WARN ZEON 12 - Manual (Page 6)

WARN INDUSTRIES
11 83449A0
FIRST TIME OPERATING INSTRUCTIONS
Step 4 - System Check
Once you have performed a system check, you are
ready to confirm winch function. Proceed to First
Time Operation Instructions and Final Analysis and
Maintenance sections in this booklet.
Step 5 - First Time Operating
Instructions
WARNING Always understand your winch and the
winching operation by reviewing The Basic Guide to Winching
Techniques included with your winch.
Remote Control Switch
Do not leave the remote plugged into the winch
when not in use. Leaving the remote plugged in
may result in a dangerous condition and/or battery
drain.
Clutch Operation:
WARNING Never engage or disengage clutch if winch is
under load, winch rope is in tension or drum is moving.
When the clutch is engaged, the gear train is
coupled to the winch drum and power can be
transferred from the winch motor. When the clutch
is disengaged the drum is in the freespool position
and the gear train and winch rope drum are
uncoupled allowing the drum to rotate freely.
The clutch lever, located on the winch housing
opposite the motor, controls the clutch position.
To prevent damage, always fully engage or fully
disengage the clutch lever.
Spooling Out
WARNING Never operate winch with less than 5 wraps of
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.
WARNING Always keep hands clear of winch rope, hook
loop, hook and fairlead opening during installation, operation,
and when spooling in or out.
WARNING Always wear heavy leather gloves when
handling winch rope.
Freespooling is generally the quickest and easiest
way to spool out winch rope. Before freespooling
winch rope out from the winch, power out enough
rope to remove any tension the winch rope might
be under. Disengage the clutch. Then freespool
by manually spooling out enough winch rope for
the winching operation. See The Basic Guide to
Winching Techniques for more information.
NOTICE Do NOT power out more than 30ft without allowing
the winch to cool for 20 minutes before powering rope back in.
Instead, place the clutch in freespool and pull the rope out by
hand.
WARNING Always use supplied hook strap whenever
spooling winch rope in or out, during installation or operation
to avoid injury to hands and fi ngers.
Spooling In Under Load
WARNING Never exceed winch’s rated line pull.
Power-in the winch rope evenly and tightly on
the drum. This prevents the outer winch wraps
from sinking into the inner wraps, binding, and
damaging the winch rope.
Avoid shock loads when spooling, by pulsing the
control switch to take up winch rope slack. Shock
loads can momentarily far exceed the winch and
rope ratings.
OUT
IN
DISENGAGED
ENGAGED
WARN INDUSTRIES
83449A0 12
FIRST TIME OPERATING INSTRUCTIONS
Spooling In Under No Load
WARNING Never touch winch rope or hook while
someone else is at the control switch or during winching
operation.
Spooling with an Assistant: Have the assistant
hold the hook strap putting as much constant
tension on the winch rope as possible. While
keeping tension, the assistant should walk toward
the winch while you operate the control switch
spooling in the winch rope. Release the switch
when the hook is a minimum of 6 ft. (2m) from the
fairlead opening.
Spool in the remainder for storage as directed
below.
Spooling Alone: Arrange the winch rope to
be spooled so it will not kink or tangle when
spooled. Be sure any winch rope on the drum is
tightly and evenly layered. Spool enough winch
rope to complete the next full layer on the drum.
Tighten and straighten the layer. Repeat process
until the hook is a minimum of 6 ft. (2 m) from the
fairlead opening.
Spool in the remainder for storage as directed
below.
Spooling Remainder for Storage
When the hook is within 6 ft. (2 m) of the fairlead,
disconnect the hook from the anchor or load.
Hold onto the supplied hook strap and hold
tension on the winch rope. Slowly power-in the
winch by “pulsing” the power-in switch on the
remote control until the hook is within 3 ft. (1 m)
of the fairlead.
Stop winching in and attach the hook to a
suitable anchor point on the vehicle.
NOTICE Do not power the hook into the fairlead. This could
cause damage to the fairlead.
Once the hook is suitably attached to the
vehicle, power-in the remaining slack in the winch
rope by “pulsing” the power-in switch on the
remote control until there is minimal slack in the
winch rope.
Overloading/Overheating
This winch is rated for intermittent duty. When
the motor approaches stall speed, very rapid heat
buildup occurs which may cause motor damage.
Double-line rigging (see The Basic Guide to
Winching Techniques) will reduce the amperage
draw, and reduce heat buildup in the motor. This
allows longer continual use.
STRETCHING WINCH ROPE
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
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.
The life of a winch rope is directly related to
the use and care it receives. During its first use, a
new winch rope must be spooled onto its drum
under a load of at least 1000 lbs. (454 kgs). Use
the following instructions to properly stretch the
winch rope onto the winch drum.
1) Choose a FLAT AND LEVEL location that is large
enough to run out the entire length of winch
rope.
2) Turn the clutch lever on the winch to the “Free
Spool” position. Spool out the winch rope to the
last 5 wraps on the drum. Once the winch rope is
spooled out, turn the clutch lever on the winch to
the “Engaged” position.
3) Attach the hook end of the rope to a suitable
anchor point and back the vehicle away from the
anchor point until there is very little slack in the
winch rope. Before getting out of the vehicle, set
the parking brake, place the vehicle in gear or
park and turn the vehicle off .
4) Connect the remote control to the winch.
Standing approximately 8 ft. (2.44 m) away from
the winch, power-in the winch until all of the
slack is wound onto the winch drum. Disconnect
the remote control from the winch. Hold tension
on the winch rope with one hand; carefully push
the winch rope to the side of the drum the winch
rope is attached to so there are no gaps between
each coil on the drum. Be sure to check that the
winch rope is winding off of the bottom if the
drum, not the top, or the automatic load holding
brake will not function properly. (If the winch
rope is winding off the top you have powered the
winch “out” instead of “in” on the remote control).