Zeon-XC-Service-manual-111999A0

ZEON® XC 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.

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

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.

TABLE OF CONTENTS

SECTION 4 - MAINTENANCE Section

SECTION 1 - GETTING STARTED Section

Description

Page

Description

Page

4.1

General Winch Maintenance

49 50

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

51-52

Page

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

6-8

9-11

12-15 16-19 20-24 25-33 34-37 38-40 41-42 43-44 45-46

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 Power In/Out

47 47

3.2 Brake 3.3 Clutch 3.4 Noise

47-48

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® XC 10, 12, 14

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 control pack. This label gives winch capacity and model.

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

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® XC

Control Pack

Remote Socket

Freespool Clutch Lever

Motor

Winch Rope

Winch Drum

Transmission (Gear Train)

Remote Control

BRAKE: All ZEON® XC 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® XC Winches. Pay particular attention to the steps as some may or may not apply to your specific winch.

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

Motor Coupler

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.

2.2 Winch Disassembly

Remove tie plate and ground cable bolts Remove tie plate and ground cable bolts. 2.

1 Remove tie plate and bus bar cover bolts Remove tie plate and bus bar cover bolts. 1.

Head: T47 M8 x 1.25 x 25mm Torque: 15-17Nm (133-150inlb)

Head: 13mm Hex M8 x 1.25 x 14mm Torque: 10.6-13Nm (94-115inlb)

Remove bus bar dust cover 4.

Separate tie plate, geartrain and motor assemblies. 3.

Head: 13mm Hex M8 x 1.25 x 14mm Torque: 10.6-13Nm (94-115inlb) 5 Remove Motor Terminal Bolts Remove motor terminal bolts 5.

6 Remove Control Pack Mounting Bolts Remove control pack mounting bolts 6.

Head: T30 M6 x 1.0 x 16mm Torque: 3-5Nm (27-44inlb)

Remove control pack and busbar separator 7.

2.3 Winch Reassembly

Install motor assembly, geartrain assembly, and tie plate. 1.

Install tie plate bolts. 2.

Head: T47 M8 x 1.25 x 25mm Torque: 15-17Nm (133-150inlb)

Install tie plate bolts and ground cable bolt 3.

Install bus bar separator and control pack 4.

Head: T47 M8 x 1.25 x 25mm Torque: 15-17Nm (133-150inlb)

Head: 13mm Hex M8 x 1.25 x 14mm Torque: 10.6-13Nm (94-115inlb)

Install control pack mounting bolts 5.

Install motor terminal bolts 6.

Head: 13mm Hex M8 x 1.25 x 14mm Torque: 10.6-13Nm (94-115inlb)

Head: T30 M6 x 1.0 x 16mm Torque: 3-5Nm (27-44inlb)

Install bus bar dust cover 7.

2.4 Motor Disassembly

Remove motor drum support assembly (Section 2.1, steps 1-7). 2.

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

Remove motor from drum support. 4.

Remove motor bolts. 3.

Head: T30 M6 x 1mm x 160mm Torque: 10.6-13Nm (94-115inlb)

Remove motor from drum support. 5.

Remove motor from drum support. 6.

Remove motor from drum support. 7.

Remove motor from drum support.

Remove motor from drum support. 9.

Remove motor from drum support. 8.

2.5 Motor Reassembly

Press in motor drum seal. 1.

Install motor bushing. 2.

Install motor bushing

Press seal until fully seated

Verify seal does not sit above pocket wall

Flip motor drum support 4.

Press in motor bearing 5.

Install motor o-ring. 6.

Ensure ground surface is clean!

Install motor 8.

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

Install motor bolts 9.

Grease motor drum seal 10.

Head: T30 M6 x 1mm x 160mm Torque: 10.6-13Nm (94-115inlb)

Shell Gadus S5 V220 2 (7-11g)

2.6 Geartrain Disassembly

Remove geartrain (Section 2.2, steps 1-3) 1.

Remove drum driver assembly 2.

Remove geartrain drum support 4.

Remove geartrain bolts 3.

Head: 4mm Hex M5 x 0.8 x 60mm Torque: 10.6-13Nm (94-115inlb)

O-ring may be stuck to either part 5.

Remove 3 rd stage ring gear and o-rings

Remove 3rd stage ring gear and o-rings. 6.

Remove 3rd stage carrier, thrust washer, and 2nd stage carrier assemblies. 7.

Remove 1st stage carrier and input gear. 8.

Remove 2nd stage ring gear snap ring. 9.

Remove 2nd stage ring gear. 10.

Remove clutch lever bolt. 11.

Remove clutch lever and X-ring seal. 12.

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

Remove geartrain drum bushing. 14.

Remove geartrain drum seal. 13.

2.7 Geartrain Reassembly

Grease X-ring seal. 1.

Install clutch lever and X-ring seal. 2.

Shell Gadus S5 V150XKD (light coat)

Install clutch lever bolt. 3.

Grease and install 2nd stage ring gear and snap ring. 4.

Aeroshell Fluid 4 Mineral Oil (light coat)

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

Seat 2nd stage ring gear snap ring. 5.

Verify snap ring is seated and pushed into snap ring groove. 6.

Inspect 2nd stage snap ring.

