Zeon-XP-Service-Manual-989765A0

ZEON® XP Winch Service Manual

GENERAL SAFETY PRECAUTIONS

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 identifies 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. CAUTION signals 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.

WARN I NG

CAUT I ON

IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to severe injury or death • Always 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. • Always use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when/if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or personal injury. • Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury.

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury

• Always use proper tools when making repairs. • Always utilize a qualified WARN service technician when specialized tools are required. • Always disconnect all wires from the positive battery terminal or disconnect hydraulic hoses from the winch motor before beginning any work on the winch. Read installation and operating instructions thoroughly.

CAUT I ON

• Always remove jewelry and wear eye protection. • Never lean over battery while making connections. • Never route electrical cables: o Across any sharp edges.

Observe precautions for handling Electrostatic Sensitive Devices

o Through or near moving parts. o Near parts that become hot.

• Always insulate and protect all exposed wiring and electrical terminals. • Always install terminal boots as directed in installation instructions. • Always use appropriate and adequate care in lifting components into place. • Always insure components will remain secure during installation and operation. • Always tighten all nuts and bolts securely, per the installation instructions.

• Always replace all worn or damaged parts before operating. • Never operate this WARN product with damaged or missing parts.

Read installation and operating instructions thoroughly.

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TABLE OF CONTENTS

SECTION 4 - MAINTENANCE Section

SECTION 1 - GETTING STARTED Section

Description

Page

Description

Page

4.1

General Winch Maintenance

59 60

1.1 Identification 1.2 Definitions 1.3 Winch Operation

4.2 Winch Rope Maintenance

4-5

SECTION 5 - SERVICE KITS AND DIAGRAMS Section Description

SECTION 2 - DISASSEMBLY & ASSEMBLY Section Description

Page

5.1 Replacement Parts List 5.2 Replacement Parts Diagram

61 62

Page

2.1 Suggested Tools 2.2 Winch Disassembly 2.3 Winch Reassembly 2.4 Motor Disassembly

6-8

9-11

12-15 16-20 21-26 27-37 38-43 44-50 51-52 53-54 55-56

2.5 Motor Reassembly 2.6 Geartrain Dissembly 2.7 Geartrain Reassembly 2.8 Control Pack Disassembly 2.9 Control Pack Reassembly

2.10 Brake Disassembly 2.11 Brake Reassembly 2.12 Geartrain Clocking

SECTION 3 - TROUBLESHOOTING Section

Description

Page

3.1 HUB App

57 57

3.2 Light Indicators 3.3 Power In/Out

57-58

3.4 Brake 3.5 Clutch 3.6 Noise

58 58 58

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This manual is intended for use by a WARN authorized service technician. It is important to make repairs with the proper tools and equipment. WARNING Read all instructions and safety information provided. Failure to do so, may cause the winch to fail, leading to personal injury. For full winch operation and techniques, as well as other product specific literature, visit www.warn.com. BEFORE YOU BEGIN

This manual covers models: •

ZEON® XP 8, 8s, 10, 10s and 12

SECTION 1 - GETTING STARTED

1.1 Identification To ensure proper winch repair, it is necessary to correctly identify the model and part number of your winch. This makes ordering replacement parts easier and helps you obtain the necessary information from WARN customer service at 1-800-543-9276. NOTE: For a part description, item number and quantity, refer to the Specification Sheet for your specific winch model at www.warn.com. Winch identification: The product label is typically located on front of winch. This label gives winch capacity and model.

Winch serial number: The serial number is stamped on the drum support.

