TROUBLESHOOTING
TROUBLE
PROBABLE CAUSE
REMEDY
A
The winch will not lower
the load or not lower the
load smoothly.
1. The problem could be a plugged
or loose pilot orifice. The pilot orifice
is a small pipe plug with a hole drilled
through it, located behind the pilot port
fitting on the brake valve. If it becomes
plugged, it will prevent the pilot pres-
sure, from the manifold, from opening
the brake valve. If it becomes loose,
it will allow an unregulated amount of
oil in to operate the brake valve which
causes erratic brake valve operation.
2. The friction brake may not be releas-
ing as a result of a defective brake
cylinder seal.
NOTE:
If the brake cylinder seal is
defective you will usually find oil leaking
from the winch vent plug.
3. Friction brake will not release as a
result of damaged brake discs.
Remove the pilot hose and fitting from the
brake valve, then use a 5/32-inch Allen
wrench to remove the pilot orifice. The
diameter of the orifice is approximately
.020 inch. Clean and install the pilot orifice
tightly in the brake valve.
Check brake cylinder seal as follows:
A. Disconnect the swivel tee from the
brake release port. Connect a hand pump
with accurate 0-2000 PSI gauge and shut-
off valve to the –4 JIC fitting in the brake
release port.
B. Apply 1000 PSI to the brake. Close
shut-off valve and let stand for five (5)
minutes.
C. If there is any loss of pressure in five
(5) minutes, the brake cylinder should be
disassembled for inspection of the sealing
surfaces and replacement of the seals.
Refer to “Motor Support — Brake Cylinder
Service.”
Disassemble brake to inspect brake discs.
Check stack-up height as described in
“Motor Support — Brake Cylinder Service.”
B
Oil leaks from vent plug.
1. Same as A2.
2. Motor seal may be defective as a
result of high system back pressure or
contaminated oil.
Same as A2.
System back pressure must not exceed
150 PSI. Inspect hydraulic system for a
restriction in the return line from the con-
trol valve to the reservoir. Be sure control
valve and plumbing is properly sized to
winch motor.
Oil analysis may indicate contamina-
tion has worn motor shaft and seal.
Thoroughly flush entire hydraulic system
and install new filters and oil. Install new
motor seal.
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