Warn ZEON Installation And Operator's Manual

Warn Industries, Inc.

12900 S.E. Capps Road

Clackamas, OR USA 97015-8903

1-503-722-1200 FAX: 1-503-722-3000

www.warn.com

Customer Service / Service Clients: 1-800-543-9276

ZEON® Platinum Winch and

Advanced Wireless Remote Control

INSTALLATION AND OPERATOR’S GUIDE

GUIDE D’INSTALLATION ET OPERATEUR

92821A4

English .......................................................................... 1

Français ......................................................................25

Español .......................................................................49

92821A4

Every winching situation has the potential for personal injury. In order to minimize that risk, it is important to read ALL instructions and safety information regarding your product. Please familiarize yourself with the operation of your winch before using it and be constantly safety oriented. These instructions provide important safety information and instructions on how to

install and operate your winch.

In this kit you will find the following pieces of literature:

• Winch Installation Guide/ First Time Operation Instructions

• Product Warranty

SAVE THIS MA NUAL and other product literature for future reference and review frequently

for continuing safe operation.

Instruct all users of this product to review this manual before operating this product.

Additional Product Literature Available Online

• Basic Guide to Winching Techniqu es

• Provides a basic understanding of the winch and teaches basics of proper winching techniques. It is a valuable resource to help winch safely and efficiently.

• Product Specification and Performance Data

• Provides product specifications, performance data and replacement parts information.

• Other product literature specific to some products

Go to

www.warn.com/corporate/literaturerequest.shtml

for additional or replacement

product literature available to view/download.

WARN INDUSTRIES

Warn Industries Inc.

12900 SE Capps Road

Clackamas, OR 97015

USA

Customer Service: (800) 543-9 276

International Fax: (503) 722 -3005

Fax: (503) 722-3000

www.warn.com

ZEON® Platinum Winch and Advanced Wireless Remote Control Installation and Operation Guide

TABLE OF CONTENTS:

SAFETY

Symbol Index .......................................................... ............................................................................................................... 3-4

General Safety Precaut ions/FCC & IC Regulations .................................................................................................. .5-8

INSTRUCTIONS

Know Your Winch ................................................................................................... ........................................................... 9-10

Know Your Advanced Wireless Remote Control....................................................... ................................................. 11

Mounting ..................................................................................................................................... .......................................12-13

Electrical Connections ........................................ ................................................................................................................. 14

System Check .................................................................................................................................. ........................................ 14

First Time Operation Instructions ............................................................................................ ..................................15-22

Getting Started ......................................................... .................................................................................................. 15

Home Menu Operat ion ......................................................................................................................................... ...15

Winch Menu Operati on ..................................................................... ................................................................15-18

Auxiliary Menu Operat ion..................................................................................................................................... ..19

Setting Operation ................................................................... .............................................................................20-22

Trouble Shooting/Error Conditions ........................................................... ..................................................................... 23

Final Analysis and Maintenance ................................................................................................................ .....................2 4

WARN INDUSTRIES

ORIGIN AL INSTRUC TIONS

92821A4

SYMBOL EXPLANATION

Read All Product Literature

* Some literature available only onlinewww.warn.com/corporate/ literaturerequest.shtml.

Always Wear Hearing and Eye Protection

Never Use Winch as a Hoist

Properly Seat Load in Throat of Hook

Wind Rope on Bottom of Drum

Finger/Fairlead Crushing Hazard

Hand Piercing/Cutting Hazard

Explosion/Bursting Hazard

Never Route Electrical Cables through Sharp Edges Hazard

Avoid Installing Electrical Cables around Pinch and Wear/Abrasion Points

SYMBOL EXPLANATION

Always Wear Leather Gloves

Do Not Move People

Always Use Supplied Hook Strap

Never Apply Load to Hook Tip or Latch

Never Wind Rope Over Top of Drum

Fairlead Pinch Point

Hot Surface Hazard

Fire and Burn Hazard

Never Route Electrical Cables through or near Moving Parts Hazard

Exposed Wiring Hazard, Insulate Exposed Wiring and Terminals

Never Hook Back on Rope

WARN INDUSTRIES 3

SYMBOL INDEX

Symbol Index for Winch

WARN INDUSTRIES 4

SYMBOL INDEX

Symbol Index for Advanced Wireless Remote Control

SYMBOL EXPLANATION

Auxiliary (Aux)

Auxiliary 1 (Aux 1)

Auxiliary 2 (Aux 2)

Brightness

Clutch Disengaged

Clutch Engaged

Clutch Disengagement Function Error

Dual Auxiliary (Dual Aux)

Home

Unlinked from High Beam

Linked to High Beam

SYMBOL EXPLANATION

Pairing

Power

Thermal Protection

Advanced Wireless Remote Control Battery Charge

Settings

Vehicle Battery Charge

Winching

Winch Motor Temperature

Winching In

Winching out

Wireless Signal Strength

92821A4

FCC Regulation

This device complies with Part 15 of the FCC Rule. Operation is subject to the following two conditions:

(1) this device may not cause harmful interference, and (2) this device must accept any interference received,

including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment oﬀ and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit diﬀ erent from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

§ 15.21 Information to user.

