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 a handheld remote switch.
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 winch. If you can hear the relay make a click noise when you push the RUN switch, then power is present and you can proceed to the next trouble shooting step. 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 winch 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 temporily removing it from the system. Also check the entire length of the wiring harness for a broken wire. Once you confirm that 12 volt power is getting to the relay inside the winch, then proceed to the next trouble shooting steps.
Winch motor continues to run when switch is released
Corrective Action:
First, unplug the switch cord from the winch. If this causes the winch to stop, then the switch is faulty and needs to be replaced. Order switch number 306237. If this did not stop the winch, then replace the relay 204639.
Winch runs immediately when power cord is attached
Corrective Action:
First, unplug the switch cord from the winch. If this causes the winch to stop, then the switch is faulty and needs to be replaced. Order switch number 306237. If this did not stop the winch, then replace the relay 206439.
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.
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.
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.
Winch will not hold load
Corrective Action:
Tighten clutch knob.
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.
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.