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1.2 Definitions 1.2.1 Definitions Operation and service of a Warn planetary winch can be explained easier by defining a few major structural components. Refer to Figure 1.2 for the following definitions: MOTOR : The electric winch is driven by a high speed, low torque electric motor. A 12-volt DC vehicle battery generally powers the electric motor. REMOTE SOCKET : The remote socket is where the operator plugs in the wired remote control in order to control the winch. WINCH ROPE : 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. Synthetic winch rope is constructed of a unique ultra high molecular weight polyethylene material and offers tremendous tensile strength. It is coated with a high temperature urethane and equipped with a temperature resistant sleeve on the first layer for added protection. The synthetic rope’s high flexibility and low weight make it much easier to handle out in the field. WINCH DRUM : 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 remote control. DRUM SUPPORTS : Drum supports are the structural components of the winch that mount the winch to the vehicle. The drum rotates while being held by the drum supports and both the motor and gear train are attached to a drum support. 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. CLUTCH LEVER: The clutch lever allows the operator to manually disengage and engage the winch drum from the geartrain. Disengaging the clutch enables the drum to rotate freely (known as “freespooling”). Engaging the clutch “locks” the winch drum back onto the gear train. CONTROL PACK: 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 rota- tion.

ZEON® XP

Control Pack

Motor

Remote Socket

Freespool Clutch Lever

Winch Drum

Winch Rope

Transmission (Gear Train)

Remote Control

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BRAKE: All ZEON® XP 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. When the winch rope is reeled in, the brake is not activated. When reeling out under load, however, the brake slows the winch drum to an acceptable speed and holds the load when the winch is shut off. The brake is located inside the winch drum and dissipates heat through the drum and winch rope.

SECTION 2 - DISASSEMBLY AND ASSEMBLY

NOTE: This service manual covers service steps for ZEON® XP Winches. Pay particular attention to the steps as some may or may not apply to your specific winch.

Motor Coupler

2.1 Suggested Tools The following tools are suggested for these procedures: • 1 - 5/32” Hex Key Wrench • 1 - ¼” Hex Key Wrench • 1 - 13mm, 1 – ½ ‘, 3/8 ‘ Box or Open End Wrenches • 1 - Flat Head Screwdriver • 1 - Pliers, including Long Nose Needle • 1 - Torque Wrench • Assortment of Torx Bits

Drive Shaft

Direct Drive Cone Brake Pad

1.3 Winch Operation A Warn winch is a compact device used to pull heavy loads over short distances. The vehicle battery and charging system generates the power for pulling the load. Power feeds from the battery power source into the winch control pack. At the push of a remote control switch the power flows to the winch motor. The winch motor turns the electrical energy into mechanical energy. The motor shaft turns the motor coupler, which, in turn, drives the brake. On power-in operation, the brake simply rotates and drives the planetary gears, starting with the gear carrier stage farthest from the winch drum (the first stage carrier.) The first stage carrier, in turn, drives the second stage carrier, which then drives the third stage carrier. The third stage directly drives the drum. Since the winch rope is connected to the drum, the rope winds around the drum, causing the load to be drawn in. On power-out operation, the motor is reversed and the winch drum is rotated in the opposite direction. All winch components operate in the same manner as during power in except the brake. During power- out, the load tries to “over speed” the motor (make the motor turn faster than it would under its own power.) When the brake detects this over speed it engages just enough to make the load and motor run at the same speed and slow the load. When the remote control switch is released, the brake engages and completely stops the load.

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2.2 Winch Disassembly

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Head: T25 Plastite – 6mmx25mm Torque: 3-5Nm (27-44inlb) 1

Remove tie plate and ground cable bolts

Remove tie plate and bus bar cover bolts

Head: T45 M8x1.25x25mm Torque: 15-17Nm (133-150inlb)

Head: 13mm Hex M8x1.25x14mm Torque: 10.6-13Nm (94-115inlb)

Remove terminal bolts

Remove upper bus bar cover

Head: 13mm Hex M8x1.25x35mm Torque: 10.6-13Nm (94-115inlb)

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Remove control pack and lower bus bar cover

Disconnect remote clutch wire harness

Separate geartrain and motor assemblies

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2.3 Winch Reassembly

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Install geartrain assembly, motor assembly, and brake coupler.

Engage hex shaft with brake

Align brake coupler tabs to highlighted area. There will be some play when assembled.

