6
TROUBLESHOOTING GUIDE
CONDITIONS
POSSIBLE CAUSE
CORRECTION/ACTION
MOTOR RUNS IN ONE
DIRECTION ONLY
1. Inoperative solenoid or stuck
solenoid
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal
(it should make an audible click when energized).
MOTOR RUNS EXTREMELY
HOT
2. Inoperative remote control switch
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. Long period of operation
1. Cooling-off periods are essential to prevent overheating.
2. Insufficient battery
2. Check battery terminal voltage under load. If 10 volts or less, replace
or parallel another battery to it.
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED
1. Electrical cable from battery to
winch or ground strap from engine
block to vehicle chassis too small.
1. Must be Grade 2 or equivalent or larger if longer than 4,5 M (15 feet).
2. Bad electrical connections
2. Check all connections for looseness or corrosion; tighten, clean and
grease.
WINCH WILL NOT PULL
RATED LOAD
3. Insufficient charging system
1. Rated load limiter mis-adjusted.
3. Replace with larger capacity charging system.
1. Adjust rated load limiter per instructions on page 4 and 5.
MOTOR RUNS, BUT DRUM
DOES NOT TURN
1. Clutch not engaged
1-4 If clutch engaged by symptom still exists, it will be necessary to
disassemble winch to determine cause and repair.
2. Sheared drum shaft key
3. Stripped bronze gear
4. Parted shaft
MOTOR WILL NOT
OPERATE
1. Inoperative solenoid or stuck
solenoid
1. Jar solenoid to free contacts. Check by applying 12 volts to coil
terminal (it should make an audible click when energized).
2. Inoperative remote control switch
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. Inoperative motor
3. If solenoids operate, check for voltage at armature post, replace
motor.
4. Loose connections
4. Tighten connections on bottom side of hood and on motor.
MOTOR WATER DAMAGED 1. Submerged in water or water from
high pressure car wash
1. Allow to drain and dry thoroughly, then run motor without load in
short bursts to dry windings
CLUTCH INOPERATIVE OR
BINDS UP
1. Dry or rusted shaft
1. Clean and lubricate
2. Dog point setscrew too tight
2. Remove rubber plug from clutch housing and rotate setscrew
outward until clutch operates smoothly. Replace rubber plug.
3. Bent yoke
3. Replace yoke or shifter assembly.
4. Keys pulled out of shape by
overload
4. If drum shaft keyways are rounded or damaged replace shaft and
keys. If not, file off burrs and replace keys.
CLUTCH SPRING DOES
NOT OPERATE
1. Broken spring
1. Replace
CLUTCH DOES NOT
LOCK AT DISENGAGED
POSITION
1. Setscrew loose or worn
1. Remove rubber plug from clutch housing, tighten setscrew or replace.
Replace plug.
OIL LEAKS FROM HOUSING 1. New seal
1. New seals sometimes leak until seated to shaft.
2. Seal damaged or worn
2. Replace.
3. Too much oil
3. Drain excess oil per lubrication instructions.
4. Damaged gasket
4. Replace.
