Zeon Platinum - Operators & Install Manual - 92821.A5

97734.A1 - 16.5TI-S Replacement Parts List

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

92821A5

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

Français....................................................................... 23

Español........................................................................ 45

ORIGINAL INSTRUCTIONS

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

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.

TABLE OF CONTENTS:

SAFETY

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

General Safety Precautions/FCC & IC Regulations ...................................................................................................5-8

INSTRUCTIONS

In this kit you will find the following pieces of literature: • Winch Installation Guide/ First Time Operation Instructions • Product Warranty

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

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

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

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

SAVE THIS MANUAL 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.

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

First Time Operation Instructions..............................................................................................................................15-22 Getting Started ........................................................................................................................................................... 15 Home Menu Operation............................................................................................................................................ 15 Winch Menu Operation .....................................................................................................................................15-18 Auxiliary Menu Operation.......................................................................................................................................19 Setting Operation ................................................................................................................................................20-22 Trouble Shooting/Error Conditions ................................................................................................................................ 23 Final Analysis and Maintenance .....................................................................................................................................24

Additional Product Literature Available Online : • Basic Guide to Winching Techniques • 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 for additional or replacement product literature available to view/ download.

Warn Industries Inc. 12900 SE Capps Road Clackamas, OR 97015 USA

Customer Service: (800) 543-9276 Fax: (503) 722-3000 www.warn.com

WARN INDUSTRIES 1

WARN INDUSTRIES 2

SYMBOL INDEX

Symbol Index for Winch

Symbol Index for Advanced Wireless Remote Control

SYMBOL

EXPLANATION

SYMBOL

EXPLANATION

SYMBOL

EXPLANATION

SYMBOL

EXPLANATION

Read All Product Literature

Always Wear Leather Gloves

Auxiliary (Aux)

Pairing

* Some literature available only online www.warn.com.

Auxiliary 1 (Aux 1)

Power

Always Wear Hearing and Eye Protection

Do Not Move People

Always Use Supplied Hook Strap

Auxiliary 2 (Aux 2)

Thermal Protection

Never Use Winch as a Hoist

Advanced Wireless Remote Control Battery Charge

Never Apply Load to Hook Tip or Latch

Brightness

Properly Seat Load in Throat of Hook

Never Wind Rope Over Top of Drum

Clutch Disengaged

Settings

Wind Rope on Bottom of Drum

Vehicle Battery Charge

Clutch Engaged

Fairlead Pinch Point

Finger/Fairlead Crushing Hazard

Clutch Disengagement Function Error

Winching

Hot Surface Hazard

Hand Piercing/Cutting Hazard

Winch Motor Temperature

Dual Auxiliary (Dual Aux)

Fire and Burn Hazard

Explosion/Bursting Hazard

Never Route Electrical Cables through or near Moving Parts Hazard

Winching In

Home

Never Route Electrical Cables through Sharp Edges Hazard

Unlinked from High Beam

Exposed Wiring Hazard, Insulate Exposed Wiring and Terminals

Winching out

Avoid Installing Electrical Cables around Pinch and Wear/Abrasion Points

Linked to High Beam

Wireless Signal Strength

Never Hook Back on Rope

WARN INDUSTRIES 3

WARN INDUSTRIES 4

GENERAL SAFETY PRECAUTIONS

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 certiöcation 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.

WARNING

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 different 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 modiöcations 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 speciöc 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!

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.

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 www.warn.com . • 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 inøuence 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 sufficiently 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 conörm 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.

WARN INDUSTRIES 5

WARN INDUSTRIES 6

GENERAL SAFETY PRECAUTIONS

WARNING

CAUTION

WARNING

CUT AND BURN HAZARD Failure to observe these instructions could lead to minor or moderate injury. • Never let winch rope slip through your hands.

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury. To avoid injury to hands or öngers: • 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.

