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Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have
provided installation and operating instructions and other information on labels and in this guide. This information
alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential
hazards associated with this product, you must use your own good judgment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND
UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING
THIS PRODUCT.
This guide identi es potential hazards and has important safety messages that help you and others avoid personal injury or death.
WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean:
WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations.
a hazard that may cause minor to moderate injury, if you do not follow recommendations.
This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general
information worthy of special attention.
SERVICE MANUAL
ZEON® and ZEON® Platinum Winch
• ZEON® 8, 8s, 10, 10s and 12
• ZEON® Platinum 10, 10s and 12
• WARN 12v and 24v DC Electric Winch
Includes Complete Repair / Replacement Instructions and
WARN INDUSTRIES, INC. 12900 S.E. Capps Road,
Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000
Customer Service: 1-800-543-9276
Dealer Locator Service: 1-800-910-1122
International Fax: 1-503-722-3005
©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc.
G E N E R A L S A F E T Y P R E C A U T I O N S
Troubleshooting Guide
CAUTION signals
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Summary of Contents for Warn ZEON

  • Page 1 This information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must use your own good judgment.
  • Page 2: Table Of Contents

    Some images shown in steps may not necessarily represent your actual product. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥...
  • Page 3: Section 1 - Getting Started

    GEAR TRAIN: Warn electric planetary winches consist of a gear train made up of three planetary gear stages. The purpose of the gear train is to multiply motor torque and to reduce motor speed transmitted to the drum. Warn gear trains are enclosed in a housing and are lubricated with grease.
  • Page 4 Control Pack Ground Cable BRAKE: All ZEON® winches are equipped with a directional sensitive automatic brake. The brake requires that the winch rope be wound onto the drum in the correct direction to operate properly. A Drum rotation label is located on the motor end drum support to help identify proper rotation.
  • Page 5: Winch Operation

    1.2.2 Winch Operation A Warn winch is a compact device used to pull heavy loads over short distances up to 100’ . (Refer to Figure 1.2 when reading the following section). The vehicle battery and charging system generates the power for pulling the load.
  • Page 6: Disassembly

    Check the drum bushing and drum support for excessive wear, replace if worn. Inspect lip seal. Replace if damaged. Bushing Lip Seal ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. © ¡ ¢ ¢...
  • Page 7 Check the drum bushing and drum support for excessive wear, replace if worn. Inspect lip seal. Replace if damaged. Bushing Lip Seal ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¡ ¢ ¢ ¢...
  • Page 8 Remove the drive spline from the third stage carrier. Remove the ring gear from the end housing. Inspect teeth of ring gear. Replace if worn or damaged. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¢ ¡...
  • Page 9 Remove the loose rst stage sun gear. Check for worn or chipped gear teeth. Check all gears for excessive wear and replace if necessary. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¡ ¡...
  • Page 10 NOTE: If you have a ZEON® Platinum continue on to Section 2.3.1 Disassembly of ZEON® Platinum Winch Remote Clutch below to complete disassembly. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. £ ¡ ¢...
  • Page 11 Remove pawl stop. Check for wear. Replace if chipped or worn. Remove ve pan cap screws. Remove end cap from gear train housing. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¡ ¢ ¢...
  • Page 12 Resistance between terminal 2 and 1 to be 1Mohm with switch open • Resistance between terminal 2 and 1 to be less than 1ohm with switch closed ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¡ ¢ ¢...
  • Page 13: Reassembly

    Install plunger and spring into clutch solenoid. Secure clutch solenoid assembly with two pan head screws previously removed. Torque to 53-79 in. lbs. Ensure plunger moves freely, no binding. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ ¡ ¢...
  • Page 14 Install the ve pan head screws previously removed. Torque to 53-79 in. lbs. Insert pawl stop. Secure with pan head screw. Torque to 53-79 in. lbs. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. § ¡ ¢...
  • Page 15 2nd stage ring gear may need to rotate to allow clutch lever to be in the en- NOTE: This step does not apply to Zeon Platinum gaged position. Winches. Proceed to next step. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¨ ¡ ¢...
  • Page 16 Use light grade machine oil on the three planetary gear bushings inside the carrier assembly. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. © ¡...
  • Page 17 Make sure that the splined end of the third stage planetary is facing up. Install the third stage ring gear on to the third stage planetary gear set and the housing. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¡ ¢ ¢...
  • Page 18 N O T E For the bushing to t properly the slot in the bushing must t over the index tab in the drum support. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¢ ¡...
  • Page 19 For the bushing to t properly the slot in the bushing must t over the index tab in the drum support. Install the motor sub assembly to the drum. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¡ ¡...
  • Page 20: Section 3 - Brake Removal And Replacement

