Warn ZEON-12-S User Manual

WARN Industries, Inc. 95961A0
ZEON-12-S PLATINUM WINCH
Part Number: 95960
Rated Line Pull: 12,000 lbs. (5440 kgs)
Motor: 12V DC, Series Wound
Controls: Advanced Wireless Remote Control
Gear Train: 3-Stage Planetary
Gear Ratio: 162:1
Clutch (Freespool): Rotating Ring Gear
Brake: Automatic Direct Drive Cone
Drum Diameter/length: 3.15”/9.3” (8.0cm/23.6cm)
Kit Shipping Weight: 80 lbs (36.3 kgs)
Rope: Synthetic, Ø 3/8” x 80’ (Ø 9.5mm x 24.4m)
Fairlead: Hawse
Recommended Battery: 650CCA Minimum for winching
Duty Cycle: Intermittent
Battery Leads: 2 GA, 72” (1.83m)
Finish: Black Powder Coat
Warranty: Limited Lifetime
Mounting Bolt Pattern: 10.0” x 4.5” (254mm x 114.3mm)
Winch Dimensions: 24.25 L x 7.14” D x 10.52” H (615.9mm L x 181.6mm D x
267.1mmH)
WARN Industries, Inc. 95961A0
SERVICE INSTRUCTIONS
Should you encounter a problem during installation or operation of your winch, please
follow these steps toward resolving the problem:
1. Refer to your operator’s guide and installation instructions. It has illustrations and
detailed information on the installation and safe and proper operation of your
winch. It also includes a replacement parts list and assembly diagrams. If you are
unable to resolve the problem, then go to step 2.
2. Contact your dealer where you purchased your winch. If, after discussing the
problem with their parts and service sta , you are still unable to resolve the
problem then go to step 3.
3. Call an Authorized WARN Service center from the list provided on the back of
the warranty sheet included with the product. When calling, please have the
following information available: winch model number and purchase date, make,
model and year of vehicle.
4. If you are unable to resolve the problem to your satisfaction, please call Warn
Industries Customer Service at: 1-800-543-9276. When calling, please have the
following information available: winch model number and purchase date, make,
model and year of vehicle. You may also contact Warn Industries by visiting our
website: www.warn.com
SERVICE/UPGRADE KITS
PN# ITEM QTY DESCRIPTION
KIT 1 93338 S/P ASSY_ULT PERF_TRANS_216
(2) 1 S/P ASSY_END HOUSING_ULT PERF
(3) 1 S/P END CAP
(4) 1 S/P REMOTE CLUTCH ASSY
(5) 1 S/P, DRUM SUPPORT, GEARTRAIN
9 1 SUN GEAR, 12T
10 1 CARRIER ASSY, STAGE 1
11 1 CARRIER ASSY, STAGE 2
12 1 WASHER, THRUST
13 1 CARRIER ASSY, STAGE 3
14 1 RING GEAR, 75T
17 1 DRIVE SPLINE
19 1 DRUM DRIVER
21 1 DRIVE SHAFT
KIT 2 93036 S/P ASSY_END HOUSING_ULT PERF END
2 1 GASKET END CAP
3 10 TORX, PAN HEAD, M5-0.8X25
5 1 HOUSING_ULT PERF
6 1 PAWL STOP
7 1 ROTATING RING GEAR
8 1 RETAINING RING
15 1 GEARTRAIN GASKET
47 1 TORX, PAN HEAD, M5-.08X12
KIT 3 93596 S/P END CAP
1 1 END CAP
2 1 GASKET, END CAP
3 5 TORX, PAN HEAD, M5-0.8X25
KIT 4 93038 4 1 S/P ASSY_REMOTE CLUTCH

Warn ZEON-12-S Specifications

General

Gear Train	3-Stage Planetary
Recommended Battery	650 CCA minimum
Pulling Capacity	12, 000 lbs
Motor	12V DC
Cable	3/8"
Remote Control	Remote switch with 12' (3.7m) lead
Brake	Automatic Load Holding Brake
Fairlead	Roller Fairlead
Battery Leads	72" Battery Leads
Drum	2.5"
Clutch	Freespooling manual clutch

Summary

WARN ZEON-12-S PLATINUM WINCH Specifications

Part Number and Rated Line Pull

Details the WARN winch part number 95960 and its rated line pull capacity of 12,000 lbs.

Motor, Controls, and Gear Train

Specifies the winch motor type (12V DC), control system (Wireless Remote), and gear train (3-Stage Planetary).

Brake, Drum, Rope, and Fairlead

Details the brake system, drum dimensions, synthetic rope specifications, and fairlead type.

Battery, Duty Cycle, and Finish

Outlines recommended battery CCA, winch duty cycle, battery lead specifications, and finish.

Warranty and Mounting Dimensions

Provides information on the limited lifetime warranty and the winch mounting bolt pattern.

Service Instructions for WARN Winches

Refer to Operator's Guide and Installation Instructions

First step for troubleshooting, consult operator's guide, installation instructions, parts lists, and assembly diagrams.

Contact Your Dealer

Second step for problem resolution: contact the dealer where the winch was purchased for assistance.

Contact Authorized WARN Service Center

Third step: contact an Authorized WARN Service Center with winch model, purchase date, and vehicle details.

Contact Warn Industries Customer Service

Fourth step: contact Warn Customer Service at 1-800-543-9276 with specific winch and vehicle information.

Service and Upgrade Kits

Kit 1: Performance Transmission Parts

Kit 1 (PN# 93338) includes various performance transmission assembly and housing components.

Kit 2: Housing and Gasket Components

Kit 2 (PN# 93036) contains housing, gasket, and fasteners for the ultimate performance housing.

Kit 3: End Cap and Fastener Kit

Kit 3 (PN# 93596) supplies end cap components and specific fasteners for assembly.

Kit 4: Remote Clutch Assembly

Kit 4 (PN# 93038) provides the remote clutch assembly for the winch.