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to serious injury or death. • Always ensure hook latch is closed and not supporting 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 or twisted. • Always use a hook with a latch. • Always ensure the operator and bystanders are aware of the stability of the vehicle and/or load. • Never hook back on rope.

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 effort 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 speciöed 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

NOTICE

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.

CHEMICAL AND FIRE HAZARD Failure to observe these instructions could lead to serious injury or death. • Always remove jewelry and wear eye protection. • 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. • Always place the supplied terminal boots on wires and terminals as directed by the installation instructions. • Never lean over battery while making connections. • Never route electrical cables over battery terminals. • Never short battery terminals with metal objects. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc., when drilling. • Always consult operator’s manual for proper wiring details. • Always insulate and protect all exposed wiring and electrical terminals. • Always connect red (+) power cable ONLY to the positive (+) terminal of the battery. • Always connect black ground (-) power cable ONLY to the negative (-) terminal of the battery. • Never connect red (+) power cable to the negative (-) terminal of the battery.

WARNING

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.

CUT AND BURN HAZARD Failure to observe these instructions could lead to serious injury or death. To avoid injury to hands and öngers: • 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.

WARN INDUSTRIES 7

WARN INDUSTRIES 8

KNOW YOUR WINCH

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

Wireless Control Activation Switch

Auxiliary Power Port 2

Control Pack

Motor

Auxiliary Power Port 1

Transmission

Remote Controlled Clutch

Winch Drum

Remote Controlled Clutch Wire Harness

Winch Rope

Motor :

The winch motor is powered by the vehicle’s battery. The motor provides power to the gear mechanism, which turns the winch drum and winds the winch rope. The winch drum is the cylinder onto which the winch rope feeds. The drum is driven by the motor and drive train. Its direction can be changed using the Advanced Wireless Remote Control. 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. The reduction gear converts the winch motor power into a large pulling force. The gear train design makes it possible for the winch to be lighter and more compact. The remote controlled clutch is concealed within the end cap housing. It is controlled by the Advanced Wireless Remote Control. It allows for engagement and disengagement of the clutch with the Advanced Wireless Remote Control. Using electrical power from the vehicle’s battery, the control pack’s contactor switches power to the motor, enabling the operator 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.

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 Advanced Wireless Remote Control to operate the winch. The wireless control unit uses a very small 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.

Winch Drum:

Winch Rope:

Auxiliary Power Ports (1 and 2): The auxiliary power ports allow 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 Harness : The remote controlled clutch wire harness plugs into the winch control pack.

Transmission:

Remote controlled clutch:

Control Pack:

WARN INDUSTRIES 9

WARN INDUSTRIES 10

KNOW YOUR ADVANCED WIRELESS REMOTE

MOUNTING

Before you begin, you should familiarize yourself with your WARN® Advanced Wireless Remote Control and each of its functions.

Step 1 - Mount the Winch Winch mounting kits are available to satisfy nearly all applications. For information on available kits, contact your WARN® product dealer. 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 sufficiently strong enough to withstand the maximum pulling capacity of your winch.

Mounting Orientation and Hardware Feet down mounting: • ( 4 ) M10 -1.5 øanged hex locknut • ( 4 ) M10-1.5 x 35 hex øange, 8.8, bolt • ( 2 ) 7/16-14 x 1 hex bolt

USB Charging Port

(4) M10-1.5 øanged hex locknut

LCD

Left Button

Right Button

WARNING Never use bolts that are too long.

WARNING Always spool the winch rope onto the drum in the direction speciöed 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 mounted in a horizontal orientation with the rope winding on and off the drum on the mount side (bottom) of the drum. Correct rotation is required for the automatic brake to function properly. Horizontal mounting helps prevent the rope from piling up on one end of the drum which can damage the winch. Always use recommended bolt and washer combinations torqued to recommended levels. Specifications listed below. Mounting system will dictate bolt length.