Install lower bus bar cover

Install control pack cover assembly

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Install tie plate bolts and wire clip, ground wire bolt, and reconnect remote clutch wire harness

Install tie plate bolts

Head: T45 M8x1.25x25mm Torque: 15-17Nm (133-150inlb)

Head: 13mm Hex M8x1.25x14mm Torque: 10.6-13Nm (94-115inlb)

Install terminal bolts

Head: T25 Plastite – 6mmx25mm Torque: 3-5Nm (27-44inlb) 7 Install bus bar cover bolt

Head: 13mm Hex M8x1.25x35mm Torque: 10.6-13Nm (94-115inlb)

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2. 4 Motor Disassembly

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Remove motor cover

Remove motor (Section 2.1, steps 1-6)

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb)

Remove motor bolts

Remove motor

Head: T30 M6x1mmx160mm Torque: 10.6-13Nm (94-115inlb)

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Do NOT hold or place motor with shaft UP. The motor may disassemble.

Remove motor bearing 7

Remove motor O-ring

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Bushing may be stuck to either part

Flip motor drum support

Remove motor drum seal

Remove motor bushing

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2.5 Motor Reassembly

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1 Press in motor bearing

3 Press in motor drum seal

2 Flip motor drum support

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Verify seal does not sit above pocket wall

Press seal until fully seated

6 Flip motor drum support

5 Install motor bushing

Install motor O-ring

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Do NOT hold or place motor with shaft UP. The motor may disassemble.

9 Install motor

Install motor bolts

10 Head: T30

Install motor cover

M6x1mmx160mm Torque: 10.6-13Nm (94-115inlb)

Loctite 271

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Grease motor drum seal

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb) 12

Install motor cover bolts

Shell Gadus S5 V220 2 (7-11g)

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2.6 Geartrain Disassembly

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Remove drum driver assembly

Remove Geartrain (Section 2.1, steps 1-6)

Remove geartrain drum support

Remove geartrain bolts

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb)

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Remove 3 rd stage ring gear and o-rings

O-ring may be stuck to either part

Remove 1 st stage carrier and input gear

Remove 3 rd stage carrier, thrust washer, and 2 nd stage carrier assemblies

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Remove 2 nd stage ring gear

Remove 2 nd stage ring gear snap ring

Remove end cap bolts

Push rubber grommet through mount hole and slide end cap and seal off remote clutch cable

Head: T25 Torx M5x0.8x35mm Torque: 5-7Nm (44-62inlb)

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Remove remote clutch bolts

Remove remote clutch pin and assembly

Head: T25 Torx M5x0.8x8mm Torque: 5-7Nm (44-62inlb)

Remove clutch lever bolt

Remove clutch lever and X-ring seal

Head: 4mm Hex 10-24, Custom Tip Torque: 3-5Nm (27-44inlb)

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Remove geartrain drum bushing

Remove geartrain drum seal

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2.7 Geartrain Reassembly

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Grease X-ring seal and clutch hole

Install clutch lever and X-ring seal

Shell Gadus S5 V150XKD (light coat)

Install remote clutch pin and assembly

Install clutch lever bolt

Head: 4mm Hex 10-24, Custom Tip Torque: 3-5Nm (27-44inlb)

Engage plunger with clutch pin

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Pass remote clutch cable through end cap gasket and end cap and install

Install remote clutch bolts

Head: T25 Torx M5x0.8x8mm Torque: 5-7Nm (44-62inlb)

Install end cap bolts

Lubricate (WD-40) and pull grommet sleeve through until fully seated

Head: T25 Torx M5x0.8x35mm Torque: 5-7Nm (44-62inlb)

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Oil and install 2 nd stage ring gear and snap ring

Seat 2 nd stage ring gear snap ring

Aeroshell Fluid 4 Mineral Oil (light coat)

Verify snap ring is seated and pushed into snap ring groove

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Inspect 2 nd stage snap ring

Verify turning the clutch handle engages and disengages the 2 nd stage ring gear

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Press in geartrain drum seal

