3.5 Clutch 3.5.1 Winch will not shift to freespool or engaged
3.3.2 Winch pow- ers IN, but will not power OUT or pow- ers out very slowly. 3.3.3 Reduced Pull Capacity
Brake is not disengaging
Replace brake and drum
Load exceeds rating of winch and drum deformed
Refer to winch capacity on product label. DO NOT EX- CEED LINE PULL RATING SHOWN ON PRODUCT LABEL.
Manual override handle is in freespool position
The manual clutch handle will prevent remote clutch pin from engaging Power out short distance to release line tension. Inspect clutch handle, clutch pin, and end housing. If excessive wear on clutch features, replace end housing and clutch assembly Disassemble gear train to investigate binding in drive- shaft, gear carriers, and ring gears. Replace if damaged or has excessive wear.
Internal contactor components sticking Replace contactor
Rope is under tension. Excessive Housing Wear
Too many layers of rope.
Pull capacity is reduced by approximately 14% per layer. Use winch on first layer of drum for maximum power. Rewind rope on drum so that it is level and not rubbing on other parts of winch. Ensure fairlead opening is properly sized for drum length Allow winch motor to cool for at least 10 minutes between short pulls. Increase cooling time for heavy loads or long pulls. See winch specification sheet. Reduce distance between winch and battery. Remove rope and replace with recommended rope dia. (3/8")
Damaged Gear Train
Rope is interfering with tie rod or other part of winch.
Remote clutch mechanism stuck
Replace remote clutch solenoid
3.5.2 Winch is
Rope is stuck between lower layers on the drum Shift winch to freespool, connect rope to an anchor point, and slowly back up vehicle to free stuck layers of rope Rope stacked to one side of drum Avoid sharp angle pulls, make sure rope is wound level on drum Winch operation in cold environment. Shift winch to freespool and then power in for about 30 seconds without drum moving to redistribute geartrain grease.
difficult to freespool.
Motor is hot
Electrical wires too long Rope diameter too large
3.3.4 Excess Pull Capacity
Winch has not been broken in.
Tension rope per Winch Quick Start instructions Remove and reinstall remote clutch plug
Excessive power supply capacity for winch Use standard 12V OEM power system equipment (alter- nator, battery, etc.) Incorrectly sized power cables used Any deviation from factory power cables will modify performance. Install Warn factory power cables.
Poor contact between remote clutch plug and smart control pack Incorrect mounting bolt pattern
Inspect the mounting bolt pattern. If the winch is not mounted flat or the drum supports are not parallel, the geartrain may bind Power the winch in and out while watching the drum flanges. A drum with bent flange must be replaced.
3.4 Brake 3.4.1 Winch will not hold load.
Bent drum flange.
Rope is spooled onto the drum in the wrong direction.
Remove all rope and reinstall in the proper direction.
3.6 Noise 3.6.1 Winch makes rattle/ratchet
Load exceeds rating of winch
Refer to winch capacity on product label. DO NOT EX- CEED LINE PULL RATING SHOWN ON PRODUCT LABEL.
Brake is not broken in yet Drum bushing not lubricated.
Run winch normally. Brake pads will even out over time.
Brake is worn Replace brake assembly and drum Brake or brake coupler are damaged Replace brake assembly. Inspect brake couplers for damage or excess wear. Replace couplers if necessary. Power out distance is too long.
Grease drum bushings.
noise on power in.
Allow winch to cool for at least 10 minutes between short pulls. Increase cooling time for heavy loads or long pulls.
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