Warn 71983 - User Manual

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WARN® INDUSTRIES PAGE 1 72171 Rev A0

INSTALLATION INSTRUCTIONS

Kawasaki Mule Plow Mounting Kit

WARNING

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ys Read the Plow Operator’s Manual, the Winch Operator’s Manual and all warning labels before operating.

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ys 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, fire or personal injury.

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ys wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye

injury.

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ys use extreme caution when cutting and trimming during fitting.

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ys remove jewelry and wear eye protection.

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er lean over battery while making connections.

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e electrical cables:e electrical cables:

e electrical cables:

o Across any sharp edges.

o Through or near moving parts.

o Near parts that become hot.

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ys insulate and protect all exposed wiring and electrical terminals.

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ys install terminal boots as directed in installation instructions.

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ys use appropriate and adequate care in lifting components into place.

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ys insure components will remain secure during installation and operation.

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ys tighten all nuts and bolts securely, per the installation instructions.

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ys operate the vehicle at a walking speed with the blade installed. Never exceed 5 mph (8 km/h), even with blade up.

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ys plow cautiously, impact with hidden or stationary object may cause the vehicle to stop suddenly or go out of control.

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er operate the vehicle on slopes greater than 10 degrees with the plow installed.

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er stand or ride on the plow.

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ys stay clear of moving parts and joints. Always keep others away when operating or adjusting plow.

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ys perform regular inspections and maintenance on the plow mechanism, fasteners, cable and related hardware.

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ys replace all worn or damaged parts before operating.

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er operate this WARN product with damaged or missing parts.

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ys 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.

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ys drive at speeds such that the plow does not bounce and be aware of the plow position while driving at all times.

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ys be aware that the purpose of the j-bolt is to break the connection between the plow and the winch, to prevent serious

damage to the ATV if the plow is raised too high. The plow blade will drop suddenly if the j-bolt breaks, so always be sure there

are no bystanders when you raise and lower the plow.

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er raise the top of the plow above the headlights of the ATV, as it may damage the vehicle and plow.

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ys replace a deformed or broken j-bolt with the spare j-bolt included in the kit.

INJURY HAZARD

Failure to observe these instructions could lead to severe injury or death.

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 identifies 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

genera

l information worthy of special attention.

WARN Part Number: 71983

Application: Kawasaki Mule 2003 and newer

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Summary

Installation

Plow Mount Installation

Details the process for mounting the plow to the vehicle's frame.

Plow Support Installation

Guides the user through assembling and installing the plow support structure.

Operation

Attaching the Plow to the Vehicle

Explains how to correctly connect the plow assembly to the vehicle mount.

Operating the Plow

Details the procedures for lifting, lowering, and angling the plow blade.

Removing the Plow from the Vehicle

Provides step-by-step instructions for safely detaching the plow from the vehicle.

Summary

Installation

Plow Mount Installation

Details the process for mounting the plow to the vehicle's frame.

Plow Support Installation

Guides the user through assembling and installing the plow support structure.

Operation

Attaching the Plow to the Vehicle

Explains how to correctly connect the plow assembly to the vehicle mount.

Operating the Plow

Details the procedures for lifting, lowering, and angling the plow blade.

Removing the Plow from the Vehicle

Provides step-by-step instructions for safely detaching the plow from the vehicle.

This document describes the WARN Kawasaki Mule Plow Mounting Kit, part number 71983, designed for Kawasaki Mule models from 2003 and newer. It provides detailed installation, operation, and maintenance instructions, emphasizing safety throughout.

Function Description

The WARN Kawasaki Mule Plow Mounting Kit is an accessory designed to attach a plow blade to a Kawasaki Mule utility vehicle, enabling it to be used for plowing tasks such as snow removal or moving loose materials. The kit facilitates the mechanical connection between the vehicle and a plow blade, allowing the operator to raise, lower, and angle the plow using a WARN winch (sold separately). The system is specifically designed for non-commercial use.

Important Technical Specifications

The kit includes various components and hardware, with specific torque specifications for secure assembly.

Hardware Sizes: The kit utilizes a range of bolt and nut sizes, including #6, #10, 1/4", 5/16", 3/8", 7/16", 1/2", and 5/8" diameters.
Torque Specifications:
- #6 diameter screw: 3 ft-lbs (4 N-m)
- #10 diameter bolt and nuts: 4 ft-lbs (5.5 N-m)
- 1/4" diameter bolt and nuts: 7 ft-lbs (9.5 N-m)
- 5/16" diameter bolt and nuts: 12 ft-lbs (16.5 N-m)
- 3/8" diameter bolt and nuts: 20 ft-lbs (27 N-m)
- 7/16" diameter bolt and nuts: 30 ft-lbs (41 N-m)
Plow Support Adjustments: The plow support features multiple sets of holes (top arm positions #1, #2, #3; bottom arm positions #1, #2, #3; arm stop positions #1, #2) to accommodate different vehicle heights, tire sizes, pressures, weights, and shock settings. This adjustability is crucial for proper plow calibration and operation.
Fairlead: A special plow roller fairlead (part number 69373) is included, featuring a larger roller on top, designed for use with the plow system. This replaces the standard fairlead that may come with a WARN winch kit.
Materials: Components include bronze spacers (5/8" dia x 3/4" long, 5/8" outer dia x 3/4" long), nylon lock nuts, nylon bushings, and various steel brackets, mounts, and bolts.