Select Button

Winch Power-out Button

Winch Power-in Button

Reset Button

(2) 7/16-14 x 1 hex bolt

(4) M10-1.5 x 35 øanged hex bolt

For feet forward mounting: • ( 4 ) M10x1.5 øanged locknut 15mm hex • ( 4 ) M10-1.5 x 35 hex øange, 8.8, bolt • ( 2 ) M10-1.5 x 40 hex øange, 8.8, bolt (found in separate plastic bag)

Advanced Wireless Remote Control:

The Advanced Wireless Remote Control allows the operator to control the winch and two auxiliaries. Display of function menus, important vehicle feedback and winch functions.

LCD:

(4) M10-1.5 øanged hex locknut

Mounting Bolt Pattern: Standard: 10”x 4.5” (54 mm x 114.3 mm) Smooth and øat mounting surface, minimum thickness = 1/4” (6.4 mm)

Select Button:

Press to confirm/activate selections.

(2) M10-1.5 x 35

Left Button:

Press to navigate left through each menu display.

Right Button:

Press to navigate right through each menu display.

Winch Power-out Button:

Press to control the power-out operation of the winch.

Winch Power-in Button:

Press to control the power-in operation of the winch.

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 battery.

Helpful Hint: Connect your remote

USB Cable (not shown) :

Used to connect Advanced Wireless Remote Control to chargers or your computer to charge.

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.

Car Charger Adapter (not shown) :

(2) M10-1.5 x 40 (found in separate bag)

Car charger allows plugging into car’s DC socket to keep your Advanced Wireless Remote Control powered when you are on the go.

WARN INDUSTRIES 11

WARN INDUSTRIES 12

MOUNTING

ELECTRICAL CONNECTIONS

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

1. Plan the routing path. 2. Loosely secure power cables along path. 3. Confirm power cables are protected from 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 should 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. FIRST, attach the winch power (red) cable to the positive (+) battery terminal. SECOND, 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 cable ONLY to the negative (-) terminal of the battery. Step 3 - System Check Perform system 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 (+) and 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 are ready to perform “First Time Operating Instructions”.

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 öre: Never route electrical cables across sharp edges.

Mount Winch: 1. Choose a mounting location that is sufficiently strong enough to withstand the maximum pulling capacity of your winch. 2. Install your mounting bracket per your specific mounting kit instructions. 3. Fasten fairlead to mounting bracket using the (2) bolts specified above for your specific mounting orientation. See the Mounting

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

6. Set winch in mount. 7. See table below to confirm required bolt length.

Plate Thickness

Bolt Length

Never route electrical cables near parts that get hot.

7 mm (1/4”)

32 mm

Never route electrical cables through or near moving parts.

10 mm (3/8”)

40 mm

13 mm (1/2”)

40 mm

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 causing a potential short circuit. The winch power wire must be routed to the battery. A direct battery connection of the power (red) and ground (black) cable is required. Do not connect ground to vehicle chassis. Routing the battery connection cables may require removal of vehicle facia or body parts. Always route battery cables along a path that allows the cables to be secured with zip ties. WARNING Loose or unsecured power cables can cause serious injury or death. Always protect power cables from sharp edges, areas that get too hot to touch with your hand and any moving parts.

8. Review mounting orientation on page 10 for bolt sizing. 9. Install bolts and tighten to 41 to 47 Nm (30-35 ft. lbs.). WARNING Always conörm required bolt length to ensure proper thread engagement. 10. Attach hook to winch rope loop.

Orientation section for hardware specifics .

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

11. Attach hook strap to hook. 12. Remove plastic wrap from remaining rope on drum. 13. Mounting your winch is now complete. Check all hardware to be sure it is tight and to torque. You can now move on to Install the Wiring. NOTE OPTIONAL SYNTHETIC ROPE INSTALLATION 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.

Wireless Control Activation Switch

Ground (black) Cable

Control Pack Ground Wire

Power (red) Cable

WARN INDUSTRIES 13

WARN INDUSTRIES 14

FIRST TIME OPERATING INSTRUCTIONS

The bars on the wireless signal strength icon will light up in sequence to show signal strength.

