point during operation. Keep hands and clothing clear of the rope and fairlead.
- Spooling the Rope: Once the winching task is complete, carefully re-spool the rope onto the drum under light tension. Ensure the rope spools evenly to prevent damage.
Safety Precautions
- Never exceed the winch's rated pulling capacity.
- Always wear heavy-duty gloves when handling the winch rope.
- Keep spectators at a safe distance.
- Never step over a taut winch rope.
- Use a winch dampener or heavy blanket over the rope to absorb energy in case of breakage.
- Avoid prolonged continuous winching to prevent overheating. The digital control will provide temperature feedback.
Maintenance
Regular maintenance ensures the longevity and reliable performance of your WARN AXON 55 winch.
- Inspection: Regularly inspect the winch, rope, fairlead, and electrical connections for any signs of wear, damage, or corrosion.
- Cleaning: After use, especially in muddy or wet conditions, clean the winch thoroughly with fresh water. The IP68 waterproof sealing protects internal components.
- Lubrication: Periodically check and lubricate moving parts as recommended in the full product manual.
- Rope Care: Inspect the steel rope for frays or broken strands. If damaged, replace the rope. Ensure the rope is spooled evenly on the drum.
- Electrical System: Check battery terminals and winch connections for corrosion. Keep them clean and tight.
Troubleshooting
If you encounter issues with your WARN AXON 55 winch, consult the following basic troubleshooting steps. For complex problems, refer to the full product manual or contact WARN customer support.
- Winch Not Operating:
- Check battery connections for tightness and corrosion.
- Ensure the vehicle's engine is running and the battery is charged.
- Verify the control switch and wireless remote are properly connected and powered.
- Check for tripped circuit breakers or blown fuses.
- Slow or Weak Pull:
- Ensure the vehicle's engine is running at a higher RPM to provide maximum power.
- Check battery charge level.
- Inspect electrical connections for resistance or corrosion.
- Verify the load is within the winch's rated capacity.
- Winch Overheating:
- The digital control provides temperature feedback. Allow the winch to cool down before resuming operation.
- Avoid prolonged continuous pulls. Use intermittent operation for heavy loads.
- Rope Damage:
- Inspect the steel rope for frays, kinks, or broken strands. Replace damaged rope immediately.
- Ensure the fairlead is clean and free of burrs that could damage the rope.
Specifications
| Attribute | Value |
|---|---|
| Brand | WARN |
| Model Number | 101155 |
| Pulling Capacity | 5,500 lb (2.75 Ton) |
| Rope Type | Steel Wire Rope |
| Rope Dimensions | 1/4" Diameter x 50' Length |
| Motor/Contactor | Integrated Motactor |
| Control | Dash-mounted switch, HUB Wireless Receiver |
| Waterproof Rating | IP68 |
| Finish | Black Powder-Coated |
| Gear Train | 3-Stage Planetary |
| Brake | Load-Holding Mechanical Brake |
| Item Weight | 35.2 pounds |
| Product Dimensions | 12.2 x 17.32 x 5.91 inches |
Product Images
Official Product Videos
This video provides a detailed overview of the WARN AXON Powersports Winch series, highlighting its key features, advanced technology, and robust construction. It demonstrates the winch in various challenging off-road scenarios, emphasizing its reliability and performance.
This video showcases the features and capabilities of WARN VRX Powersports Winches. While focusing on the VRX series, it provides relevant insights into WARN's engineering principles, durability, and performance aspects applicable to the AXON series.
This video demonstrates the process of installing a WARN synthetic cable. Although the AXON 55 comes with steel rope, the general principles and techniques for securing the rope to the drum and fairlead are similar and can be adapted for steel rope installation.
This video demonstrates the pulling power of a winch by showing it pulling a 3-ton tractor onto a tilt-bed trailer. It provides a real-world example of the kind of heavy-duty tasks a robust winch like the AXON 55 can handle, showcasing its capacity and operational strength.
This video provides an overview of the Black Ops 6000lb Winch, highlighting its features and capabilities. While a different brand, it offers general insights into winch design, components, and performance characteristics relevant to understanding high-capacity powersports winches.
Warranty Information
WARN stands behind the quality and performance of its products. For specific warranty details, including coverage period and terms, please refer to the warranty card included with your product or visit the official WARN website. Keep your proof of purchase for any warranty claims.
Customer Support
For technical assistance, troubleshooting, or parts inquiries, please contact WARN customer support. Contact information can be found in your product packaging or on the official WARN website. When contacting support, please have your model number (101155) and serial number ready.
