TROUBLESHOOTING
CHART
Motor will not operate or 1. Damaged or stuck CAUTION Be prepared to
runs in one direction only solenoid disconnect power when
performing this test. If a
solenoid sticks once, it
is likely to stick again
and must be replaced
immediately
.
1. Tap solenoid to free stuck
contacts. Check by applying
voltage to the small solenoid
terminal. Be sure solenoid is
grounded back to source. A
solenoid that is not stuck will
make an audible “click” when
first energized.
2. Switch inoperative 2. Replace switch.
3. Broken wires or bad connection 3. Check for poor connections.
CAUTION Always use 2
wrenches (See Figure 1).
4. Damaged motor 4 Replace or repair motor.
5. Solenoids not grounded 5. Check the ground path
between battery negative and
solenoid base.
Winch will not shut off Solenoid stuck “ON” If a solenoid sticks on, reverse
direction and hold trigger switch
until the power lead can be dis-
connected. A safety disconnect
switch is available as an accessory.
Motor runs extremely hot 1. Long period of operation 1. Allow to cool.
2. Damaged motor 2. Replace or repair motor.
3. Damaged brake 3. Replace or repair brake.
Motor runs but with insufficient 1. Weak battery 1. Recharge or replace battery.
power or line speed Check charging system.
2. Battery to winch wire
extended with same size wire 2. Use larger diameter wire.
3. Poor battery connection 3. Check battery terminals for
corrosion. Clean as required.
4. Poor ground 4. Check and clean connections.
5. Damaged brake 5. Repair or replace brake.
Winch runs backward 1. Motor wires reversed 1. Recheck wiring.
2. Solenoids wired incorrectly 2. Recheck wiring.
Will not hold load 1. Excessive load 1. Reduce load or double line.
2. Worn or damaged brake 2. Repair or replace brake.
Symptom Possible Cause(s) Corrective Action
wire rope. To prevent this prob-
lem, keep the wire rope tightly
and evenly wound on the drum
at all times. A good practice is to
rewind the wire rope under ten-
sion after each use. One way to
do this is to attach the hook to a
small load and winch that load to
rewind rope.
2. To maximize winch and wire rope
life, use pulley block to double
line heavier loads.
3. PREVENT KINKS BEFORE THEY
OCCUR. (See Figure 11.)
a. This is the start of a kink. At this
time, the wire rope should be
straightened.
b. The wire rope was pulled and the
loop has tightened to a kink. The
wire rope is now permanently dam-
aged and must be replaced.
c. Kinking causes the wire strands
under the greatest tension to break
and thus reduces the load capacity
of the wire rope. The wire rope
must be replaced.
LUBRICATION
The winch is permanently lubri-
cated. There may be grease leakage
out of winch, especially during first
few operations. This is normal and
it is not necessary to grease or oil
any internal part of winch at any
time.
Periodically lightly lubricate wire
rope with penetration oil and wipe
off excess.
Figure 11
a
b
c
12
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