GENERAL SAFETY PRECAUTIONS
TROUBLESHOOTING Trouble Shooting: Note: These trouble shooting tips apply to both electrical and hydraulic winches except where notes.
WARNING
CAUTION
Problem Possible cause
Corrective action
CUT AND BURN HAZARD Failure to observe these instructions could lead to minor or moderate injury. • Never let winch rope slip through your hands.
Refer to the product data sheet for the correct line pull rating for your winch.
Load exceeds winch rating
CHEMICAL AND FIRE HAZARD Failure to observe these instructions could lead to serious injury or death. • Always remove jewelry and wear eye protection. • Never route electrical cables across sharp edges. • Never route electrical cables near parts that get hot. • Never route electrical cables through or near moving parts. • Always place the supplied terminal boots on wires and terminals as directed by the installation instructions. • Never lean over battery while making connections. • Never route electrical cables over battery terminals. • Never short battery terminals with metal objects. • Always verify area is clear of fuel lines, fuel tank, brake lines, electrical wires, etc., when drilling. • Always consult operator’s manual for proper wiring details. • Always insulate and protect all exposed wiring and electrical terminals. Failure to observe these instructions could lead to property damage, severe injury, or death • Never exceed the maximum recommended hydraulic pressure or flow for any of the components used. • Always use a tandem-center type control valve ( A & B work ports blocked) to insure proper brake operation. • Always make sure all hydraulic system components are functioning correctly. • Never use a standard motor valve. • Never use a relief valve that exceeds the hydraulic motor pressure rating. Use of this valve can overload the winch. WARNING
Winch does not hold load when stopped
Brake is badly worn or broken
Replace brake. NOTE: Entire brake assembly must be replaced.
Verify that the hydraulic control valve is an “open- center” type spring return valve and that all hydraulic pressure to the winch is released in the OFF position.
Incorrect hydraulic control valve installed
AVOID WINCH AND EQUIPMENT DAMAGE • Always avoid side pulls which can pile up winch rope at one end of the drum. This can damage winch rope or winch. • Always ensure the clutch is fully engaged or disengaged. • Always use care to not damage the vehicle frame when anchoring to a vehicle during a winching operation. • Never submerge winch in water. NOTICE
Rotate drum and inspect for bent flanges. Bent drum must be removed and repaired. Remove drum. Inspect bushings and replace if neces- sary. Verify that clutch lever rotates freely. Verify that clutch lever is turned to the release position. Verify that air pressure to the clutch is 50-120 psi (air clutch only). Disassemble winch and verify that driveshaft moves freely and that the driveshaft spring is not damaged. Verify that piston O-ring is not damaged (air clutch only). Connect the winch to a load and alternately power-in and power-out. The rope will usually work itself free. Inspect the rope for damage and replace if necessary. USE EXTREME CAUTION. Remount the winch following specifications and procedures in this manual. Be sure mounting surface is flat to within .020 inch. Use shims if necessary. Be sure mounting bolts are tight.
Bent flange on drum
Worn drum bushings
Freespool clutch is not fully disengaged
Clutch is damaged
Difficulty unspooling rope
Rope is bound up on drum
Drum binds, because improper mounting causes winch to twist
Ambient temperature too low
Run the winch for several minutes to warm the gearbox to operating temperature.
WARN INDUSTRIES 16
WARN INDUSTRIES 5
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