Install geartrain drum bushing and seal

Verify seal does not sit above pocket wall

Press seal until fully seated

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Install 3 rd stage ring gear

Install lower 3 rd stage ring gear O-ring

Step

Verify the dimple on the 3 rd stage ring gear is visible and in the 12’o-clock position

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Grease the 3 rd stage ring gear, filling each tooth completely

Install the upper 3 rd stage ring gear o-ring

Shell Gadus S5 V150XKD (8.5-36g)

Grease 2 nd stage sun gear, filling each tooth completely. Install the thrust washer and 2 nd stage carrier.

Install the 3 rd stage carrier

Spline plate down

Shell Gadus S5 V150XKD (1.5-10g)

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Grease and install the 1st stage sun gear, filling each tooth completely. 24

Grease and install the input sun gear, filling each tooth completely.

Shell Gadus S5 V150XKD (0.5-2g)

Shell Gadus S5 V150XKD (1.5-10g)

Grease the 1st and 2 nd stage ring gears inside of the end housing, filling each tooth completely.

Install the end housing

Shell Gadus S5 V150XKD (4.5-12g)

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Apply light pressure to the end cap while spinning the driveshaft to seat the end housing

Install the driveshaft

Hold end housing and drum support together and flip upside down

Inspect the end housing gap to verify the end housing is seated

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Install the geartrain bolts

Install the drum driver assembly

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb)

Grease the geartrain drum seal

Shell Gadus S5 V220 2 (7-11g)

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2.8 Control Pack Disassembly

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(OPTIONAL) Remove D-plug screws

Remove Control Pack (Section 2.1, steps 1-6)

Head: T15 Torx Plastite 8-16x0.5” Torque: Until Seated

Remove control pack cover

Remove control pack cover bolts

Head: 8mm Hex M5x0.8x16mm Torque: 4-5Nm (35-44inlb)

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Remove Power-In bus bar Bolt

(OPTIONAL) Remove Dust Cover and accent light inserts from Control Pack cover

Head: 13mm Hex M8x1.25x14mm Torque: 8-9.5Nm (71-84inlb)

Remove power cable

8 Remove bolt from geartrain side of control module

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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Disconnect current sensor and drum light connectors from control module

Rotate control module to access current sensor and bus bar connectors

11 Remove bus bar nuts and power-in retention screw

Remove power-in contactor wires from contactor stud

Head: 13mm Hex M8x1.25 Torque: 8-9.5Nm (71-84inlb)

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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Remove tie plate and drum light assembly

Remove bus bars, current sensor, and bus bar separator

(OPTIONAL) Remove drum light screws

(OPTIONAL) Remove drum light from tie plate

Head: T10 Torx M3x6mm 0.8-1.2Nm (7-11inlb)

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Remove control module assembly

Remove contactor control terminals, ground bolt, and motor side control module bolt

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

Remove contactor bolts

Remove contactor and ground wire

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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2.9 Control Pack Reassembly

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Install contactor on control pack base plate

Intall ground wire under retention tabs

Install control module assembly

Install contactor bolts

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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Install contactor control terminals and motor side control module bolt

(OPTIONAL) Install drum light through tie plate

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

Brown Wire White Wire

Green Wire

Install tie plate and drum light assembly

(OPTIONAL) Install drum light screws

Head: T10 Torx M3x6mm 0.8-1.2Nm (7-11inlb)

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10 Install bus bar separator, bus bars, and current sensor

Pass drum light cable through base plate and connect to control module

Install contactor positive terminals over positive contactor stud

Install contactor nuts and positive bus bar bolt

Head: 13mm Hex M8x1.25 Torque: 8-9.5Nm (71-84inlb)

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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14 Install header block into base plate slots, slide forward to secure

Route current sensor wire and connect current sensor to control module

Route all ground cables to ground cable stud and install ground bolt

Rotate control module into position and install geartrain side bolt

Head: 8mm Hex M6x13mm Torque: 8-9.5Nm (71-84inlb)