In this section, we’ll show you the first time operating instructions for effective basic winching. For complete winch operation and techniques read the Basic Guide to Winching Techniques found online at www.warn.com. Getting Started Your ZEON® Platinum Winch is operated by the new Advanced Wireless Remote Control. The Advanced Wireless Remote Control is designed to allow the operator to control the winch and two auxiliaries remotely. 1. Verify the wireless control switch (located on back of control pack) is “ON” (a green flashing light appears inside switch). The switch must be ‘ON’ (activated) in order for the Advanced Wireless Remote Control to operate the winch. Step 4 - First Time Operating Instructions

Winch Menu Your winch is completely controlled by the WARN® Advanced Wireless Remote Control. You should practice activating the Winch Menu a few times to get familiar with its functions before you move on to the “Winching” section of this manual. Activate Winch Operation Menu 1. Read The Basic Guide to Winching Techniques thoroughly before you attempt to operate your winch. 2. From the Home Menu, navigate to the Winch Icon using the Left and Right buttons and press Select.

The main purpose of the Winch Operation Menu is to operate your winch. However, you are also able to control your auxiliary systems, keep track of your vehicle battery level, winch motor temperature, winch operation direction, clutch status, wireless signal strength and the remote battery life.

No Signal

Weak Signal

Fair Signal

Strong Signal

The remote control’s battery indicator icon indicates the state of the internal battery by changing color and fill level of battery icon. NOTE: If your battery icon shows at a critically low level, you must charge the battery or plug into power source.

Winch Operation Direction Status

Vehicle Battery Level

Winch Motor Temp.

Clutch Status (Disengaged)

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

Clutch Disengage Icon

Home

Home Menu Turn on the remote by pressing any button. This will automatically bring up the Home Menu. From the Home Menu, you can access each of the four operations.

Aux 1

Aux 2

Wireless Control Activation Switch

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

Charging the Battery Your WARN® Advanced Wireless Remote Control is powered by an internal rechargeable lithium ion battery. Although the battery will arrive partially charged, you must fully charge the battery or plug into a power source before use. 1. Connect the included USB charger to the Advanced Wireless Remote Control. 2. Plug other end of the USB charger into a power source (such as the included auto charger, a wall charger or a computer USB port). NOTE: Remote is operable while charging. 3. The remote control will power on and the charging icon ( ) will appear inside the battery indicator in the upper right corner of the menu, indicating the remote is charging. 4. The remote is fully charged when the battery indicator icon is filled. NOTE: Allow a minimum of two hours for battery to fully charge. The Status Bar The status bar allows the operator to keep track of the wireless signal strength and the remote’s battery life during all menu operations. NOTE: A strong wireless signal and a fully charged battery is recommended for optimal performance.

Remote Controlled Clutch Basics The WARN® ZEON® Platinum winch is equipped with a remote controlled clutch. It allows for engagement and disengagement of the clutch with the Advanced Wireless Remote Control. When the clutch is engaged, power is transferred from the winch motor to the drum and winch rope, resulting in the power-in or power-out operation. NOTE: Your WARN® ZEON® Platinum winch clutch will always default to the engaged position. When the clutch is disengaged the drum is in the freespool position, allowing the drum to rotate freely. Freespooling is generally the quickest and easiest way to spool out winch rope.

Winching

Auxiliary

Select

3. Following the Winch Activation Menu prompt, press and hold the Left and Right buttons simultaneously for 3 seconds to activate the Winch Operation menu.

Settings

Power Off

Four Operations: 1) Winching 3) System Settings

2) Auxiliary

4) Power Off 1. Use the left and right buttons on your remote to navigate through the operation menus.

Left

Right

Left

Right

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

2. To activate an operation, press select.

Select

Engaged Clutch (Winching)

Disengaged Clutch (Freespool)

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

) in the menu

Wireless Signal Strength

Battery Indicator Icon

bar and press Select.

