Warn 79700 User manual

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WARN INDUSTRIES, INC. 12900 S.E. Capps Road,
Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: [phone]
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
International Sales/Customer Service: 1-503-722-3008
International Fax: [phone]
INSTALLATION INSTRUCTIONS
PLOW MOUNTING KIT
Part Number: 79700
Application: 2009+ Polaris Ranger XP,HD
GENERAL SAFETY PRECAUTIONS
WARNING
Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have
provided installation and operating instructions and other information on labels and in this guide. This information
alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards
associated with this product, you must use your own good judgment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND
UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS
PRODUCT.
This guide identies potential hazards and has important safety messages that help you and others avoid personal injury
or death. WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean:
WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations. CAUTION
signals a hazard that may cause minor to moderate injury, if you do not follow recommendations.
This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general
information worthy of special attention.
Impact and Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO SEVERE INJURY OR DEATH
• AlwaysReadthePlowOperator’sManual,theWinchOperator’sManualandallwarninglabelsbeforeoperating.
• Alwaysuseextremecautionwhendrillingonanyvehicle.Makesurethatallfuellines,brakelines,electricalwires,andotherobjectsarenotpunctured
ordamagedwhen/ifdrillingonthevehicle.Thoroughlyinspecttheareatobedrilled(onbothsidesofmaterial)priortodrilling,andrelocateanyobjects
thatmaybedamaged.Failuretoinspecttheareatobedrilledmayresultinvehicledamage,electricalshock,reorpersonalinjury.
• Alwayswearsafetyglasseswheninstallingthiskit.
• Alwaysuseextremecautionwhencuttingandtrimmingduringtting.
• Alwaysremovejewelryandweareyeprotection.
• Alwaysuseappropriateandadequatecareinliftingcomponentsintoplace.
• Alwaysinsurecomponentswillremainsecureduringinstallationandoperation.
• Alwaystightenallnutsandboltssecurely,pertheinstallationinstructions.
• Alwaysoperatethevehicleatawalkingspeedwiththebladeinstalled.Neverexceed5mph(8km/h),evenwithbladeup.
• Alwaysplowcautiously,impactwithhiddenorstationaryobjectmaycausethevehicletostopsuddenlyorgooutofcontrol.
• Neveroperatethevehicleonslopesgreaterthan10degreeswiththeplowinstalled.
• Neverstandorrideontheplow.
• Alwaysstayclearofmovingpartsandjoints.Alwayskeepothersawaywhenoperatingoradjustingplow.
• Alwaysperformregularinspectionsandmaintenanceontheplowmechanism,fasteners,cableandrelatedhardware.
• Alwaysreplaceallwornordamagedpartsbeforeoperating.
• NeveroperatethisWARNproductwithdamagedormissingparts.
• Alwaysdriveslowlyoverbumpyandroughterrain.Drivingatspeedsthatcausetheplowtobouncewhileintheuppositioncancausethewinchtoback-
drive,causingtheplowtoworkitswaydown.Thismayresultintheplowimpactingastationaryobjectandcausedamagetothevehicleandoperator
injuryordeath.
• Alwaysdriveatspeedssuchthattheplowdoesnotbounceandbeawareoftheplowpositionwhiledrivingatalltimes.
• NeverraisethetopoftheplowabovetheheadlightsoftheATV,asitmaydamagethevehicleandplow.
Read installation and operating instructions thoroughly.

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NOTICE
Equipment Damage
• AlwaysrefertotheInstallationandSpecicationGuide,suppliedinthewinchkit,forallwiringschematicsandspecicdetailsonhowtowirethisWARNproducttoyourvehicle.
Read installation and operating instructions thoroughly.
CAUTION
Moving Parts Entanglement Hazard
FAILURE TO OBSERVE THESE INSTRUCTIONS COULD LEAD TO MINOR OR MODERATE INJURY
• AlwaystaketimetofullyreadandunderstandtheinstallationandOperationsGuideincludedwiththisproduct.
• Never operate this product if you are under 16 years of age.
• Neveroperatethisproductwhenundertheinuenceofdrugs,alcoholormedications.
Read installation and operating instructions thoroughly.
TABLE OF CONTENTS
Tools Required.......................................................................................................page 2
Torque Specications............................................................................................page 2
Parts List................................................................................................................page 3
Installation.............................................................................................................page 4
Operation........................................................................................................... page 5-6
Tips/Troubleshooting ............................................................................................page 7
Maintenance/Care................................................................................................page 7
TOOLS REQUIRED
• Ratchet
• Sockets: 13mm,15mm, 16mm,17mm, 18mm,19mm
• Wrenches: 13mm, 15mm,16mm,17mm, 18mm, 19mm
• Torque Wrench
TORQUE SPECIFICATIONS
1/4 8 lb. ft. (10.8 N-m)
5/16 17 lb. ft. (12.5 N-m)
3/8 30 lb. ft. (40.7 N-m)
7/16 50 lb. ft. (67.8 N-m)
1/2 75 lb. ft. (101.7 N-m)

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PARTS LIST
Reference Part Number Qty Description
A1 81577 1 Plow mount
A2 81582 1 Bracket
A3 81698 1 Flange, Plow mount
B1 22508 2 8mm dia x 25mm long capscrew
B2 1324 4 5/16” Flat Washer
B3 22491 2 8mm Nylon Locknut
B4 2079 2 5/16 nut
B5 61461 1 U-bolt
B6 2002 2 5/16 Lock nut
C1 28514 2 12mm dia x 35mm Long Capscrew
C2 9213 4 1/2” Flat Washer
C3 70117 2 12mm Nylock Locknut
D1 22527 2 10mm dia x 25mm Long Capscrew
D2 29926 4 3/8” Flat Washer
D3 69807 2 10mm Nylon Locknut
E1 79712 2 Retaining Pin
F1 82466 1 Strap
B2
A2
E1
A1
D1
D2
C2
C1
A3
B3
C3
D3
B1

