1. Introduction
This manual provides essential information for the proper installation, operation, and maintenance of your WARN 106842 Long Tensioner Service Kit. This kit is designed specifically for WARN XL Series Winches to enhance wire rope management. Please read this manual thoroughly before installation and use to ensure safe and effective performance.
Safety First: Always follow all safety guidelines provided with your WARN winch and any associated equipment. Improper installation or use of this tensioner kit can lead to equipment damage or personal injury.
2. Product Overview
The WARN 106842 Long Tensioner Service Kit is an accessory designed to improve the performance and longevity of your WARN XL Series Winch's wire rope. Its primary functions include:
- Preventing wire rope tangling during free spooling operations.
- Assisting in uniform wire rope spooling onto the winch drum.
- Contributing to consistent power delivery and reduced rope slip.
2.1. What's in the Box
- Long Tensioner Service Kit components (specific parts may vary, refer to packaging for detailed list).
2.2. Product Image
Image 1: The WARN 106842 Long Tensioner Service Kit. This image displays the main components of the tensioner kit, including the spring-loaded roller mechanism and mounting brackets, designed to guide the winch rope.
3. Setup and Installation
The WARN 106842 Long Tensioner Service Kit is designed for integration with WARN XL Series Winches. Proper installation is crucial for its functionality. Always refer to your specific WARN XL Series Winch manual for detailed instructions on accessory installation points and procedures.
- Preparation: Ensure the winch is powered off and disconnected from any power source. The winch rope should be fully extended or spooled off the drum to allow access.
- Identify Mounting Points: Locate the designated mounting points on your WARN XL Series Winch for the tensioner kit. These are typically above the winch drum.
- Position the Tensioner: Carefully position the tensioner kit components according to the instructions provided with the kit and your winch manual. The roller mechanism should be aligned to guide the wire rope onto the drum.
- Secure Hardware: Use the provided hardware (bolts, nuts, washers) to securely fasten the tensioner kit to the winch. Ensure all fasteners are tightened to the manufacturer's specified torque settings.
- Check Alignment: Verify that the tensioner roller is properly aligned with the winch drum and the path of the wire rope. It should apply even pressure across the rope as it spools.
- Test Functionality: Once installed, slowly spool the wire rope onto the drum, observing the tensioner's operation. Ensure it moves freely and guides the rope uniformly without binding or excessive friction.
If you are unsure about any step of the installation process, consult a qualified technician or contact WARN customer support.
4. Operating the Tensioner Kit
The Long Tensioner Service Kit operates passively to assist in proper wire rope management during winch use. It does not require active user input during operation, but its presence is critical for optimal performance.
- During Free Spooling: The tensioner helps maintain a slight tension on the wire rope, preventing it from tangling or creating bird's nests as it is pulled out freely from the drum.
- During Winching (Spooling In): As the wire rope is reeled back onto the drum, the tensioner's roller applies consistent pressure, guiding the rope into even layers. This uniform spooling is essential for maximizing the winch's pulling power and preventing rope damage.
Always ensure the tensioner is clean and free of debris before and after each winching operation.
5. Maintenance
Regular maintenance of your WARN 106842 Long Tensioner Service Kit will ensure its continued effectiveness and extend the life of your winch rope.
- Inspection: Before each use, inspect the tensioner for any signs of wear, damage, or loose components. Check the roller for smooth rotation and ensure the springs provide adequate tension.
- Cleaning: After each use, especially in dirty or muddy conditions, clean the tensioner components to remove dirt, mud, and debris. A mild soap and water solution can be used, followed by thorough rinsing and drying.
- Lubrication: Periodically apply a light lubricant to the roller pivot points and spring mechanisms to ensure smooth operation. Avoid over-lubrication, which can attract dirt.
- Hardware Check: Regularly check all mounting hardware for tightness. Re-torque fasteners to specifications if necessary.
- Component Replacement: If any part of the tensioner kit shows significant wear or damage, replace it immediately with genuine WARN replacement parts.
6. Troubleshooting
If you encounter issues with your WARN 106842 Long Tensioner Service Kit, consider the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Wire rope tangling during free spooling | Insufficient tension from the tensioner; damaged springs; improper installation. | Inspect springs for damage; ensure proper installation and alignment; replace worn components. |
| Uneven wire rope spooling | Tensioner roller binding; misaligned tensioner; excessive dirt/debris. | Clean and lubricate roller; check tensioner alignment; remove debris. |
| Tensioner not moving freely | Dirt/corrosion in pivot points; bent components. | Clean and lubricate pivot points; inspect for physical damage and replace if necessary. |
If the problem persists after attempting these solutions, contact WARN customer support for further assistance.
7. Specifications
- Model: WARN 106842
- Compatibility: WARN XL Series Winches
- Item Weight: 29.6 pounds
- Package Dimensions: 22 x 14.5 x 2.25 inches
- Manufacturer Part Number: 106842
8. Warranty and Support
For information regarding the warranty of your WARN 106842 Long Tensioner Service Kit, please refer to the official WARN website or the warranty documentation included with your purchase. For technical support or replacement parts, please contact WARN customer service directly.
WARN Official Website: www.warn.com
