SYMPTOM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
Safety hook spreads
1. Point loading of hook.
1. Replace hook.
2. Load exceeds rated capacity of unit.
2. Lighten load, reduce % of incline or reduce load friction.
Strap breaks
1. Improperly maintained strap.
1. See “Maintenance.”
2. Overloading.
2. Reduce load.
Strap folds over (binds up)
Pulling load at too severe of
Make straighter pulls.
an angle.
Load creeps when power is OFF
1. Clutch out of adjustment.
1. TW4000 - tighten knob. TW9000 - adjust (see
Maintenance)
2. Roller clutch, not engaging.
2. Replace.
3. Overloading.
3. Reduce load.
Winch does not hold load
Strap wound on drum incorrectly.
Strap must be wound over top of drum on TW4000 & under
the drum on model TW9000.
Winch motor runs hot
In operation too long.
Let motor cool for at least 20 minutes. (See Winch Rating
Section.)
Winch motor fails to run
Electrical.
Check the following: power supply, wiring, control
switch, male/female connections, motor and circuit
breakers.
Winch motor runs but fails
1. Clutch is slipping.
1. Check clutch lining for grease or oil. See “Maintenance”
to wind strap
for clutch adjustment procedure.
2. Gear train is damaged.
2. Check entire gear train and replace any damaged parts.
Strap will not pull out (freewheel)
Sticking clutch.
a. “Jog” power switch with clutch in freewheel (No load only).
b. Remove cover (see Maintenance) and separate clutch
gear from mating gear.
Smokes (TW9000 only)
Normal on initial power down use.
None.
TROUBLESHOOTING CHART
bearings in the clutch mechanism and place a drop of
oil on the roller clutch. Do not over lubricate these
areas and do not use grease in the roller clutch. The
clutch mechanism and the brake pads and brake disc
on the TW9000 must be kept clean and oil free.
ADDITIONAL MAINTENANCE TW9000
3. Check the operation of the roller clutch in the brake
disc assembly (AF). Carefully rotate the brake disc
and observe the motor shaft. When the disc is turned
clockwise the motor shaft should turn with it. When the
disc is turned counterclockwise the motor shaft should
not turn.
4. If the clutch has been slipping and requires adjust-
ment the following procedures should be used. The
clutch is adjustable in ten degree increments. With a
screwdriver and pliers, remove the end of the clutch
spring from the hole in the winch base. The spring
tension is quite high so be careful to maintain a firm
grip on the spring. The O-ring should be rotated so
that the cut out portions align with the lugs on the
spring keeper. (See FIG. 3)
The ring can then be expanded with a pencil or similar
object and the spring keeper can be lifted free from
the clutch nut. Rotate the keeper clockwise 10
degrees and install on the next serration in the clutch
nut. Reinstall O-ring and rotate slightly so that the cut
outs are not in line with the lugs on the spring keeper
and reinstall the clutch spring into the hole in the
base. Adjustment of the clutch more than 10 degrees
to 20 degrees should normally not be necessary. With
only spring pressure (do not forcibly tighten the clutch
mechanism) the spring lug on the spring keeper
should come to rest at approximately the 2:30 o’clock
position. (See FIG. 4)
FIG. 3
FIG. 4
O-Ring Illustration (TW9000)
Clutch Spring Illustration (TW9000)
Spring Lug
Horizontal
Adjust to
this posi-
tion (2:30
oʼclock)
Clutch Spring
Keeper
Clutch Spring