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Route power cable and ground cable through cable guide

Install power cable with power cable bolt

Head: 13mm Hex M8x1.25x14mm Torque: 8-9.5Nm (71-84inlb)

Fuse holder

Route wires away from pinch points

Drum light harness

Current Sensor harness

Header block harness

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(OPTIONAL) Install Dust Cover and accent light inserts from Control Pack cover

Install control pack cover

23 Install control pack cover bolts

(OPTIONAL) Install D-plug to control pack cover

Head: 8mm Hex M5x0.8x16mm Torque: 4-5Nm (35-44inlb)

Head: T15 Torx Plastite 8-16x0.5” Torque: Until Seated

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2.10 Brake Disassembly

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1 Press or tap brake assembly towards the open end of the drum. Can use drive shaft or dowel.

2 Once brake protrudes from the end of the drum bore, apply a cable tie to the perimeter of the brake to prevent the brake from disassembling.

Press or tap brake completely out of drum bore.

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2.11 Brake Reassembly

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1 Assemble brake driver with brake assembly and insert into the drum bore. Rotate brake driver clockwise to allow ease of assembly. Remove cable tie once brake pads are retained by the drum bore.

2 Continue until brake assembly is fully seated inside the bore. Tip of brake assembly will be aligned with the second step of the drum bore .

Align brake coupler tabs to highlighted area. There will be some play when assembled.

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2.12 Geartrain Clocking

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Remove geartrain bolts

Remove Geartrain (Section 2.1)

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb)

3 Turn until bolt holes line up in desired clocking position. Warning : DO NOT SEPARATE! O-ring Seal may dislodge. Note : Remote Clutch Extension may be necessary for some clocking positions.

4 Install geartrain bolts

Head: 4mm Hex M5x0.8x60mm Torque: 10.6-13Nm (94-115inlb)

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3.2.3 Accent/Drum lighting stays on after winching

SECTION 3 – WINCH TROUBLE SHOOTING GENERAL WINCH TROUBLESHOOTING This section covers general troubleshooting. NOTICE You must use a 12VDC battery to perform any analysis on the ZEON XP . Using any other type of power supply could result in an incorrect diagnosis. PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 3.1 HUB App 3.1.1 Intermittent Operation Poor signal Get closer to winch Maintain line of sight to winch Avoid sources of radio interference (e.g. power lines, radios, etc.) Low Voltage to control pack Turn vehicle on. Verify HUB app shows a good voltage reading Control pack overheating Relocate control pack to a cooler location 3.1.2

Lights are in low power mode and will time out after 15-20min

Allow lights to time out

3.2.4 No Accent

Damaged control pack module

Replace control pack. Observe ESD precautions for handling ESD sensitive components

Lights on the control pack, but the winch can power in/ out 3.2.5 No drum lights above the drum, but the winch can power in/out

Damaged drum light assembly or har- ness

Replace drum light assembly. Observe ESD precautions for handling ESD sensitive components

3.3 Power in/Out 3.3.1 Winch lights are ON but will not power in or powers in very slowly.

Clutch handle in freespool

Turn clutch handle to "Engaged"

Winch will not pair or connect

Device Bluetooth or Location are OFF Turn ON device Bluetooth and Location Intermittent internet connection

Ground cable is not directly attached to battery. Control pack ground is not connected to the drum support Power or ground cables are damaged Loose or corroded connection on bat- tery or motor terminals. Vehicle charging system cannot keep up with winch

Attach ground cable to negative post of battery and/or clean battery post Connect or repair control pack ground wire as required

Turn ON Airplane Mode. Winch will operate offline and in Airplane mode.

Smart device is out of range Interference with another device Too many devices are connected

Move closer to control pack

Disconnect from other bluetooth devices

Route cables away from hot or moving surfaces. Re- place or repair power/ground cables as required

Too many devices paired to winch. Clear device "bonds" by holding pairing button for 10s.

