Problem
Possible Cause(s)
Corrective Action
Handle turns, drum doesn’t turn
• Loose or broken pins
• Loose, stripped or broken gears
• Inspect winch, repair as necessary
• inspect gears and repair as necessary
Handle turns hard or not at all
• Gears broken or locked
• Load too heavy
• Pins loose or broken on winch
• Drum shaft broken or seized
• Brake disc damaged or locked
• inspect and repair as necessary
• Lighten load
• Inspect winch, repair as necessary
• Inspect, repair or replace as necessary
• Inspect brake, repair as necessary
Brake does not operate properly
• Friction discs worn or damaged
• Friction discs damaged from lubrication
• Disc brake ratchet pawl damaged
• Handle adapter loose
• Inspect and replace as necessary
• Inspect and replace as necessary
• Inspect and repair as necessary
• Tighten handle adapter on drive shaft
Excessively worn gears or bushes
• Load too heavy
• Poor lubrication of gears or bushes
• Lighten load
• Inspect and relubricate as necessary
Overheating
• Operated too long without rest
• Load too heavy
• Poor lubrication
• Bushings seized up / damaged
• Allow to cool
• Lighten load
• Inspect and lubricate as necessary
• Inspect and replace as necessary
Unusual noises
(high pitched squeak /
grinding noise / rattling noise)
• Poor lubrication
• Contaminated lubrication
• Loose bolts, or other fasteners
• Inspect and lubricate as necessary
• Clean and re-lubricate winch
• Tighten all bolts and other fasteners
Troubleshooting Guide
Inspections (continued)
Figure 1 - Broken Wires
The wire rope assembly must be replaced
if more than 6 wires are broken in one lay,
or if more than 3 wires are broken in one
strand in one lay.
Figure 2 - Load Hook Inspection
The wire rope assembly must be replaced
if the throat opening is 15% wider than
nominal, if the thickness is 10% less than
nominal, or if the hook is twisted 10
degrees or more.
Figure 3 - Rope Diameter
The wire rope assembly must be replaced if
the diameter measures less than the mini-
mum diameter at any point.
IF YOUR WINCH INSTALLED
WITH FIBRE ROPE:
1. Unwind the fibre rope completely.
• Check the entire length of fibre rope for
excessive wear, chafing, cuts, dirt and
grit, and other damage.
Then,
• Make sure the snap hook is securely
attached to the fibre rope.
• Check the throat opening, thickness, and
twist of the snap hook. Replace the hook
if it shows signs of damage.
See figure 2.
• Make sure the hook latch opens without
binding and closes when released.
• Check the anchor holes in the drum
flange, clamp fittings and bolts for signs
of wear or distortion.
IF YOUR WINCH INSTALLED
WITH WIRE CABLE:
1. Remove the wire cable entirely from
the drum.
• Always wear protective clothing when
handling wire cable.
• Check the entire length of wire cable
for bent wires, crushed areas, broken or
cut wires, corrosion, and other damage.
Carefully inspect areas that pass over
sheaves or through roller guides.
• Note the location and concentration of
broken wires. Replace the wire cable if
more than 6 wires are broken in one lay,
or more than 3 wires are broken in one
strand in one lay.
See Figure 1.
• Make sure the snap hook is securely
attached to the wire cable, and the wire
cable where it is attached is not frayed,
corroded, broken, or otherwise damaged.
• Check the throat opening, thickness, and
twist of the snap hook. Replace the hook
if it shows signs of damage.
See figure 2.
• Make sure the hook latch opens without
binding and closes when released.
• Check the anchor holes in the drum
flange, clamp fittings and bolts for signs
of wear or distortion.
• Measure the diameter of the wire
cable, especially in areas where wear is
noticeable. Replace the wire cable if the
diameter measures below the minimum
diameter at any point.
See figure 3.
2. Remove the winch from the
foundation.
• Check fasteners for stripped threads,
wear, bending, and other damage.
• Check the frame (winch body) for
bending, distortion, cracks, and other
damage. A bent frame is caused by
overloading, and is a sign that your
application may require a winch with a
larger load rating.
• Move the drum with your hands.
• Check for excessive movement indicating
worn or loose gears, bushings, or shafts.
• Disassemble the winch if necessary.
Inspect gears, shafts and bushes for wear,
corrosion, distortion, and other damage
3. Fasten the winch securely to the
foundation.
4. Install the wire cable.
5. Test winch performance by operating
the winch with a test load equal to the
load rating.
• Listen for unusual noises, and look for
signs of damage as you operate the
winch.
• Make sure the winch cable winds evenly
and tightly onto the drum. If it is loose or
uneven, rewind it before continuing.
• Make sure the handle moves freely in
both directions.