    Remove the winch rope from the drum or secure it on the drum for ease of working. Remove the drum from the winch as described in winch disassembly section 2.3. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ £ ¡...
  • Page 21 2 1/8” to hold the brake assembly together. Remove the complete brake assembly from the drum. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¡...
  • Page 22: Reassembly

    90 degree angle to the tangs on the cam follower of the brake assembly. Cam follower tang correctly installed. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¥...
  • Page 23 Drum seals must be greased prior to drum installation. As drum is presented to drum seal, the drum must be gently rotated and angled to seat properly into lip seal. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¦...
  • Page 24: Section 4 - Electric Motor & Control Pack Overview And Wiring

    (+) battery lead. The ground cable should be attached directly to the bolt located on the underside of the motor housing from the three terminals and to the negative (-) battery terminal. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥...
  • Page 25: Zeon® Winch Control Pack Wiring

    ® Winch Control Pack Wiring Figure 4.1 is the basic wiring diagram of the ZEON® winch control pack. The redundant switching of the power and ground circuits provides safety against run on from a shorted contactor control circuit. Figure 4.1 Control Pack and Wiring Schematic ZEON® Winches Figure 4.2 is the basic wiring diagram of the 5-wire remote control.
  • Page 26: Zeon® Platinum Winch Control Pack Wiring

    Platinum Winch Control Pack Wiring Figure 4.4 is the basic wiring diagram of the ZEON® Platinum Winch control pack. The control module has a 40A fuse to protect against high current overload draw by the aux channels or remote controlled clutch solenoid.
  • Page 27 Unbolt power cable from (+) buss bar Unscrew thermistor from (+) buss bar Unbolt (+) buss bar from contactor, remove power wire Disconnect blade connectors from contactor ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¡ ¢...
  • Page 28 Cut zip tie Pull Ground wire through plastic grommet Unscrew control module retention screw Slide snap features out of their grooves ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¢ ¡ ¢ ¢...
  • Page 29 Insert control module snap features into groves on baseplate Install control module retention screw Route wires as shown to avoid damage caused by buss bars ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¥ ¡ ¡...
  • Page 30 Install power wire onto (+) buss bar using nut and lock wash- Install thermistor to (+) buss bar. Route ground cable through plastic grommet ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ £...
  • Page 31 Install power cable to +buss bar, route through plastic grommet Advanced Wireless Remote Battery Replacement Unscrew all 8 screws holding the remote halves together. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ ¡ ¢...
  • Page 32 Separate the 2 remote halves. Remove original gasket from remote. Locate battery plug and note orientation. Unplug battery and remove. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ ¥ ¡ ¢ ¢ ¢...
  • Page 33 Insert new seal in gland, ensure it is fully seated with no twists. Place back on remote. Tighten 8 screws to 1 Nm in a crisscross pattern. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ ¦ ¡...
  • Page 34 Internal corrosion on ring gear, will not al- Disassemble gear train, inspect and clean slid- low ring gear to rotate smoothly. ing ring gear, replace if necessary. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ § ¡...
  • Page 35 Ground wire was not installed, or the with minimum of 650 cold cranking amps battery around wires and wire terminals are rating. corroded. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ ¨ ¡ ¢...
  • Page 36 12v and draw less than 16 amps. Decrease distance between remote control and Wireless signal strength is low winch. ©2014 Warn Industries, Inc.WARN® and the WARN logo are trademarks of Warn Industries Inc. ¦ © ¡ ¢...

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