The users manual or instruction manual for an intentional or unintentional radiator shall caution the user that changes or modi cations not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. In cases where the manual is provided only in a form other than paper, such as on a computer disk or over the Internet, the information required by this section may be included in the manual in that alternative form, provided the user can reasonably be expected to have the capability to access information in that form.

As you read these instructions,

you will see

WARNINGS,

CAUTIONS, NOTICES

and

NOTES

. Each message has a speci c purpose. WARNINGS are safety messages that indicate a potentially hazardous situation, which, if not avoided could result in serious injury or death. CAUTIONS are safety messages that indicate a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. A CAUTION may also be used to alert against unsafe practice. CAUTIONS and WARNINGS identify the hazard, indicate how to avoid the hazard, and advise of the probable consequence of not avoiding the hazard. NOTICES are messages to avoid property damage. NOTES are additional information to help you complete a procedure.

PLEASE WORK SAFELY!

Warnings and Cautions

Industry Canada

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including

interference that may cause undesired operation of the device.

Under Industry Canada regulations, this radio transmitter may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that necessary for successful communication.

This radio transmitter (identify the device by certi cation number, or model number if Category II) has been approved by Industry Canada to operate with the antenna types listed below with the maximum permissible gain and required antenna impedance for each antenna type indicated. Antenna types not included in this list, having a gain greater than the maximum gain indicated for that type, are strictly prohibited for use with this device.

WARN INDUSTRIES 5

GENERAL SAFETY PRECAUTIONS

MOVING PARTS ENTANGLEMENT HAZARD

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

General Safety:

• Always Know Your Winch. Take time to fully read the

Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations, found online at http://www. warn.com/corporate/literaturerequest.shtml.

• Never exceed winch or winch rope rated capacity. Double

line using a snatch block to reduce winch load.

• Always wear heavy leather gloves when handling winch

rope.

• Never use winch or winch rope for towing. Shock loads

can damage, overload and break rope.

• Never use a winch to secure a load.

• Never operate this winch when under the in uence of

drugs, alcohol or medication.

• Never operate this winch if you are under 16 years of age.

Installation Safety:

• Always choose a mounting location that is suﬃ ciently

strong to withstand the maximum pulling capacity of your winch.

• Always use class 8.8 metric (grade 5) or better hardware.

• Never weld mounting bolts.

• Always use factory approved mounting hardware,

components, and accessories.

• Never use bolts that are too long.

• Always con rm required bolt length to ensure proper

thread engagement.

• Always complete the winch installation and hook

attachment before installing the wiring.

• Always keep hands clear of winch rope, hook loop, hook

and fairlead opening during installation, operation, and when spooling in or out.

• Always position fairlead with warning readily visible on

top.

• Always prestretch rope and respool under load before

use. Tightly wound rope reduces chances of “binding”, which can damage the rope.

WARNING

MOVING PARTS ENTANGLEMENT HAZARD

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

Winching Safety:

• Always inspect winch rope, hook, and slings before

operating winch. Frayed, kinked or damaged winch rope must be replaced immediately. Damaged components must be replaced before operation. Protect parts from damage.

• Always remove any element or obstacle that may

interfere with safe operation of the winch.

• Always be certain the anchor you select will withstand

the load and the strap or chain will not slip.

• Always use supplied hook strap whenever spooling

winch rope in or out, during installation and during operation.

• Always require operators and bystanders to be aware of

vehicle and or load.

• Always be aware of stability of vehicle and load during

winching, keep others away. Alert all bystanders of an unstable condition.

• Always unspool as much winch rope as possible when

rigging. Double line or pick distant anchor point.

• Always take time to use appropriate rigging techniques

for a winch pull.

• Never touch winch rope or hook while someone else is

at the control switch or during winching operation.

• Never engage or disengage clutch if winch is under

load, winch rope is in tension or drum is moving.

