Installation Guide

Symptom Possible Cause(s) Corrective Action
Winch will not operate
Winch runs backwards
Motor runs but drum doesn’t turn
Winch will not reverse
Load creeps backwards
Branch circuit breaker continually trips
Will not go into freewheel
Wire rope spooling unevenly
Winch does not pull rated load
Drum doesn’t turn, motor hums
1. No power
2. Bad wiring/connection
3. Damaged motor
1. Incorrect wiring
1. Freewheel clutch disengaged
1. Motor not stopped before
reversing
2. Incorrect wiring
3. Damaged motor
1. Excessive load
2. Brake is worn
1. Excessive load
2. Low voltage
3. Electrical short
4. Damaged motor
1. Tension on wire rope
1. Insufficient tension on wire rope
2. Pulling at angle
1. Too much wire rope on drum
2. Low voltage
3. Damaged motor
1. Excessive load
2. Incorrect wiring
3. Low voltage
4. Damaged motor
1. Check branch circuit
2. Check wiring
3. Repair or replace motor
1. Check wiring
1. Engage clutch
1. Allow motor to stop before
reversing
2. Check wiring
3. Repair or replace motor
1. Use pulley block or reduce load
2. Replace brake
1. Use pulley block or reduce load
2. Check branch circuit
3. Check wiring
4. Repair or replace motor
1. Remove tension
1. Rewind rope under small load
2. Align winch for straighter pull
1. Reduce amount of rope on drum
2. Check branch circuit
3. Repair or replace motor
1. Use pulley block or reduce load
2. Check wiring
3. Check branch circuit
4. Repair or replace motor
TROUBLESHOOTING CHART
11
10
REPLACING WIRE ROPE
A part of the winch that will require
attention and eventual replacement
is the wire rope. Inspect the wire
rope for wear frequently. A frayed
rope should be replaced immediately.
Always replace damaged wire rope
with the manufactuer’s identical
replacement part (see Replacement
Parts List). Never substitute a heavier
or lighter weight rope. Never use
rope made of any material other
than wire. Because all wire ropes are
subject to wear, it is excluded from
the warranty.
Place winch in freewheel and
unwind the wire rope off the drum.
Loosen the set screw that secures
the wire rope to the drum. Feed the
end of the new wire rope into the
side-drilled hole and tighten the set
screw. Make sure that the wire rope
feeds from the underwind position.
(
See Figure 10). Make sure freewheel
handle is in the engaged position.
While watching the winch drum
rotation, turn the winch on in the
forward direction. Make sure that
the rope is winding onto the drum
from the bottom (underwind) as
illustrated in Figure 10.
Once correct wind is obtained, con-
tinue winding remaining rope onto
drum. To keep the rope spooling
tightly and evenly, keep the rope
under tension during the wind. One
method is to attach a small load to
end of wire rope and winch load in.
Figure 10
Drum rotation
for Cable-In