WARN INDUSTRIES 15

WARN INDUSTRIES 16

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 the winch rope is not under tension. NOTE: The clutch will not disengage if the winch rope is under tension. If tension exists, power- out enough rope to remove any tension from the winch rope. 2. Activate the Winch Operation Menu ( refer to page 14 ). 3. Navigate to the clutch disengage icon ( ) in the menu bar on the winch function menu and press Select.

Engage Remote Controlled 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 Winch Power-in or Winch Power-out button.

Next, are condensed procedures for winching operation. You must read the Basic Guide to Winching Techniques manual for complete

5. Confirm clutch (disengage /freespool) status.

procedure instructions. Stretching Winch Rope

Tensioning the winch rope is critical to ensure a long product life. Tensioning the winch rope will prevent outer layers of winch rope from pinching and deforming the inner layers. 1. Read your Basic Guide to Winching Techniques for Stretching Winch Rope instructions. Rigging 1. Thoroughly read The Basic Guide to Winching Techniques for complete Rigging Instructions. 2. Select Winching function.

6. Freespool winch rope to anchor point and secure.

Winch Power-out

Winch Power-in

Pulling 1. Thoroughly read The Basic Guide to Winching Techniques for complete Pulling Instructions. 2. Power-in to start winching.

Clutch Status (Engaged)

• Return to the Home Menu and the clutch will immediately return to engage status. • After five minutes the clutch will automatically engage. Once clutch is successfully engaged, the clutch status icon and the clutch disengage icon will change from “disengaged” ( ) status to “engaged” ( ) status. If clutch does not engage when requested, a warning error will display within the clutch status icon. See Trouble Shooting section in this manual for possible solutions.

Clutch Disengage Icon

Select

4. Once the clutch is successfully disengaged, the gears in both the clutch status and clutch disengage icon will change from “engaged” ( ) status to “disengaged” ( ) status.

3. Activate winch.

Clutch Status (Disengaged)

Clutch Status (ERROR)

Clutch Disengage Icon

3. Secure vehicle. 4. Power-out to release tension in winch rope.

Clutch Disengage Icon

If clutch does not disengage when requested, a warning error will display within the clutch status icon. See Trouble Shooting section in this manual for possible solutions.

4. Disengage Clutch.

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.

Clutch Status (ERROR)

Clutch Disengage Icon

5. Disconnect winch rope from anchor. 6. Power-in winch rope for storage. WARNING Never spool in rope hook against the fairlead.

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

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FIRST TIME OPERATING INSTRUCTIONS

Link Auxiliary High Beam With your Advanced Wireless Remote, you are able to link your auxiliaries to your vehicle high beam setting. 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.

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

Auxiliary Menu Your WARN® Advanced Wireless Remote Control can control up to two separate auxiliary systems*. NOTICE * Auxiliary systems must be rated for 12v and draw less than 16 amps. Auxiliary connection adapter kits are necessary in order to operate the auxiliary system. For information on available kits, contact your WARN® product dealer, WARN Customer Service or www. warn.com. Activate Auxiliary Operation Menu 1. From the Home Menu, navigate to the Auxiliary Icon and press Select.

Settings Menu From your Setting menu, you are able to adjust screen brightness, pair your remote, link auxiliaries to your high beam setting and turn on the thermal shut-off option. Activate the Settings Operation Menu 1. From the Home Menu, navigate to the Settings Icon and press Select.

Auxiliary 2

Auxiliary 1

Dual Auxiliary ON

Select

2. The auxiliaries default as unlinked.

Select

Adjust Brightness 1. To adjust the brightness, navigate to the Brightness Icon and press Select.

Auxiliary 1 Unlinked

Brightness Icon

Select

Auxiliaries can be switched on and off together using the Dual Auxiliary Icon or individually by using the Auxiliary 1 and Auxiliary 2 Icon and then pressing Select.