• Never touch winch rope or hook while under tension or

under load.

• Always stand clear of winch rope and load and keep

others away while winching.

• Never use vehicle to pull load on winch rope. Combined

load or shock load can damage, overload and break rope.

• Never wrap winch rope back onto itself. Use a choker

chain or tree trunk protector on the anchor.

• Never use remote when vehicle is not in line of sight of

operator.

• Never pair more than one winch and one remote

together at the same time.

WARNING

WARN INDUSTRIES 6

GENERAL SAFETY PRECAUTIONS

92821A4

FALLING OR CRUSHING HAZARD

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

•

Always

stand clear, keep hands clear, keep others away.

• Never operate winch with less than 5 wraps of wire

rope/10 wraps of synthetic rope around the drum. Rope could come loose from the drum, as the rope attachment to the drum is not designed to hold a load.

• Never use winch as a hoist or to suspend a load.

• Always be certain anchor will withstand load, use

appropriate rigging and take time to rig correctly.

• Never use winch to lift or move persons.

• Never use excessive eﬀ ort to freespool winch rope.

•

Always

use proper posture/lifting technique or get lifting

assistance while handling and installing product.

• Always wind the winch rope on bottom (mountside) of

drum.

• Never wind rope over top of drum.

• Always spool the winch rope onto the drum in the

direction speci ed by the drum rotation labels on the winch and/or in the documentation. This is required for the automatic brake (if so equipped) to function properly.

CUT AND BURN HAZARD

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

To avoid injury to hands and  ngers:

• Always wear heavy leather gloves when handling winch

rope.

• Always be aware of possible hot surfaces at winch

motor, drum or rope during or after winch use.

WARNING

MOVING PARTS ENTANGLEMENT HAZARD

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

•

Always

ensure hook latch is c losed and not supporti ng load.

•

Never

apply load to hook tip or latch. Apply load only to

the center of hook.

•

Never

use a hook whose throat opening has increased, or

whose tip is bent o r twisted.

•

Always

use a hook with a latch.

•

Always

ensure the operator and bystanders are aware of

the stability of t he vehicle and/or load.

•

Never

hook back on rope.

WARNING

CHEMICAL AND FIRE HAZARD

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

•

Always

remove jewelry and we ar eye protection.

•

Never

route electrical cab les across sharp edges.

•

Never

route electrical cab les near parts that get hot.

•

Never

route electrical cab les through or near moving par ts.

•

Always

place the supplied ter minal boots on wires and

terminals as directed by the installation instructio ns.

•

Never

lean over battery w hile making connections.

•

Never

route electrical cabl es over battery terminals.

•

Never

short batter y terminals with metal objec ts.

•

Always

verify area is clear of fu el lines, fuel tank, brake

lines, electrical wires, etc., when drilling.

•

Always

consult operator’s manual for proper wiring details.

•

Always

insulate and protect al l exposed wiring and

electrical terminal s.

•

Always

connect red (+) power cable ONLY to the positive

(+) terminal of the battery.

•

Always

connect black g round (-) power cable ONLY to the

negative (-) terminal of the battery.

•

Never

connect red (+) power cable to the negative (-)

terminal of the batter y.

WARNING

WARN INDUSTRIES 7

GENERAL SAFETY PRECAUTIONS

AVOID WINCH AND EQUIPMENT DAMAGE

• Always avoid side pulls which can pile up winch rope

at one end of the drum. This can damage winch rope or winch.

• Always ensure the clutch is fully engaged or disengaged.

• Always use care to not damage the vehicle frame when

anchoring to a vehicle during a winching operation.

• Never submerge winch in water, if not IP68 rated.

• Always store the remote control in a protected, clean,

dry area.

NOTICE

MOVING PARTS ENTANGLEMENT HAZARD

Failure to observe these instructions could lead to minor or moderate injury.

To avoid injury to hands or  ngers:

• Never leave winch remote control where it can be

activated during free spooling, rigging, or when the winch is not being used.

• Never leave the wireless winch remote control turned on

when installing, freespooling, rigging or servicing winch, or when the winch is not being used.

CUT AND BURN HAZARD

Failure to observe these instructions could lead to minor or moderate injury.

• Never let winch rope slip through your hands.

CAUTION CAUTION

This manual provides instructions on how to install and operate your WARN® ZEON® Platinum

winch and operating your Advanced Wireless Remote Control.

Always read the Basic Guide To Winching Techniques for complete operational instructions

for your WARN® winch system.

Safety

When installing your WARN® winch system, read and follow all mounting and safety

instructions.