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INSTALLATION INSTRUCTIONS
1. Position front plow mount against front and underside of
vehicle’s bumper as shown in Figure 1. Loosely secure
with 12mm hardware using existing holes in factory
bumper.
2. Secure mount to bottom skidplate of vehicle using 10mm
hardware as shown in Figure 2. Do not tighten hardware at
this time.
3. Slide support bracket through vehicle frame on top of
mount in orientation shown in Figure 3. Secure bracket to
mount using 8mm hardware. Once this bracket is in place
all hardware can be tightened and torqued in place per
specications on page 2.
Figure 1
Figure 2
Figure 3
12mm hard-
ware
10mm hard-
ware
8mm hardware
support bracket

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INSTALLATION INSTRUCTIONS
Operation
Attaching the plow to the vehicle:
1. Stage the plow assembly on level solid ground. See Plow
operator guide “Installing the Plow” for more information
on installing plow mount ange (A3). See Figure 4.
2. SLOWLY drive the vehicle up to the plow assembly with the
vehicle as square to the plow as possible.
3. Turn off the vehicle and set the parking brake. Lift the plow
mount ange end of the push tube assembly up to the
plow mount on the vehicle. Insert the plow mount ange
into the plow mount receiver. See Figure 5.
4. Double check that the plow is fully engaged with the align-
ment pucks on the plow mount ange. The alignment
pucks should be fully seated into the plow mount cradle
feature.
5. With both alignment pucks seated into the plow mount the
retaining pins can be inserted. Once inserted the retaining
clips on the pins can be clipped onto locking tab on plow
mount, refer to Figure 6. See Plow operator guide “Install-
ing the Plow” for more information.
6. With both retaining pins secure, pull out the line from the
winch.
7. Pull the retaining pin on the plow assembly that is secur-
ing the pulley assembly. With the pulley assembly loose,
place the pulley assembly over the winch line and reinstall
the pulley assembly onto the push tube assembly securing
the pulley assembly with the retaining pin. See “Double
Line Rigging” in the Plow Lift section of the Plow Operators
Guide.
Figure 6
Figure 4 Install Plow Mount Flange
Figure 5
Retaining
Pin
A3

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INSTALLATION INSTRUCTIONS
8. Connect the winch hook to the vehicle’s front tow hook.
See Figure 7.
9. When using the WARN bumper, attach to the square u-bolt
that you attach the bottom of the bumper to. See exploded
view in parts list. See Figure 8.
10. Turn the ignition switch to ON, and operate the winch to lift
and lower the plow. The plow is now ready for operation.
Read the Plow Operators Guide before operating plow.
Helpful Hints
When removing the plow assembly from the plow mount,
use a block under the base of the push tube assembly to
hold up the assembly at the connection height. This will
aid in the next connection on the plow assembly.
Figure 7
Figure 8

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CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL
SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.
TROUBLESHOOTING
MAINTENANCE / CARE
• Avoidengagingorremovingtheplowfromthevehicleonuneven,sloped,orsoftground.Doingsomaymisaligntheplow
mountandmakeitdifcultforproperengagementanddisengagementoftheretainingpins
• Ifyouarehavingtroublegettinganalignmentpuckintotheplowmount,itmayneedsomesimpleadjustment.Ensurethat
theplowandvehiclearesittinglevel.Ensurethattheplowbaseisinthecenterlatchedposition
• Afterusingtheplow,thewinchcablemaybegintotanglearoundthedrum.Toxthis,pullofftheplowassemblyandfree
spoolthecableoutofthewinch.Oncethetangledcableispulledoffthedrum,switchthewinchoutoffreespooland
winchthecableneatlybackaroundthedrum.DoNOTgrabthecableorwinchhook,insteadusethewinchhookstrap
providedwithyourwinchandfollowtheguidelinesasdescribedinthewinchingguide.
Ifyouarehavingproblemswithyourplow,pleasefollowthestepsbelow:
1. Reference the installation instructions for tips or notes.
2. Contact the dealer where you purchased the kit.
3. Call an authorized WARN Service Center from the warranty sheet included in the kit. Please have the following information avail-
able before calling; part number (listed on front of instructions), date of purchase, and make, model, and model year of ATV.
4. Contact WARN customer service at 1-800-543-9276 or www.warn.com. Again, please have the following information available
before calling; part number (listed on front of instructions), date of purchase, and make, model, and model year of ATV.
Contact your nearest WARN Dealer to order. To nd a dealer nearest you, please call the WARN Dealer locator line at 1 800-
910-1122
WARNING
Failure to perform regular inspections and maintenance on the plow, plow mount, winch, and related hardware may
result in vehicle damage and operator injury or death.
• Inspectallmetalpartsontheplow,plowmount,andrelatedhardwarepriortoeachuse.Replaceallpartsthatappear
rustedordeformed.
• Inspectallnutsandboltsontheplow,plowmount,andrelatedhardwarepriortoeachuse.Tightenallnutsandbolts
thatappeartobeloose.Stripped,fractured,orbentboltsornutsmustbereplaced.
• Checkallcablespriortouse.Replacecablesthatarewornorfrayed.
• Checkallmovingandrotatingparts.Removedebristhatmayinhibitthepartfrommovingfreely.
• SeeWarnPlowOperatorsGuideformoreinformation.