Clean and tighten all connections

3.2 Light Indicators 3.2.1

Stop and allow the battery to recharge

Winch lights do not turn ON

No connection to HUB app

Pair to HUB app or connect a physical remote. Verify control pack lights are WHITE then turn GREEN when powering in Disconnect/Reconnect the power and ground cable from the battery for 10s Open D-plug dust cover and locate pairing button. Refer to pairing instructions on the HUB app Refer to pairing instructions on the HUB app. Disconnect any other smart devices from receiver

Worn motor brushes Replace motor Internal contactor components sticking Replace contactor Brake is binding

Winch remains in pairing mode but will not pair

Replace brake and drum

Excessive gear train wear, broken gear train components.

Disassemble gear train to investigate driveshaft, gear carriers, and ring gears. Replace if damaged or has excessive wear.

3.2.2 Winch lights are ON, but does not operate

Can't Enter Pairing Mode

Remote clutch solenoid stuck in free- spool

Replace clutch solenoid

No connection to HUB app

Another device is connected and at- tempting to operate the winch

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3.5 Clutch 3.5.1 Winch will not shift to freespool or engaged

3.3.2 Winch pow- ers IN, but will not power OUT or pow- ers out very slowly. 3.3.3 Reduced Pull Capacity

Brake is not disengaging

Replace brake and drum

Load exceeds rating of winch and drum deformed

Refer to winch capacity on product label. DO NOT EX- CEED LINE PULL RATING SHOWN ON PRODUCT LABEL.

Manual override handle is in freespool position

The manual clutch handle will prevent remote clutch pin from engaging Power out short distance to release line tension. Inspect clutch handle, clutch pin, and end housing. If excessive wear on clutch features, replace end housing and clutch assembly Disassemble gear train to investigate binding in drive- shaft, gear carriers, and ring gears. Replace if damaged or has excessive wear.

Internal contactor components sticking Replace contactor

Rope is under tension. Excessive Housing Wear

Too many layers of rope.

Pull capacity is reduced by approximately 14% per layer. Use winch on first layer of drum for maximum power. Rewind rope on drum so that it is level and not rubbing on other parts of winch. Ensure fairlead opening is properly sized for drum length Allow winch motor to cool for at least 10 minutes between short pulls. Increase cooling time for heavy loads or long pulls. See winch specification sheet. Reduce distance between winch and battery. Remove rope and replace with recommended rope dia. (3/8")

Damaged Gear Train

Rope is interfering with tie rod or other part of winch.

Remote clutch mechanism stuck

Replace remote clutch solenoid

3.5.2 Winch is

Rope is stuck between lower layers on the drum Shift winch to freespool, connect rope to an anchor point, and slowly back up vehicle to free stuck layers of rope Rope stacked to one side of drum Avoid sharp angle pulls, make sure rope is wound level on drum Winch operation in cold environment. Shift winch to freespool and then power in for about 30 seconds without drum moving to redistribute geartrain grease.

difficult to freespool.

Motor is hot

Electrical wires too long Rope diameter too large

3.3.4 Excess Pull Capacity

Winch has not been broken in.

Tension rope per Winch Quick Start instructions Remove and reinstall remote clutch plug

Excessive power supply capacity for winch Use standard 12V OEM power system equipment (alter- nator, battery, etc.) Incorrectly sized power cables used Any deviation from factory power cables will modify performance. Install Warn factory power cables.

Poor contact between remote clutch plug and smart control pack Incorrect mounting bolt pattern

Inspect the mounting bolt pattern. If the winch is not mounted flat or the drum supports are not parallel, the geartrain may bind Power the winch in and out while watching the drum flanges. A drum with bent flange must be replaced.

3.4 Brake 3.4.1 Winch will not hold load.

Bent drum flange.

Rope is spooled onto the drum in the wrong direction.

Remove all rope and reinstall in the proper direction.

3.6 Noise 3.6.1 Winch makes rattle/ratchet

Load exceeds rating of winch

Refer to winch capacity on product label. DO NOT EX- CEED LINE PULL RATING SHOWN ON PRODUCT LABEL.

