WARN 83665 Hand Held Plug-In Truck Winch Remote Controller

Introduction

This manual provides instructions for the safe and effective use of the WARN 83665 Hand Held Plug-In Truck Winch Remote Controller. This controller is designed to provide reliable operation for compatible WARN truck winches, offering a convenient and secure way to manage winching operations.

Key Features

• Weather resistant with an ergonomic handle
• Easy to use, even while wearing gloves
• 12ft (3.7m) lead for extended reach
• Ultra-weather/mud resistant thanks to improved sealing
• "D" shaped plug, designed to fit both older round sockets and newer "D" shaped sockets

Safety Information

Always read and understand your winch owner's manual before operating any winch or accessory. Failure to follow safety instructions can result in serious injury or property damage. This remote controller is an integral part of your winching system; proper handling and awareness are crucial.

• Ensure the winch and remote controller are in good working condition before each use.
• Keep hands and clothing clear of the winch cable, hook, and fairlead during operation.
• Do not exceed the rated capacity of your winch.
• Always wear appropriate personal protective equipment, including gloves and eye protection.
• Disconnect the remote controller when not in use to prevent accidental operation.
• Avoid operating the winch in extreme weather conditions that could compromise safety.
• Never operate the winch with frayed or damaged cables.

Package Contents

• 1 x WARN 83665 Hand Held Plug-In Truck Winch Remote Controller

Product Overview

The WARN 83665 remote controller features a durable, ergonomic design for comfortable and secure handling. It includes a robust 12-foot cable and a versatile "D" shaped plug for connection to compatible WARN truck winches. The control switch allows for intuitive winch-in and winch-out operations.

Figure 1: The WARN 83665 Hand Held Plug-In Truck Winch Remote Controller, showing the ergonomic grip, control switch, coiled 12-foot cable, and the "D" shaped plug connector. This view highlights the overall design and components.

Figure 2: A different perspective of the WARN 83665 remote controller, emphasizing the textured ergonomic grip and the robust construction of the control unit and cable connection, designed for durability in challenging environments.

Setup

Follow these steps to properly connect your remote controller to your WARN truck winch.

1. Locate the Winch Control Socket: Identify the control socket on your WARN truck winch. This socket is typically located on the winch motor housing or a control pack. The WARN 83665 features a "D" shaped plug designed to fit both older round sockets and newer "D" shaped sockets, ensuring broad compatibility.
2. Connect the Remote Controller: Align the "D" shaped plug of the remote controller cable with the winch control socket. Insert the plug firmly until it is fully seated. Ensure a secure connection to prevent intermittent operation during winching.
3. Verify Compatibility: This controller is specifically compatible with previous generations of WARN truck winches. Refer to your specific winch manual to confirm compatibility if you are unsure or have a newer model.

Operating Instructions

The remote controller features a simple rocker switch for intuitive winch operation. Always prioritize safety during winching.

1. Prepare for Winching: Before operating the winch, ensure all safety precautions are observed. The vehicle should be properly secured, and the winch cable should be correctly spooled and attached to the load or anchor point.
2. Engage Winch Clutch: If your winch has a manual clutch, ensure it is fully engaged before operating the remote controller. Refer to your winch manual for clutch engagement procedures.
3. Winch In: To retract the winch cable, press and hold the switch in the "Winch In" position. This position is typically indicated by an arrow pointing towards the winch or a "cable in" icon on the switch.
4. Winch Out: To extend the winch cable, press and hold the switch in the "Winch Out" position. This position is typically indicated by an arrow pointing away from the winch or a "cable out" icon.
5. Release Switch: The winch will stop operating immediately when the switch is released. This momentary switch design provides immediate control and enhances safety during operation.
6. Monitor Operation: Continuously monitor the winching operation, ensuring the cable spools evenly and there are no obstructions, excessive strain, or potential hazards.
7. Disconnect After Use: Once winching is complete and the cable is properly spooled, disconnect the remote controller from the winch socket to prevent accidental activation and protect the controller from damage.

Maintenance

Proper maintenance ensures the longevity and reliable performance of your WARN 83665 remote controller.

• Cleaning: After use, especially in muddy or wet conditions, wipe down the controller and cable with a damp cloth to remove dirt, mud, and debris. Avoid using harsh chemicals or abrasive cleaners that could damage the housing or sealing.
• Inspection: Regularly inspect the cable for cuts, abrasions, kinks, or signs of wear. Check the plug for corrosion, bent pins, or damage to the housing. Inspect the controller housing for cracks or other physical damage.
• Storage: Store the remote controller in a clean, dry place, away from direct sunlight, extreme temperatures, and corrosive substances. Coil the cable neatly to prevent tangling, kinking, or damage during storage.
• Sealing: The controller features improved sealing for ultra-weather and mud resistance. While designed for harsh environments, avoid submerging the controller in water for extended periods.

Troubleshooting

If you encounter issues with your WARN 83665 remote controller, consider the following common solutions:

1. Controller Not Responding:
   • Ensure the plug is fully and securely inserted into the winch control socket. A loose connection is a common cause.
   • Check the winch's power supply and ensure it is turned on and receiving adequate power.
   • Inspect the remote cable and plug for visible damage, cuts, or corrosion that could interrupt the electrical signal.
   • Verify that the winch clutch is engaged. The winch will not operate if the clutch is disengaged.
2. Intermittent Operation:
   • This often indicates a loose or poor connection. Re-seat the plug firmly into the winch socket.
   • Inspect the plug pins for bending, corrosion, or debris that might be interfering with the connection.
3. Winch Operates in One Direction Only:
   • This could indicate an internal issue with the controller switch or a wiring problem within the winch itself. If other troubleshooting steps fail, contact WARN customer support.

For persistent issues that cannot be resolved with these steps, consult your winch's owner's manual or contact WARN customer support for further assistance.

Specifications

Warranty and Support

WARN products are manufactured to high standards and are backed by a manufacturer's warranty. For specific warranty details regarding your WARN 83665 remote controller, please refer to the documentation included with your winch or visit the official WARN website.

For technical assistance, troubleshooting, or parts inquiries, please contact WARN customer support directly. Their team can provide expert guidance and support for your product.

WARN Official Website: www.warn.com