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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