Use this manual if your electric winch has a gray cover, it operates on a 12 volt battery, it has a strap, and it has the switch on the side of the winch.
Find in the list below the problem you are experiencing with your winch, then click the “+” sign near a “Possible Cause” for an explanation of how to fix it.
Symptoms & Solutions
Motor will not run
Corrective Action:
Make certain that 12 volt power is getting to the switch. If not, check the battery and the connection of the wiring harness to the battery. The most common problem is an insufficient ground connection on the negative wiring harness wire. It is possible to measure 12 volts at the switch with a meter, but have a ground connection that will not allow sufficient current to run the motor. Disconnect and clean the ground connection and reassemble. Check to be sure that the red connector on the end of the wiring harness is securely snapped into the mating connector on the winch and that all four wires going to this connection are secure. If these steps do not solve the problem, check for a faulty circuit breaker by temporarily removing it from the system. Also check the entire length of the wiring harness for a broken wire.
Corrective Action:
Remove the green motor wire from the switch on the inside of the winch cover. Then use jumper wires directly from a 12 volt battery to test the motor. Connect the green motor wire to positive and the black motor wire to negative. If the motor fails to run, or runs erratically, it needs to be replaced. Order motor assembly 306224.
Corrective Action:
After confirming that 12 volt power is present at the winch and that the motor runs when connected directly to a battery, then the only other possibility is the switch. You can double check this by removing the two wires from the switch and then connecting these two wires together with a jumper wire. This should cause the motor to run and confirms that the switch is faulty. Order switch 206249.
Corrective Action:
Because this winch only runs in one direction, reversing the battery wires will cause the motor to immediately stall when the switch is activated. If when the switch is activated, the motor attempts to run and immediately stalls, check to be sure the positive harness wire is connected to the positive (+) battery terminal and that the rest of the wiring is exactly as shown in the diagram.
Motor runs hot
Corrective Action:
Limit motor run time to a maximum of three minutes followed by at least 20 to 30 minutes of cooling. Motor run time is critical even when winch is not pulling its full capacity.
Motor has difficulty pulling load
Corrective Action:
If motor slows down a lot and groans to pull load, winch is probably overloaded. Reduce the amount of load being pulled.
Corrective Action:
Recharge or replace battery and confirm good clean connections for both positive (+) and ground (-) wires.
Motor runs but winch fails to pull strap
Corrective Action:
If the winch is new or has a new strap installed, it may take several revolutions of the winch reel before the strap tightens sufficiently on the reel to begin pulling a load.
Corrective Action:
Tighten clutch knob. If tightening the knob does not solve the problem, but you know for sure the clutch is slipping, then there are two possible causes. The thrust bearings could be worn out or the clutch pad could be damaged. To investigate, remove the slotted nut from the center of the clutch knob, the clutch knob and the winch cover. On the clutch stud you will see the outer thrust bearing with a hardened bearing race (flat washer) on both sides. Lift this bearing and both of the gears off of the stud and notice that there is a small spring washer between them. The inner thrust bearing and two races can then be removed. There will be additional spacer washers on the stud and these should remain in place. Check the condition of both of the thrust bearings and the races and replace if noticeably worn, dry or burned. Order and install thrust bearing kit 5703194, which includes two bearings and four races. Examine the condition of the clutch pad. This is bonded to the large gear in newer models or bonded to the flange of the small gear in older models. If there are portions of the clutch pad missing or torn away, or any other significant damage to the pad, a replacement is necessary. If the clutch pad in your winch is bonded to the large gear, you can replace just that gear. Order 120 tooth gear assembly 306102. If the clutch pad in your winch is bonded to the clutch gear flange it will be necessary to order clutch gear assembly 306100 in addition to the 120 tooth gear. Reassemble the clutch by the following procedure. Place one of the thrust bearings (with a race on each side) on the clutch stud. Next install the clutch gear and the spring washer oriented as shown in the photo on the stud followed by the 120 tooth gear turned with the pad facing the clutch gear. Install the outer thrust bearing (with a race on each side) and then reinstall the cover, clutch knob and slotted nut.
Corrective Action:
Remove the winch cover and reinstall and tighten the clutch knob. Run the winch and observe which parts are turning and which are not. This should make the source of the problem obvious. Refer to the owner’s manual or website for the necessary repair parts.
Circuit breaker trips
Corrective Action:
The circuit breaker is designed to cut power to the winch in the event of a substantial overload. It will automatically reset after a short cooling period. Note that the circuit breaker will not protect the motor from damage due to excessive run time.
Corrective Action:
If problem persists after confirming that the load being pulled is within the capacity of the winch, then replace circuit breaker 204039.
Winch will not hold load
Corrective Action:
Tighten clutch knob.
Corrective Action:
Remove the winch cover to observe which parts are moving as the load slips out. This should pinpoint the problem. If the motor shaft is turning, replace the roller clutch assembly 304698.
Strap will not freewheel
Corrective Action:
First confirm that clutch knob is in freewheel position. Then with no load on winch jog power switch to see if clutch will open and allow freewheeling. If this does not work, remove any load from the winch and remove the winch cover. Then gently pry the clutch gear and mating gear apart by inserting a screwdriver between them.
Strap damage
Corrective Action:
The strap is considered a perishable item and will periodically need to be replaced. Follow these suggestions to maximize strap life: It is essential that the winch is aligned with the load so that the strap goes straight into the front opening of the winch without severely rubbing on the edges of the opening. Allowing the strap to rub on anything, or allowing it to feed onto the winch reel in a bunched up or folded over fashion will quickly damage and weaken the strap. The strap must lay flat on the winch drum. Strap can easily be cut if it is under tension and allowed to contact any metal edge, even if it does not seem especially sharp. Keep the strap in good condition and replace when damaged.
Strap breaks
Corrective Action:
See Strap damage section above.
Corrective Action:
The winch has sufficient power to break the strap if overloaded. Monitor load carefully to prevent a sudden rise in strap tension. Keep strap in good condition and replace when damaged.
Hook spreads open
Corrective Action:
Make certain that load is fully engaged into the throat of the hook allowing the safety latch to close. Engaging only the point of the hook on the load could cause hook to open up or break.
Corrective Action:
Overloading the hook will cause it to spread open and possibly break. Reduce the load.