Verify turning the clutch handle engages and disengages the 2nd stage ring gear. 8.

Press in geartrain drum seal. 10.

Install geartrain drum bushing and seal. 9.

11.

Press seal until fully seated

Verify seal does not sit above pocket wall

Install 3rd stage ring gear. 13.

Install lower 3rd stage ring gear o-ring. 12.

Verify the dimple on the 3rd stage ring gear is visible and in the 12’ o-clock position. 14.

Grease the 3rd stage ring gear, filling each tooth completely. 15.

Shell Gadus S5 V150XKD (8.5-36g)

Install the upper 3rd stage ring gear o-ring. 16.

Install the 3rd stage carrier. 17.

Grease and install the 1st stage sun gear, filling each tooth completely. 19.

18.

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

Shell Gadus S5 V150XKD (1.5-10g)

Install the upper 3rd stage ring gear o-ring. 20.

Install the upper 3rd stage ring gear o-ring. 21.

Shell Gadus S5 V150XKD (0.5-2g)

Install the driveshaft. 23.

Apply light pressure to the end cap while spinning the driveshaft to seat the end housing. 24.

Inspect the end housing gap to verify the end housing is seated. 26.

Hold end housing and drum support together and flip upside down seat the end housing. 25.

Install the geartrain bolts. 27.

Install the drum driver assembly. 28.

Head: 4mm Hex M5 x 0.8 x 60mm Torque: 10.6-13Nm (94-115inlb)

Grease the geartrain drum seal. 29.

Shell Gadus S5 V220 2 (7-11g)

2.8 Control Pack Disassembly

Remove d-plug cover. 2.

Remove Control Pack (Section 2.2, steps 1-7) 1.

Remove control pack cover bolts. 3.

Remove control pack cover. 4.

Head: T25 M5 EJOTThread x 12mm Torque: 1-1.9Nm (9-17inlb)

Remove ground cables from terminals. 5.

Lift contactor from control pack. 6.

Disconnect ground cable and power cable. 7.

Remove contactor nuts, busbars, and power cable. 8.

Head: 13mm Hex M8 x 1.25 Torque: 8-9.5Nm (71-84inlb)

Remove Screws from Control Harness. 9.

Remove Control Harness from Control Pack Cover. 10.

Head: T25 M5 EJOTPTx 12mm Torque: 1-1.9Nm (9-17inlb)

2.9 Control Pack Reassembly

Install control harness in control pack cover 1.

Install control harness screws 2.

Head: T25 M5 EJOTPTx 12mm Torque: 1-1.9Nm (9-17inlb)

Install bus bars and ground cable 3.

Install ground cable & power cable 4.

Head: 13mm Hex M8 x 1.25 Torque: 8-9.5Nm (71-84inlb)

Place contactor into control pack. 5.

Install wires. 6.

Close control pack. 7.

Install control pack bolts. 8.

Head: T25 M5 EJOTThread x 12mm Torque: 1-1.9Nm (9-17inlb)

2.10 Brake Disassembly

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

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. 2.

Press or tap brake completely out of drum bore. 3.

2.11 Brake Reassembly

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

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

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

2.12 Geartrain Clocking

Remove Geartrain (Section 2.2 steps 1-3) 1.

Remove geartrain bolts 2.

Head: 4mm Hex M5 x 0.8 x 60mm Torque: 10.6-13Nm (94-115inlb)

Turn until bolt holes line up in desired clocking position. 3.

Install geartrain bolts 4.

Head: 4mm Hex M5 x 0.8 x 60mm Torque: 10.6-13Nm (94-115inlb)

WARNING: DO NOT SEPARATE! THE O-RING SEAL MAY DISLODGE.

3.1.3

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 XC . Using any other type of power supply could result in an incorrect diagnosis. PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION 3.1 Power In / Out 3.1.1

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")

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

Reduced Pull Capacity

Motor is hot

Electrical wires too long Rope diameter too large

Clutch handle in freespool

Turn clutch handle to "Engaged"

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

3.1.4

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.

Excess Pull Capacity

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

Clean and tighten all connections

Winch does not power IN or OUT

3.2 Brake 3.2.1

Stop and allow the battery to recharge

Rope is spooled onto the drum in the wrong direction.

Remove all rope and reinstall in the proper direction.

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

Load exceeds rating of winch

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

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.

Winch will not hold load.

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.

3.1.2 Winch

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

Brake is not disengaging

Replace brake and drum

powers IN, but will not power OUT or powers out very slowly.

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.

Internal contactor components sticking Replace contactor

3.3 Clutch 3.3.1 Winch will not shift to freespool or engaged

Rope is under tension. Excessive Housing Wear

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.

Damaged Gear Train

3.3.2 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.

Winch has not been broken in. Incorrect mounting bolt pattern

Tension rope per Winch Quick Start instructions 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.

Bent drum flange.

3.4 Noise 3.4.1 Winch makes rattle/ratchet

Brake is not broken in yet Drum bushing not lubricated.

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

Grease drum bushings.

noise on power in.

• 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

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.

SECTION 5 - SERVICE PART/KIT LIST AND DIAGRAM

14 15 16

20 21 22

23 24

28 29

35 36

30 31 32 33 34

39 40

41 42

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