Always use caution when working with electricity and remember to verify that no exposed

electrical connections exist before energizing your winch circuit.

For specifications and performance data, refer to the specification sheet supplied with your winch.

WARN INDUSTRIES 8

GENERAL SAFETY PRECAUTIONS

92821A4

Before you begin, you should familiarize yourself with your WARN® winch and each of its components:

Motor

: The winch motor is powered by the vehi cle’s battery. The motor provides

power to the gear mechanism, which turns the winch drum and winds the winch rope.

Winch Drum:

The winch drum is the cylinder onto which the winch rope feeds. The

drum is driven by the motor and drive train. Its direction ca n be changed using the Advanced Wireless Remote Control.

Winch Rope:

The winch rope’s diameter and length are determined by the winch’s load capacity and design. Wrapped around the winch drum and fed through the fairlead, the winch rope is looped at the end to accept the hook’s clevis pin.

For synthetic rope models, be sure to fully read these instructions to

familiarize yourself completely with the Advanced Wireless Remote Control operation before you attempt to install the optional synthetic rope. See your WARN® Synthetic Rope Installation Instruction Manual for detailed synthetic rope installation instructions.

Transmission:

The reduction gear converts the winch motor power in to a large pulling force. The gear train design makes it pos sible for the winch t o be lighter and more compact.

Remote controlled clutch :

The remote controlled clutch is concealed within the end cap housing.

It is controlled by the Advanced Wireless Remote Control. It all ows for engagement and disengagement of the clutch with the Advanced Wireless Remote Control.

Control Pack:

Using electrical power from the vehicle’s battery, the control pack’s

contactor switches power to the motor, enabling the ope rator to change the direction of the winch drum rotation.

For specific applications, the optional Control Pack Relocation Kit details can be found at your WARN® Authorized Dealer or www.warn.

com.

Motor

Control Pack

Transmission

Winch Rope

Winch Dru m

Remote C ontrolled Clut ch

WARN INDUSTRIES 9

KNOW YOUR WINCH

Wireless Control Activation Switch:

The wireless control activation switch activates or deactivates the wireless control unit.

This switch

must

be ‘ON’ (activated) in order for the A dvanced Wireless Rem ote Control to operat e the winch. The wireless control unit uses a very s mall but constant current from the vehicle battery. It is recommended to turn the switch “OFF” (deactivate) the unit to prevent draining the vehicle battery when not operating the vehicle for an extended period of time.

Auxiliary Power Ports (1 a nd 2):

The auxiliary power ports a llow you to connect and control two

separate auxiliary systems from the winch.

The optional Auxiliary Kit details can be found at your WARN® Authorized Dealer or www.warn.com.

Remote Controlled Clutch Wire H arness

: The remote controlled clutch wire harness plugs into the winch

control pack.

Auxiliar y Power Port 1

Wireless C ontrol

Activatio n Switch

Remote C ontrolled

Clutch Wir e Harness

Auxiliar y Power Port 2

WARN INDUSTRIES 10

KNOW YOUR WINCH

92821A4

Before you begin, you should familiarize yourself with your WARN® Adva nced Wireless Remote Control

and each of its functions.

Advanced Wireless Remote Control:

The Advanced Wireless Remote Control allows the operator t o control the winch

and two auxiliaries.

LCD:

Display of fun ction menus, importan t vehicle feedback a nd winch functions.

Select Button:

Press to c onfirm/activate selections .

Left Button:

Press to n avigate left through each menu display.

Right Button:

Press to na vigate right through each menu display.

Winch Power-out Button:

Press to control the power-out operation of the w inch.

Winch Power-in Button:

Press to control the power-in operation of the win ch.

Reset Button

: The reset button is used to restart your remote in rare cases when it functions

incorrectly. Resetting the remote will preserve your settings.

USB Charging Port:

Used to charge the internal b attery.

USB Cable

(not shown)

: Used to c onnect Advanced Wire less Remote Control t o

chargers or your computer to charge.

Car Charger Adapter

(not shown): Car charger allows plugging into car’s DC socket to keep

your Advan ced Wireless Remote C ontrol powered whe n you are o n the go.

Helpful Hint:

Connect your remote

to a charging device now.

This will allow your remote

to charge while you are

installing your winch. Refer

to page 13 for charging

steps.

