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
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