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5. PREVENT KINKS BEFORE THEY
OCCUR.
a
b
c
a. This is the start of a kink. At this time,
the wire rope should be straightened.
b. The wire rope was pulled and loop has
tightened into a kink. Wire rope is now
permanently damaged and must be
replaced.
c. The result of kinking is that each
strand pulls a different amount causing
strands under greatest tension to break
and reduce load capacity of the wire
rope. The wire rope must be replaced.
10
6. EQUIPPING THE WINCH WITH A
ROLLER FAIRLEAD, P/N 1560,
will substantially reduce wear on
the wire rope during angle pulls.
The rollers eliminate heavy
rubbing and abrasion to the wire
rope.
T R O U B L E S H O O T I N G
C H A R T
Symptom
Possible Cause(s)
Motor will not operate
1. Damaged or stuck
or runs in one direction
solenoid; most likely
only
caused by not holding
the inner nut to keep the
stud from turning when
attaching wire to solenoid
2. Switch inoperative
3. Broken wires or bad
connection
4. Damaged motor
5. Solenoids not grounded
Winch will not shut off
1. Solenoid stuck "on"
Motor runs extremely hot
1. Long period of operation
2. Damaged motor
Motor runs but with
1. Weak battery
insufficient power or
line speed
2. Battery to winch wire
too long
3. Poor battery connection
4. Poor ground
Motor runs but drum
1. Clutch not engaged
does not turn
Winch runs backwards
1. Motor wires reversed
2. Solenoids wired incorrectly
Will not hold load
1. Excessive load
If a problem arises, contact your nearest
Superwinch dealer or repair center.
Corrective Action
1. CAUTION: Disengage
clutch before perform-
ing this test to prevent
powering the wire rope
drum. If a solenoid sticks
once, it is likely to stick
again and must be
replaced immediately.
Tap solenoid to free
stuck contacts. Check
by applying voltage to
the small solenoid ter-
minal. Be sure solenoid
is grounded back to
source. A solenoid that
is not stuck will make an
audible "click" when first
energized
2. Replace Switch
3. Check for poor connect-
tions. CAUTION: Always
use two wrenches
(spanners). (See Figure 10)
4. Replace or repair motor
5. Check the ground path
between battery
negative and solenoid base
1. If solenoid sticks on,
reverse direction and hold
trigger switch on until the
power lead can be
disconnected. A safety on-
off switch is available as an
accessory
1. Allow to cool
2. Replace or repair motor
1. Recharge or replace
battery. Check charging
system
2. Use larger gauge wire
3. Check battery terminals for
corrosion. Clean as
required
4. Check and clean connections
1. Engage clutch
1. Recheck wiring
2. Recheck wiring
1. Reduce load or double line
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