USB Charging Port

WARN INDUSTRIES 11

KNOW YOUR ADVANCED WIRELESS REMOTE

LCD

Right

Button

Select

Button

Winch

Power-in

Button

Winch

Power-out

Button

Left

Button

Reset

Button

Mounting Orientation and Hardware

Feet down mounting:

• (4) M10 -1.5  anged hex locknut

• (4) M10-1.5 x 35 hex  ange, 8.8, bolt

• (2) 7/16-14 x 1 hex bolt

For feet forward mounting:

• (4) M10x1.5  anged locknut 15mm hex

• (4) M10-1.5 x 35 hex  ange, 8.8, bolt

• (2) M10-1.5 x 40 hex  ange, 8.8, bolt (found

in separate plastic bag)

Step 1 - Mount the Winch

Winch moun ting kits are available to satisfy nearly all applicatio ns. For information on available kits, contact your WARN® product de aler.

NOTICE

For optimal performance and the results you expect,

WARN® mounting plates are strongly recommended.

CAUTION

To prevent accidental activation of the winch and serious injury, complete the winch installation and attach the hook before installing the wiring.

WARNING

Always choose a mounting location that is suﬃ ciently strong enough to withstand the maximum pulling capacity of your winch.

WARNING Never use bolts that are too long.

WARNING Always spool the winch rope onto the drum

in the direction speci ed by the drum rotation labels on the winch and/or in the documentation. This is required for the automatic brake (if so equipped) to function properly.

WARNING Always wind the winch rope on the bottom

(mount side) of the drum.

This winch should always be m ounted in a horizontal or ientation with the ro pe winding on and off t he drum on the mount side (bottom) of the drum.

Correct rota tion is required for the automatic brake to function properly. Ho rizontal mounting helps preven t the rope from p iling up on one e nd of the drum which can damage the winch.

Always u se recommended bolt and washer combinations torqued to recomme nded levels. Specifications listed below. Mou nting system will dictate bolt length.

Mounting Bolt Pattern:

Standard: 10”x 4.5” (54 mm x 114.3 mm) Smooth and  at mounting surface, minimum thickness = 1/4” (6.4 mm)

(2) M10-1.5 x 35

(2) M10-1.5 x 40

(found in separate bag)

(4) M10-1.5  anged hex

locknut

(4) M10-1.5  anged hex

locknut

(4) M10-1.5 x 35  anged hex bolt

(2) 7/16-14 x 1 hex

bolt

WARN INDUSTRIES 12

MOUNTING

92821A4

Mount Winch:

1. Choose a m ounting location that is sufficiently strong enoug h to withstand the maximum pulling cap acity of your winch.

2. Install your mounting bracket per your specific mounting kit instructions.

3. Fasten fairlead to mounting bracke t using the (2) b olts specified above f or your specific mounting o rientation. See the

Mounting

Orientation

section f or hardware specifics

4. Set the (4) flanged nuts into pockets of winch feet.

5. Thread the hook loop end of the rope through the opening of mounting bracket and fairlead.

NOTE: Do not re move plastic wrap from remaining rope on drum at this time.

6. Set w inch in mount.

7. See table b elow to confirm requ ired bolt length.

Plate Thickness Bolt Length

7 mm (1/4”) 32 mm 10 mm (3/8”) 40 mm 13 mm (1/2”) 40 mm

8. Review moun ting orientation on p age 10 for bolt sizing.

9. Install bolts and tighten to 41 to 47 Nm (30-35 ft. lbs.).

WARNING

Always con rm required bolt length to

ensure proper thread engagement.

10. Attach hook to winch rope loo p.

11. Attach hook s trap to hook.

12. Remove plastic wrap from remaining rope on drum.

13. Mounting your winch is now comp lete. Check all hardware to be sure it is tight and to torq ue. You can now move on to Install the Wiring.

NOTE

OPTIONAL SYNTHETIC ROPE INSTALLAT ION

For synthetic rope models, be sure to fully read these instructions to familiarize yourself completely with the Advanced Wireless Remote Control operation before you attempt to install the optional synthetic rope. See your WARN® Synthetic Rope Installation Instruction Manual for detailed synthetic rope installation instructions.

WARN INDUSTRIES 13

MOUNTING

Step 2 - Install the Wiring

WARNING

To prevent serious injury or death. Always place the supplied terminal boots on wires and terminals as directed by the installation instructions.

WARNING

To prevent serious injury or death from electrical  re:

Never route electrical cables across sharp edges.

Never route electrical cables near parts that get hot.

Never route electrical cables through or near moving parts.

Avoid pinch and wear/abrasion points when installing all electrical cables.

WARNING

Always insulate and protect all exposed wiring and electrical terminals.

