Page 27
If the winch fails to operate after several attempts, or if there is any fault whilst operating:
Symptom
Possible Cause
Remedy
Winch will not
operate
Cut circuit
Check battery lead
Weak battery
Recharge or replace battery (at least 650CCA)
Bad connection of wirings
Reconnect tightly
Damaged contactor
Replace contactor
Cut circuit on switch
Replace switch
Damaged motor or worn carbon brush
Replace motor or carbon brush
Faulty motor wirings
Replace wirings
Motor runs in only
one direction
Broken wirings or bad connections
Reconnect or replace wirings
Damaged or stuck contactor
Replace contactor
Switch inoperative
Replace switch
Faulty wiring
Replace wiring
Drum will not free
spool
Clutch does not disengage
Engage clutch
Damaged 1st shaft
Replace 1
st
shaft
Damaged brake cam and disc
Replace brake cam and disc
Damaged output shaft
Replace output shaft
Brake fails to
operate
The gear train is mechanically
binding up
Check to insure the winch is mounted on a
flat, rigid surface
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Faulty retaining ring
Replace retaining ring
Oil leakage at brake cavity
Clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Braking distance is
too long
Worn brake disc or loose brake spacer
Replace brake disc or adjust brake spacer
according to brake adjustment procedures
Oil leakage at brake cavity
Clean oil leakage
Brake jam
Too much brake disc powder in the
brake hub
Clean brake hub
Over pre-pressed spiral spring
Adjust pre-pressed spiral spring
Stuck between brake disc and gear box
Replace with a new brake assembly
Damaged gear box
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Stop the winch operation and reduce a load
Motor runs
extremely hot
Long period of operation
Allow to cool
Damaged motor
Replace or repair motor
Damaged or inoperative brake
Replace or repair brake
Troubleshooting
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