Brake is not broken in yet Drum bushing not lubricated.

Run winch normally. Brake pads will even out over time.

Brake is worn Replace brake assembly and drum Brake or brake coupler are damaged Replace brake assembly. Inspect brake couplers for damage or excess wear. Replace couplers if necessary. Power out distance is too long.

Grease drum bushings.

noise on power in.

Allow winch to cool for at least 10 minutes between short pulls. Increase cooling time for heavy loads or long pulls.

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• Keep winch free of dirt, oil, grease, water and other substances. Remove any overflow grease from bearings. • Check all mounting bolts and make sure they are tightened to proper torque. Replace any damaged fasteners. • Periodically check all hydraulic connections to be sure they are tight and free of corrosion. • Check rope for visible damage every time winch is operated. Examples of damage are: cuts, knots, mashed or frayed portions, and broken strands. Replace rope immediately if damaged. Failure to replace a damaged rope could result in breakage. • If winch drum continues to turn after controls are released, brake may need to be replaced. 4.1 General Winch Maintenance SECTION 4 - MAINTENANCE

Before first Operation

Check

After Each Use

Monthly

Semi-Annually

Yearly

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

X X X X X X X X X X X

Check electrical connections.

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 (chafing, cutting).

Repair or replace damaged electrical cable.

Visual Check of winch and electrical connections to ensure all components are free from corrosion:

Check Quick Connects and Contact Leads

Check Motor-Sub Assembly (Contactor, Motor/ Motor Terminals, OLI). Ensure Remote Socket and Remote control connections are not damaged

Check hydraulic connections

Visual check of winch and control valve

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4.2 Winch Rope Maintenance Cleaning: • Use low pressure water to clean synthetic rope. Do not use any chemicals. • Do not direct high pressure water (pressure washers, car washes, etc.) directly between the drum support and drum flange or clutch lever. • Use low pressure water and a soapy rag or sponge to clean the winch. • Avoid using chemicals that may damage the finish. • Thoroughly clean salt residue from the winch as soon as possible to minimize corrosion. Rope Inspection: WARNING 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. When rope is first used, the outer filaments of the rope will quickly fuzz up. This is the result of these filaments breaking and this roughened surface will actually protect the fibers underneath. The condition should stabilize, not progress. If the surface roughness increases, excessive abrasion is taking place and strength is being lost. Look closely at both the inner and outer fibers. When either is worn the rope is obviously weakened. Open the strands and look for powdered fiber—this is a sign of internal wear. Localized discolorations could potentially represent chemical attack by anything from gear oil to battery acid. When doubt exists, replace the rope. Maintenance: • Inspect the winch rope and heat sleeve before and after each winching operation. Frayed or damaged rope must be replaced immediately. See rope care and storage. • The rope must always spool onto the drum as indicated by the drum rotation decal on the winch. • Use winch cover to protect winch and synthetic rope when not in use. Prolonged exposure to ultraviolet rays from sunlight can degrade synthetic rope strength over time. • Avoid using synthetic rope over any rough surfaces without abrasion protection. • Keep winch rope free of moisture, grease, dirt or other debris. If necessary, clean with a damp cloth.

Rope should be replaced when: • Rope bulk anywhere along the length is reduced by 10% or more by abrasion. • Two or more adjacent strands are cut. • Flat areas or lumps are found that are not eliminated by flexing rope. • Excessive fused or melted fibers are found. Any such areas will be stiff and the rope will have a glazed appearance.

• Rope with original bulk.

• Rope displaying 25% strand volume reduction from abrasion—rope should be replaced.

• Rope strand showing full volume.

• Rope strand reduced by 25% abrasion—rope should be replaced.

• Rope exhibits fiber-set from compression. A slight sheen is visible. This is not a permanent characteristic and can be eliminated by flexing the rope.

• Rope displays two adjacent cut strands—rope should be replaced.

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