NOTICE

A fully charged battery and good connections are essential to the proper operation of your winch. The minimum requirement for a 12 volt DC battery is 650 Cold Cranking Amps.

Route battery connection cables in areas which will not cause them to chafe or cut through the insulation ca using a potential sh ort circuit.

The winch power wire must b e routed to the battery. A direct battery con nection of the power (red) and ground (black) cable is required.

Do not

connect ground to vehicle chassis.

Routing the battery connection cables may require remo val of vehicle facia or body parts.

Always rou te battery cables alon g a path that allows the cables to be secur ed with zip ties.

WARNING

Loose or unsecured power cables can cause

serious injury or death.

Always prot ect power cables fro m sharp edges, areas that get too hot to to uch with your hand and any moving parts.

1. Plan the routing path.

2. Loosely secure power cables along path.

3. Confirm power cables are protected f rom sharp edges, heat and moving parts. Consider chassis flex and vibration which might damage cable.

4. Carefully inspect electrical cable routing. Zip tie and secure electrical cables. Zip ties sh ould be snug, but not cutting into wire insulation. Use electrical tape, pieces of rubber hose or electrical conduit to protect electrical cables and wire harness where needed to avoid electrical cable insulation wear or abrasion.

5. FIRS T, attach the winch power (red) cable to the positive (+) battery terminal. SEC OND, attach the ground (black) cable to the negative (-) battery terminal.

WARNING

Always connect red (+) power cable ONLY to the

positive (+) terminal of the battery.

WARNING

Always connect black ground (-) power c able ONLY

to the negative (-) terminal of the battery.

Step 3 - System Check

Perform sy stem check:

1. Check fasteners and make sure they are tight and

to proper torque

2. Verify the wireless control activation switch light

turns ON. A flashing green light appears in the switch. If light does not turn on, immediately check to ensure power cables are correctly connected to the battery, red to (+) an d black to (-). If not, disconnect and reconnect as instructed.

3. Verify all electrical wiring to all components is

correct and be certain that all connections are tight.

4. Verify there is no exposed/bare wiring, terminals or

cable insulation damage.

5. Read The Basic Guide to Winching Techniques

completely before operating your winch.

6. Charge remote.

Once you have performed a system check, you ar e

ready to perform “First Time Operating Instructions”.

Ground ( black) Cable

Power (red) Cable

Wireless C ontrol

Activation Switch

Control Pack Ground

Wire

WARN INDUSTRIES 14

ELECTRICAL CONNECTIONS

92821A4

Wireless Signal Strength

Battery Indicator

Icon

Winching Auxiliary

Settings Power Oﬀ

Left Right

Select

Fully charged battery (green) Low charged battery (yellow) Critically low battery (red)

No Signal Weak Signal Fair Signal Strong Signal

WARN INDUSTRIES 15

FIRST TIME OPERATING INSTRUCTIONS

The bars on the wireless signal strength icon will

light up in sequence to show signal strength.

The remote control’s battery indic ator icon

indicates the state of the inter nal battery by

changing co lor and fill level of battery icon.

NOTE: If you r battery icon shows at a critically low level, you must charge the battery or plug into p ower source.

Home Menu

Turn on the remote by pressi ng any button. Th is

will automa tically bring up the Home Menu.

From the Home Menu, you ca n access each of

the four o perations.

Four Operations:

1) Winching 2) Auxiliary

3) System Settings 4) Power Off

1. Use the lef t and right buttons on your remote to navigate through the operati on menus.

To activate an operation, press select.

NOTE: To return to the Home Menu from othe r menus, navigate to the Home Icon (

) in the menu

bar and press Select.

In this section, we’ll show you the first time operating instructions for effective basic winch ing. For complete winch operation and techniques read the Basi c Guide to Winching Techniqu es found online at http://ww w.warn. com/corporate/literaturer equest.shtml.

Getting Started

Your ZEON ® P latinum Winch is op erated by the new Advance d Wireless Remote Control.

The Advance d Wireless Remote Control is designed to allow the operator to control the win ch and two a uxiliaries remotely.

1. Verify the wireless control switch (located on

back of c ontrol pack) is “ON” (a green flashing light appea rs inside switch). T he switch

must

be ‘ON’ ( activated) in order for the Advanced Wireless Rem ote Control to oper ate the winch.

Charging the Battery

Your WARN® Advanced Wireless R emote Control is powered by an internal rech argeable lithium ion battery. A lthough the battery will arrive partially charged, you must fully charge the battery or plug into a po wer source before u se.

1. Connect the included USB charger to the

Advanced W ireless Remote Contro l.