Auxiliary 1 ON

3. Using your left or right button to highlight the “linked” icon. A check mark will appear in the box. Press select to confirm selection.

Aux 1 Status

Aux 2 Status

Select

Dual Aux Icon

2. Use the Left and Right buttons to adjust slider to the desired brightness. Once the brightness is at the desired level, press Select to close the brightness adjust panel.

Aux 1 Icon

Aux 2 Icon

Auxiliary 1 Linked

Auxiliary 2 ON

Select

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

Select

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FIRST TIME OPERATING INSTRUCTIONS

Pairing the Remote Control WARNING Never pair more than one winch and one remote at a time. Your Advanced Wireless Remote Control will arrive already paired to your WARN® ZEON® Platinum winch system, however, replacement remotes will need to be paired. 1. To pair the remote to a winch, navigate to the Pairing Icon and press Select.

4. After selecting the green check mark icon, a timer will begin counting down from 30 seconds.

8. If pairing was unsuccessful, repeat steps 1-5. 9. To close the pairing panel, press Select.

Thermal Protection Setting Your Advanced Wireless Remote has a thermal protection setting, giving you the option to have the winch shut off automatically when it reaches a high temperature protection point. 1. To activate the thermal protection setting, navigate to the thermal Icon and press Select.

Thermal protection Icon

Pairing Icon

5. During this time, turn the Wireless Control Activation Switch on the back of the control pack to OFF and then ON again.

Wireless Control Activation Switch

Select

2. Press and hold select and the right button simultaneously for 3 seconds to bring up the pairing confirmation menu.

Select

2. The thermal protection system defaults as deactivated.

6. If pairing is successful, a green check mark will appear.

Thermal protection deactivated

Right Button

Select

3. To activate the thermal protection setting, use the left or right button to highlight the thermal protection shut-off option. A check mark will appear in the box. Press select to confirm selection.

3. To continue pairing, select the green check mark icon by navigating with the left or right buttons and press Select.

7. If pairing was unsuccessful, the red X mark will remain, and the remote will remain unpaired.

Thermal protection activated

Select

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TROUBLESHOOTING

FINAL ANALYSIS AND MAINTENANCE

Trouble Shooting/Error Conditions

Before örst operation

After each use

Check

Every 90 days

Problem Error Message Possible cause

Corrective action

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 Check fasteners and make sure they are tight and to proper torque. Replace damaged fasteners. Verify wiring to all components is correct and be certain that all connections are tight. Verify there is no exposed/bare wiring, terminals or cable insulation damage (chaöng/cutting). Cover any exposures with terminal boots. Repair or replace damaged electrical cable. Inspect rope for damage. Replace rope immediately if damaged. Keep winch, rope and switch control free from contaminants. Use a clean rag or towel to remove any dirt and debris.

Make sure your Advanced Wireless Remote Control is within range.

Low wireless strength

Wireless Remote Control Activation Switch is in the OFF position Winch control pack is under water. Wireless signal will not transmit under water. Tension or Load exists on the winch, preventing the clutch from disengaging.

Winch is not operating

Turn ON the Wireless Remote Control Activation Switch

Winch control pack needs to be above water to receive wireless signal. See www. warn.com for accessories.

Power-out winch until winch rope is no longer under load.

Check the 4-pin remote controlled clutch connector on the back of the control pack to be sure it is örmly connected.

Remote controlled clutch does not disengage when requested

The remote controlled clutch is disconnected from the control pack.

Charge Remote

The remote controlled clutch is damaged.

Contact WARN® customer service for further information.

Disposal Batteries should not be disposed of in general household waste. Observe the local waste disposal regulations, details of which can be obtained from your local authority.

Take time to fully understand your winch and the winching operation by reviewing the Basic Guide to Winching Techniques found online at: www.warn.com.

Charge the remote battery See charging instructions on page 13.

Remote will not operate

The remote battery is critically low.