Usage Features

Installation:
- Requires a WARN winch kit (winch and standard fairlead not included) and a Plow Blade kit and Utility Vehicle Plow Base kit (not included).
- Involves removing existing bumper mounting bolts, trimming front fascia plastic for brace clearance, and installing mounting brackets, braces, and a cross brace.
- The plow support is inserted into mounting brackets, which are then aligned and tightened.
- The specialized plow roller fairlead is installed, replacing any existing winch fairlead.
- Plow arms and stops are assembled onto the plow support, with generous greasing of arm bushings. Multiple arm and stop positions allow for calibration based on vehicle setup.
- Guide roller assembly, latch assemblies, and stands are installed.
Calibration:
- Crucial for proper plow operation and safety.
- Involves setting up the plow on level ground, extending the winch cable, and driving the vehicle to align the plow mount receivers with the plow support receivers.
- Adjustments are made if the bottom edge of the plow support receiver is not at the same height as the bottom surface of the plow mount. This may involve checking tire pressure, adjusting shock settings, or changing the detent pin position on the plow support.
- If the plow support receiver is still too low after these adjustments, the arm and arm stop settings on the plow support may need to be changed from position #1 to #2 or #3.
- Calibration should be performed whenever new tires are added, shock settings are changed, or weight is added/removed from the vehicle, and at least once per season.
Operation:
- The plow is attached to the vehicle by driving the vehicle into the plow support until fully engaged, then securing it with detent pins.
- The winch cable is routed over the middle roller on the plow support and attached to the quicklink on the plow base.
- The plow is raised and lowered using the winch switch.
- Plow blade angling is achieved by pulling a red handle and rotating the blade.
- Safety Precautions:
  - Always read the Plow Operator's Manual, Winch Operator's Manual, and all warning labels.
  - Wear safety glasses during installation.
  - Remove jewelry and wear eye protection.
  - Never lean over the battery while making connections.
  - Route electrical cables away from sharp edges, moving parts, or hot parts.
  - Insulate and protect all exposed wiring.
  - Operate the vehicle at a walking speed (never exceed 5 mph / 8 km/h) with the blade installed.
  - Plow cautiously to avoid sudden stops or loss of control from impacts with hidden objects.
  - Never operate on slopes greater than 10 degrees.
  - Never stand or ride on the plow.
  - Keep clear of moving parts and joints, and keep others away during operation.
  - Do NOT operate the winch without the hook properly installed and a hook strap.
  - Do NOT operate the winch when routing the cable without the hook and hook strap.
  - Do NOT mix and match position settings for the arms and arm stops, as this can cause erratic plow behavior, damage, or eject vehicle occupants upon impact.
  - Avoid lifting the plow until it stalls against the vehicle, as this can cause excessive cable wear and damage.
  - Drive at speeds that prevent the plow from bouncing in the up position, which can cause the winch to back-drive and the plow to drop unexpectedly.
  - Be aware that the j-bolt is designed to break if the plow is raised too high, preventing ATV damage but causing the blade to drop suddenly. Ensure no bystanders are present when raising/lowering the plow.
  - Never raise the top of the plow above the ATV headlights.
  - Use proper lifting techniques (bend at knees, lift with legs) when handling the heavy plow support.

Maintenance Features

Regular Inspections: Perform regular inspections and maintenance on the plow mechanism, fasteners, cable, and related hardware.
Part Replacement: Replace all worn or damaged parts before operating. This includes rusted or deformed metal parts, loose, stripped, fractured, or bent nuts and bolts, and worn or frayed cables.
Lubrication: Generously grease the inside of the arm bushings during installation and as needed to ensure free movement.
Debris Removal: Check all moving and rotating parts and remove any debris that may inhibit free movement.
J-bolt Replacement: Always replace a deformed or broken j-bolt with the spare j-bolt included in the kit.
Cable Management: If the winch cable becomes tangled around the drum, pull off the plow assembly, freespool the cable out of the winch, and then neatly spool it back onto the drum. Use a winch strap, not the cable or hook, for handling.
Calibration: Recalibrate the plow every time new tires are added, shock settings are changed, or weight is added/removed from the vehicle, and at least once per season.