Manual for ZXR 12000 - Troubleshooting and error codes + PDF Download

Manual for ZXR 12000 - Troubleshooting and error codes + PDF Download

Brand: Badland

Category: Winch

Manual Type:

Language:

Uploaded: April 8, 2025, 12:49 a.m.

Manual Publish Date: 2017

Warranty Summary

This product has a limited 90-day warranty against defects in materials and workmanship.
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  1. Examine the wire rope.
  2. Fully charge the vehicle's battery.
  3. Check the Winch's electrical connections.
  4. Put the vehicle's transmission in Neutral.
  5. Engage the emergency brake and block the wheels.
  6. Move Clutch Handle to Released position to pull out wire rope.
  7. Hook onto object using a pulling point.
  8. Re-engage the clutch to Engaged position.
  9. Operate Pendant controls to winch.
  10. Reverse direction to release tension after pulling.

Troubleshooting and error codes

Problem Possible Causes Likely Solutions
Motor overheats 1. Incorrect power cords.
2. Winch running time too long.		 1. Use only supplied power cords.
2. Allow winch to cool down periodically.
Motor does not turn on 1. Switch Assembly not connected properly.
2. Loose battery cable connections.
3. Vehicle battery needs charging.
4. Solenoid malfunctioning.
5. Defective Switch Assembly.
6. Defective motor.
7. Water has entered motor.
8. Internal damage or wear.		 1. Insert Switch Assembly all the way into connector.
2. Tighten nuts on all cable connections.
3. Fully charge battery.
4. Tap solenoid to loosen contacts. Apply 12 volts to coil terminals directly. A clicking indicates proper activation.
5. Replace Switch Assembly.
6. Check for voltage at armature port with Switch pressed. If voltage is present, replace motor.
7. Allow to drain and dry. Run in short bursts without load until completely dry.
8. Have technician service winch.
Motor runs but Wire Rope drum does not turn Clutch not engaged. Move the Clutch Handle to the Engaged position. If problem persists, a qualified technician needs to check and repair.
Motor runs slowly or without normal power 1. Insufficient current or voltage.
2. Loose or corroded battery cable connections.
3. Incorrect power cords.		 1. Battery weak, recharge. Run winch with vehicle motor running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
Motor runs in one direction only 1. Defective or stuck solenoid.
2. Defective Switch Assembly.		 1. Tap solenoid to loosen contacts. Repair or replace solenoid.
2. Replace Switch Assembly.

Troubleshooting and error codes

Problem Possible Causes Likely Solutions
Motor overheats 1. Incorrect power cords.
2. Winch running time too long.		 1. Use only supplied power cords.
2. Allow winch to cool down periodically.
Motor does not turn on 1. Switch Assembly not connected properly.
2. Loose battery cable connections.
3. Vehicle battery needs charging.
4. Solenoid malfunctioning.
5. Defective Switch Assembly.
6. Defective motor.
7. Water has entered motor.
8. Internal damage or wear.		 1. Insert Switch Assembly all the way into connector.
2. Tighten nuts on all cable connections.
3. Fully charge battery.
4. Tap solenoid to loosen contacts. Apply 12 volts to coil terminals directly. A clicking indicates proper activation.
5. Replace Switch Assembly.
6. Check for voltage at armature port with Switch pressed. If voltage is present, replace motor.
7. Allow to drain and dry. Run in short bursts without load until completely dry.
8. Have technician service winch.
Motor runs but Wire Rope drum does not turn Clutch not engaged. Move the Clutch Handle to the Engaged position. If problem persists, a qualified technician needs to check and repair.
Motor runs slowly or without normal power 1. Insufficient current or voltage.
2. Loose or corroded battery cable connections.
3. Incorrect power cords.		 1. Battery weak, recharge. Run winch with vehicle motor running.
2. Clean, tighten, or replace.
3. Use only supplied power cords.
Motor runs in one direction only 1. Defective or stuck solenoid.
2. Defective Switch Assembly.		 1. Tap solenoid to loosen contacts. Repair or replace solenoid.
2. Replace Switch Assembly.