All electrical and electronic equipment must be disposed of separately from general household waste using the sites designated by local authorities. If a product displays this symbol of a crossed-out wheelie bin, the product is subject to European Directive 2012/19/EC.

For further information or any questions contact: WARN INDUSTRIES, INC. 12900 S.E. Capps Road, Clackamas OR USA 97015-8903, 1-503-722-1200, Customer Service: 1-800-543-9276 Dealer Locator Service: 1-800-910-1122 or visit www.warn.com.

Auxiliary will not turn on

Auxiliary is not connected

Check auxiliary connector and cables.

Accessories wiring faulty; Accessory electrical load is to high. * Auxiliary systems must be rated for 12v and draw less than 16 amps.

The appropriate disposal and separate collection of used equipment serve to prevent potential harm to the environment and health. They are a prerequisite for the re-use and recycling of used electrical and electronic equipment. For further information on disposing of your used equipment, please contact your local authority or your refuse collection service.

Auxiliary short circuit

Check wiring; reduce electrical load.

Wireless signal strength is low

Decrease distance between remote control and winch.

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INSTRUCTIONS

Manuel d'utilisation et d'installation du treuil ZEON® Platinum et de la télécommande sans fil évoluée

Chaque situation de treuillage peut potentiellement occasionner des blessures. Afin de minimiser ce risque, il est important de lire attentivement TOUTES les instructions et informations de sécurité afférentes à votre produit. Veillez à vous familiariser avec le maniement du treuil avant de l'utiliser et à vous préoccuper avant tout de la sécurité. Ces instructions fournissent des informations et des consignes de sécurité importantes concernant l’installation et l’utilisation du treuil. Vous trouverez dans ce kit la documentation suivante : • Guide d’installation du treuil / Instructions relatives à une première utilisation • Garantie du produit CONSERVEZ CE MANUEL et tous les autres documents relatifs au produit à titre de référence et consultez-les fréquemment pour assurer un fonctionnement continu en toute sécurité. Demandez à tous les utilisateurs de ce produit de lire le présent manuel avant de l'utiliser.

TABLE DES MATIÈRES :

SÉCURITÉ

Index des symboles ........................................................................................................................................................27-28

Mesures générales de sécurité et Industrie Canada........................................................................................... 29-32

INSTRUCTIONS

Se familiariser avec le treuil ......................................................................................................................................... 33-34

Se familiariser avec la télécommande sans fil évoluée ........................................................................................... 35

Montage .............................................................................................................................................................................. 36-37

Raccordements électriques ............................................................................................................................................... 38

Vérifications du système ..................................................................................................................................................... 38

Instructions relatives à une première utilisation .................................................................................................39-46 Premiers contacts.......................................................................................................................................................39 Utilisation du menu principal................................................................................................................................ 39 Utilisation du menu du treuil ..........................................................................................................................40-42 Utilisation du menu des systèmes auxiliaires.................................................................................................. 43 Utilisation du menu des paramètres ............................................................................................................44-46 Dépannage/conditions d'erreur ......................................................................................................................................47 Dernière analyse et entretien ..........................................................................................................................................48

Autres documents relatifs au produit disponibles en ligne : • Manuel de base des techniques de treuillage

• Fournit une compréhension globale du treuil et vous enseigne les techniques de treuillage. Il s’agit d’une ressource utile qui favorise l’utilisation efficace et sûre du treuil. • Caractéristiques du produit et données de performance • Fournit les caractéristiques du produit, les données de performance et les renseignements concernant les pièces de rechange. • Autres documents relatifs à des produits spécifiques

Consultez le site www.warn.com pour accéder à d’autres documents ou à des documents sur les produits de remplacement, disponibles en consultation/téléchargement.

Warn Industries Inc. 12900 SE Capps Road Clackamas, OR 97015 États-Unis

Service à la clientèle : (800) 543-9276 Télécopie : (503) 722-3000 www.warn.com

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