2. Plug other e nd of the USB ch arger into a power

source (such as the included auto charger, a wall charger or a computer U SB port).

NOTE:

Remote is operable while charging.

3. The remote control will power o n and the

charging ico n (

) will appear inside the battery indi cator in the upper right corner of the menu, indicating the remote is charging.

4. The remote is fully charged wh en the battery indicator ico n is filled.

NOTE: Allow a minimum

of two hours for battery to fully charge.

The Status Bar

The status bar allows the op erator to keep track of the wi reless signal strength and the remote’s battery life during all menu o perations.

NOTE: A strong wireless signal and a fully charged battery is recommended for opt imal performance.

Step 4 - First Time Operating Instructions

Wireless C ontrol

Activation

Switch

Select

Left

Right

Winch Operation Direction Status

Vehicle Battery

Level

Home

Winch Motor Temp.

Aux 1 Aux 2

Clutch Disengage Icon

Clutch Status

(Disengaged)

WARN INDUSTRIES 16

FIRST TIME OPERATING INSTRUCTIONS

Winch Menu

Your winch is completely contr olled by the

WARN® Adv anced Wireless Remote Control.

You should practice activating th e Winch Menu a few tim es to get familiar with its functions be fore you move on to the “Winchin g” section of this manual.

Activate Winch Operation Menu

1. Read The B asic Guide to Winc hing Techniques

thoroughly b efore you attempt to operate your winch.

2. From the H ome Menu, navigate to the Winch

Icon using the Left and Right buttons and press Select.

3. Following th e Win ch Activation Menu p rompt,

press and hold the Left and Right buttons simultaneousl y for 3 seconds to activate the Winch Opera tion menu.

Note: The Win ch Activation Menu will revert back to the Home Menu if at idle for one minute.

The main purpose of the Winc h Operation Menu is to operate your winc h. However, you are also able t o control your aux iliary systems, keep track of yo ur vehicle battery level, w inch motor temperature, winch operation dire ction, clutch status, wirel ess signal strength a nd the remote battery life .

NOTE: The Winch Operation Menu is accessible from any menu by pressing and holding the left and right buttons simultane ously for three seconds.

Remote Controlled Clutch Basics

The WARN® ZEON® Platinum winc h is equipped with a re mote controlled clutch . It allows for engagement and disengagement of the clutch with the Advanc ed Wireless Remote C ontrol.

When the clutch is engaged, power is transferred from the w inch motor to the drum and winch rope, resulting in the power-in or p ower-out operation.

NOTE: Your WAR N® ZEON® Platinum winch clutch will always default to the engaged position.

When the clutch is disengaged the drum is in the freespoo l position, allowing the drum to rotate freely. Fr eespooling is generally the quickest and easiest way to spool out winc h rope.

Disengaged Clutch

(Freespool)

Engaged Clutch

(Winching)

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Clutch Status

(ERROR)

Clutch Disengage Icon

Winch

Power-out

Winch

Power-in

Clutch Status

(ERROR)

Clutch Disengage Icon

Clutch Status

(Disengaged)

WARN INDUSTRIES 17

FIRST TIME OPERATING INSTRUCTIONS

Disengage Remote Controlled Clutch

WARNING

Never engage or disengage clutch if winch is

under load, winch rope is in tension or drum is moving.

1. Make sure t he winch rope is n ot under tension.

NOTE: The clutch will not disengage if the winch rope is under ten sion. If tension exists, powerout enough rope t o remove any tension from the winch rope.

2. Activate the Winch Operation Men u (

refer to

page 14

3. Navigate to the clutch disengage icon (

) in the menu bar on the winch function menu and press Select.

4. Once the c lutch is successfully d isengaged, the gears in both the clutch status and clutch disengage ic on will change from “engaged”

(

) status to “disengaged” ( ) st atus.

If clutch d oes not disengage when requested, a warning er ror will display within the clutch status icon. Se e Trouble Shooting s ection in this manua l for possible solutions.

Engage Remote Controll ed Clutch

WARNING

Never engage or disengage clutch if winch is

under load, winch rope is in tension or drum is moving.

After you have disengaged the clutch, there are

three ways the clutch can be engaged.

• Push the Win ch Power-in

Winch Power-out

button.

• Return to the Home Menu and th e clutch will immediately r eturn to engage s tatus.

• After five minu tes the clutch will automatically engage.

Once clutch is successfully eng aged, the

clutch statu s icon and the clu tch disengage icon will change from “disengaged” (

) status to

“engaged” (

) status.

