OVERTEMPERATURE
Applicable alarms (2)
Likely outcomes — click to expand
Based on 581,259 missions where this alarm fired in the last
90 days
(for OVERTEMPERATURE) as of 2026-10-13
Grounding vs discrepancy (of 5,632 ZERP issues filed on these missions)
Top work orders
- EV2: Inspect Aircraft after Droid Left Behind (DLB) · MAINTENANCE_ACTION 559
- Inspect Droid after Droid Left Behind (DLB) · MAINTENANCE_ACTION 378
- EV3: Inspect Aircraft after Droid Left Behind (DLB) · MAINTENANCE_ACTION 284
- Reset Droid after DLB · REPAIR 253
- V4 Zipping Point: Inspect Zipping Point after Droid Left Behind (DLB) - Ranger · MAINTENANCE_ACTION 131
Frequently replaced parts
| Part | P/N | Removals |
|---|---|---|
| SERVO, ASSY, UNIVERSAL, P2 | 20398 | 1,571 |
| CCW HOVER MOTOR ASSY, ZIP, P2 | 19607 | 1,358 |
| ASSY, SPOOL AND LINE, DOCKING FIN, AIRCRAFT, P2 | 48477 | 1,036 |
| CW HOVER MOTOR ASSY, ZIP, P2 | 33333 | 796 |
| WING STBD, ZIP, P2 | 25266 | 768 |
Aggregated from fleet operations and refreshed daily. Individual outcomes may vary by site and configuration.
Background
Section titled “Background”This alarm occurs when winch temperature exceeds certain thresholds. This causes thermal protection behaviors to kick in and the zip executive will command the droid to lower. This should be rare in 2025.24.rc21+ due to changes to the portal raise logic and indicates an emergent software or hardware issue.
Operator Troubleshooting Steps
Section titled “Operator Troubleshooting Steps”graph TD
check-the-validator-results-in-baraza{"<small><b>Step 1</b></small><br/>Question: Check the validator results in Baraza..."}
complete-the-dlb-work-orders["<small><b>Step 2</b></small><br/>Action: Complete the following work orders: -..."]
replace-the-winch["<small><b>Step 3</b></small><br/>Action: Stop flying the affected zip and repl..."]
escalate-if-unsure{{"<small><b>Step 4</b></small><br/>Escalation: Stop flying the affected zip. Escalat..."}}
check-the-validator-results-in-baraza -->|SUSPECT_CRACKED_WIRE has fa...| replace-the-winch
check-the-validator-results-in-baraza -->|The values for both residua...| replace-the-winch
check-the-validator-results-in-baraza -->|I did not see either of these| complete-the-dlb-work-orders
check-the-validator-results-in-baraza -->|I'm not sure OR no results ...| escalate-if-unsure
style check-the-validator-results-in-baraza fill:#dbeafe,stroke:#3b82f6,color:#1e3a5f
style complete-the-dlb-work-orders fill:#dcfce7,stroke:#22c55e,color:#14532d
style replace-the-winch fill:#dcfce7,stroke:#22c55e,color:#14532d
style escalate-if-unsure fill:#fef3c7,stroke:#f59e0b,color:#78350f Hover or focus a block to preview it. Select the block to keep the preview open.
winch_fatigue to filter for the appropriate results.
NOTE: It may take 15-30 minutes after the mission for the results to become available. Ensure that you are viewing the mission span (not the flight) in Baraza so that the validators are visible.
Inspect the following checks:
-
winch_fatigue/SUSPECT_CRACKED_WIRE-
winch_fatigue/voltage_d/residuals_std-
winch_fatigue/voltage_q/residuals_stdDid you see either of the following cases?
- The SUSPECT_CRACKED_WIRE check has failed
- The values for both residuals_std are greater than 0.4
Seeing either or both of these indicates a damaged phase wire causing the overtemperature.
- Aircraft: Complete the work order for the relevant aircraft version:
- EV2: #195: Inspect Aircraft after Droid Left Behind (DLB)
- EV3: #662: Inspect Aircraft after Droid Left Behind (DLB)
- Droid: #1169: Reset Droid after DLB.
WORK ORDER TEMPLATE: Use the work order template that matches the hardware version:
- Work Order Template #70 - EV2: Replace Winch on Aircraft Docking Fin/Winch Assembly
- Work Order Template #1067 - EV3: Replace Winch on Aircraft Docking Fin Winch LRU.
Assign the issue to parent RCCA ISS-4284:
[Root Cause] EV2 ZIP - WINCH - phase wire cracked open at or near solder joint to PCBA.Resolution note
This plaintext block is ready to paste into the Resolution Note field on the ZERP issue you're working. The permalink below gives engineering review access to the full step-by-step timeline including any back-navigation; share it if the case needs a deeper look.
Permalink:
Session is too large to fit in a URL. Use Download session JSON to share the timeline out-of-band.
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