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CONDITIONS
MOTOR RUNS IN ONE
1. Inoperative solenoid or stuck
DIRECTION ONLY
2. Inoperative remote control switch
MOTOR RUNS EXTREMELY
1. Long period of operation
HOT
2. Insufficient battery
MOTOR RUNS, BUT WITH
1. Electrical cable from battery to
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED
2. Bad electrical connections
3. Insufficient charging system
WINCH WILL NOT PULL
1. Rated load limiter mis-adjusted.
RATED LOAD
MOTOR RUNS, BUT DRUM
1. Clutch not engaged
DOES NOT TURN
2. Sheared drum shaft key
3. Stripped bronze gear
4. Parted shaft
MOTOR WILL NOT
1. Inoperative solenoid or stuck
OPERATE
2. Inoperative remote control switch
3. Inoperative motor
4. Loose connections
MOTOR WATER DAMAGED 1. Submerged in water or water from
CLUTCH INOPERATIVE OR
1. Dry or rusted shaft
BINDS UP
2. Dog point setscrew too tight
3. Bent yoke
4. Keys pulled out of shape by
CLUTCH SPRING DOES
1. Broken spring
NOT OPERATE
CLUTCH DOES NOT
1. Setscrew loose or worn
LOCK AT DISENGAGED
POSITION
OIL LEAKS FROM HOUSING 1. New seal
2. Seal damaged or worn
3. Too much oil
4. Damaged gasket
Troubleshooting Guide
POSSIBLE CAUSE
solenoid
winch or ground strap from engine
block to vehicle chassis too small.
solenoid
high pressure car wash
overload
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal
(it should make an audible click when energized).
2. Disengage winch clutch, remove remote control switch plug from the
socket and jump pins at 8 and 4 o'clock. Motor should run.
1. Cooling-off periods are essential to prevent overheating.
2. Check battery terminal voltage under load. If 10 volts or less, replace
or parallel another battery to it.
1. Must be Grade 2 or equivalent or larger if longer than 4,5 M (15 feet).
2. Check all connections for looseness or corrosion; tighten, clean and
grease.
3. Replace with larger capacity charging system.
1. Adjust rated load limiter per instructions on page 4 and 5.
1-4 If clutch engaged by symptom still exists, it will be necessary to
disassemble winch to determine cause and repair.
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal (it should make an audible click when energized).
2. Disengage winch clutch, remove remote control switch plug from the
socket and jump pins at 8 and 4 o'clock. Motor should run.
3. If solenoids operate, check for voltage at armature post, replace
motor.
4. Tighten connections on bottom side of hood and on motor.
1. Allow to drain and dry thoroughly, then run motor without load in
short bursts to dry windings
1. Clean and lubricate
2. Remove rubber plug from clutch housing and rotate setscrew
outward until clutch operates smoothly. Replace rubber plug.
3. Replace yoke or shifter assembly.
4. If drum shaft keyways are rounded or damaged replace shaft and
keys. If not, file off burrs and replace keys.
1. Replace
1. Remove rubber plug from clutch housing, tighten setscrew or replace.
Replace plug.
1. New seals sometimes leak until seated to shaft.
2. Replace.
3. Drain excess oil per lubrication instructions.
4. Replace.
9
CORRECTION/ACTION
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