If clutch d oes not engage whe n requested, a

warning er ror will display within the clutch status icon. Se e Trouble Shooting s ection in this manua l for possibl e solu tions.

WINCHING

WARNING

Always wear heavy leather gloves when

handling winch rope.

WARNING

Never exceed winch’s rated line pull.

WARNING

Always prestretch rope and respool under load before use. Tightly wound rope reduces chances of “binding”, which can damage the rope.

WARNING

Never operate winch with less than 5 wraps of wire rope/10 wraps of synthetic rope around the drum. Rope could come loose from the drum, as the rope attachment to the drum is not designed to hold a load.

Select

Clutch Disengage Icon

Clutch Status

(Engaged)

5. Confirm clutch (disengage /freespoo l) status.

6. Freespo ol winch rope to anchor point and secure.

Pulling

1. Thoroug hly read The Basic Guide to Winching Techniques for complete Pulling Instructions.

2. Power-in to start winching.

3. Secure vehicle .

4. Power-out to release tension in winch rope.

5. Disconnect win ch rope from anch or.

6. Power-in win ch rope for storage.

WARNING

Never spool in rope hook against the fairlead.

Next, are c ondensed procedures for winching

operation. You

must

read the Basic Guide to Winching Tec hniques manual for complete procedure in structions.

Stretching Winch Rope

Tensioning t he winch rope is c ritical to ensure a long pr oduct life. Tensioning the winch rope w ill prevent oute r layers of winch rope from pinching and deformin g the inner layers.

1. Read your B asic Guide to Winch ing Techniques

for Stretchi ng Winch Rope instru ctions.

Rigging

1. Thoroug hly read The Basic Guide to Winching

Techniques for complete Rigging Instructions.

2. Select Winchin g function.

3. Activate winc h.

4. Disengage Cl utch.

NOTE: The clutch will not disengage if the winch rope is under ten sion.

WARN INDUSTRIES 18

FIRST TIME OPERATING INSTRUCTIONS

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Select

WARN INDUSTRIES 19

FIRST TIME OPERATING INSTRUCTIONS

Auxiliary Menu

Your WARN® Advanced Wireless R emote Control

can control up to two separate auxiliary systems*.

NOTICE

Auxiliary systems must be rated for 12 v and

draw less than 16 amps.

Auxiliary co nnection adapter kits are necessary in order t o operate the auxiliar y system. For information on available kits, con tact your WARN® product dea ler, WARN Customer Service or www. warn.com.

Activate Auxiliary Operation Menu

1. From the Home Menu, navigate to the Auxiliary Icon and p ress Select.

Auxiliaries c an be switched on and off together using the Dual Auxiliary Icon or individually by using the Auxiliary 1 and Aux iliary 2 Icon and then pressing Sel ect.

When an auxiliary is OFF the icons will show outlined. Wh en an auxiliary is ON, the icons will appear solid .

Dual Auxiliary ON

Auxiliary 1 ON

Auxiliary 2 ON

Aux 1 Status

Aux 2

Status

Dual Aux Icon

Aux 1

Icon

Aux 2

Icon

Select

Brightness Icon

Select

Auxiliar y 1

Unlinked

Select

Auxiliary 1

Auxiliary 2

Select

Auxiliar y 1

Linked

WARN INDUSTRIES 20

FIRST TIME OPERATING INSTRUCTIONS

Link Auxiliary High Beam

With your Advanced Wireless Re mote, you are able to link you r auxiliaries to your vehicle high beam settin g.

1. To link the auxiliary (1 or 2) with your vehicle’s

high beam setting, navigate to the Auxiliary 1 or 2 Icon and press Select.

2. The auxiliarie s default as unlinked.

3. Using your left or right button to highlight the

“linked” ico n. A check mark will appear in the box. Pre ss select to confirm selection.

Note: Images show linking Auxiliary 1. Same pr ocess will be used for Auxiliary 2 linking.

Settings Menu

From your Setting menu, you are able to adjust screen brig htness, pair your rem ote, link auxiliaries to your h igh beam setting and turn on the ther mal shut-off opt ion.

Activate the Settings Operation Menu

1. From the Home Menu, navigate to the Settings Icon and p ress Select.

Adjust Brightness

1. To adjust t he brightness, navigate to the Brightness Ic on and press Select .

2. Use the Lef t and Right buttons to adjust slider to the de sired brightness. On ce the brightness is at the desired level, press Select to close the brightness ad just panel.

Select

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+ 26 hidden pages

Warn ZEON Installation And Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual