This guide is based on the one available from http://www.britpart.co.uk/uploads/files/pdf_downloads/winch_trouble_shooting_guide.pdf. It has been written to help you identify and resolve the more common problems experienced with Britpart winches. As such, the help provided in this guide is not intended to deal with problems with other brands of winching equipment.
Please remember that winches can be very dangerous, particularly if they are not used, maintained or repaired correctly. Obviously neither Britpart or Brookwell Supplies will accept liability or responsibility for accidents or damage that may be caused by following this guide, or for any repairs carried out by an unauthorised person.
If you have any doubts about what to do regarding a fault with your Britpart winch, you should contact an authorised agent.
Please click the links below for more information about that problem:
- The winch does not work in either direction and when the remote is activated, there is no sound.
- The winch does not work in the power ‘IN’ mode.
- The winch does not work in the power ‘OUT’ mode.
- The winch does not work when the remote control is activated and a ‘clicking’ noise can be heard.
- The winch runs very fast if there is no load on it, but it stalls when there is even a light load is applied.
- The winch has lost some pulling power since it was new.
- The winch does not hold a load, or the load even slips down.
- There is no freespool.
- The winch is running very slowly and it lacks power when pulling a load, or it won’t pull a load at all.
- The rocker switch on the remote control doesn’t return to the neutral position.
- The wire rope keeps getting between the drum support and the drum flange.
- When the winch is activated the vehicle systems fail, i.e. the engine stalls or stops running.
- The winch motor gets very hot, very quickly.
- The winch motor runs, but the drum doesn’t rotate.
- There are broken strands, or kinks in the wire rope.
- The winch makes a grinding noise, or jerks when pulling a load.
- There is a loud knocking noise from the gearbox.
- There are electrical sparks from around the screw heads, or the motor.
- The clutch will not operate.
- The gear housing is cracked, or broken around the clutch lever.
- The winch still keeps running, even after the remote control switch is released.
1. The winch does not work in either direction and when the remote is activated, there is no sound.
Possible causes:
- The solenoid mounting plate is not attached to the winch motor or the winch mounting plate, therefore it is not earthed, or it is improperly earthed.
- The electrical wire terminals are corroded.
Advice:
- Attach the solenoid mounting plate to a location that is earthed to the same electrical source as the winch, such as the winch motor or winch mounting plate.
- All electrical wire terminals should be cleaned until they are shiny and then smeared with an inert grease such as vaseline.
2. The winch does not work in the power ‘IN’ mode.
Possible causes:
- The pins inside the plug have been pushed out of position or bent, preventing contact with the corresponding holes in the socket.
- The ‘IN’ side of the contactor is sticking, or is heat damaged from extended use.
Advice:
- Replace the remote control receptacle, or plug, or complete unit.
- Replace the damaged, or defective contactor.
3. The winch does not work in the power ‘OUT’ mode.
Possible causes:
- Same as in item 2 above, except the power ‘OUT’ side of the contactor.
Advice:
- See item 2 above.
4. The winch does not work when the remote control is activated and a ‘clicking’ noise can be heard.
Possible causes:
- Power source or battery problem. The battery terminals are corroded, or the battery is not fully charged, or the battery is defective or worn out.
- The electrical ground / earth wire in not secure to the motor housing. Refer to the winch installation guide for instructions.
- The motor armature is damaged or shortened, possibly from incorrect wiring of the control pack, or overheating the motor.
- Water in the motor, caused by submersion, or improper installation of motor, or motor not allowed to drain properly, causing motor to short.
- Worn or damaged brushes caused by damaged armature commutator or normal wear.
Advice:
- Clean and remake the battery terminals and wire terminals.
- Re-attach the electrical ground / earth wire to the motor housing.
- Recharge the battery
- Replace the battery.
- Replace the motor
5. The winch runs very fast if there is no load on it, but it stalls when there is even a light load is applied.
Possible causes:
- The control box is wired incorrectly to the motor, refer to the winch installation guide instructions.
- The motor armature is damaged or shortened, possibly from incorrect wiring of the control box, or over heating the motor.
Advice:
- Rewire the control box to the motor according to the winch installation guide instructions.
- Replace the motor assembly.
6. The winch has lost some pulling power since it was new.
Possible causes:
- Power source problem, battery, terminals corroded, not fully charged, defective, or worn out.
- Worn or damaged brushes caused by damaged armature commutator, or normal wear.
- Electrical wire terminals are corroded or loose.
- Electrical ground / earth wire is not secure on the motor housing.
Advice:
- Clean the battery terminals and all the other electrical connections. Surfaces should be shiny and the smeared with an inert grease like vaseline.
- Replace the motor assembly.
- Re-attach the electrical ground wire to the motor housing. Refer to the winch installation guide instructions.
7. The winch does not hold a load, or the load even slips down.
Possible causes:
- Winch brake problem: – Frequent stopping of winch under load, leading to excessive brake wear.- The wire rope is wound on the drum in the wrong direction causing the brake to function when powering ‘IN’ and not to function when powering ‘OUT’. These conditions will also load the brake in the wrong direction and could cause catastrophic failure.
Advice:
- Replace the complete brake assembly.
- Rewind the wire rope on the drum in the correct direction.
8. There is no freespool.
Possible causes:
- The sliding clutch ring gear has a burr on the outside diameter, which interferes with the inside diameter of the gear housing. This can be caused from disengaging and engaging the clutch while the winch is under a load.
- Grease, or rust, or dirt has gotten between the outside diameter of the clutch ring gear and the inside diameter of the gear housing.
- The drum flanges are bent outward from the wire rope, stacking up on one end of the drum and forcing outward against the flange, distorting the frame.
Advice:
- Try pulling the wire rope off the drum slowly and in an even motion, DO NOT JERK.
- Have a service centre remove the burr from the ring gear and internal level, lightly grease the surfaces.
- Have a service centre remove all rust, dirt and old grease from surfaces and lightly grease.
- Have a service centre straighten the drum flanges, or replace the drum, ensuring a close fit of the gearbox to the drum support.
9. The winch is running very slowly and it lacks power when pulling a load, or it won’t pull a load at all.
Possible causes:
- Power source problem, battery, terminals corroded, not fully charged, or defective, or worn out.
- Electrical wire terminals are corroded or loose.
Advice:
- Clean all electrical terminals, battery terminals and connections.
- Recharge the battery.
- Replace the battery.
10. The rocker switch on the remote control doesn’t return to the neutral position.
Possible causes:
- The centering spring in the switch is broken or defective.
Advice:
- Replace the complete remote control assembly.
11. The wire rope keeps getting between the drum support and the drum flange.
Possible causes:
- The wire rope tension plate is loose, or damaged, allowing rope to build up at the end of the drum by the flange.
Advice:
- Replace or re-install the rope tension plate.
12. When the winch is activated the vehicle systems fail, i.e. the engine stalls or stops running.
Possible causes:
- A direct short to ground / earth.
Advice:
- Check all wires and wire terminals for any connections to the electrical ground / earth of the vehicle.
- Check for melted insulation on the wires that touch the vehicle frame, or engine block.
13. The winch motor gets very hot, very quickly.
Possible causes:
- Physical damage to the motor.
- The motor armature is damaged or shorted, possibly from incorrect wiring of the control pack, or previous overworking of the motor.
Advice:
- Replace the motor and thermal switch, if fitted.
- Allow the motor to cool between long winching cycles, especially when there is no thermal overload protection.
14. The winch motor runs, but the drum doesn’t rotate.
Possible causes:
- The squared drive shaft within the brake assembly is stripped or rounded, either through excessive heat and softening, which is caused from frequent powering ‘OUT’ the wire rope instead of disengaging the clutch and freespooling.
- The drum supports have loosened through damage or vibration disengaging the drive.
- The sun or planet gear teeth are damaged / stripped through sudden engagement of drive whilst freespooling under load, or towing with the winch cable, creating snatch loads.
Advice:
- Have a service centre replace the complete brake assembly. Use the clutch to freespool the wire rope instead of powering out.
- Have a service centre replace the complete gearbox.
- Refer to winching guide for good winching practice.
15. There are broken strands, or kinks in the wire rope.
Possible causes:
- Kinks and broken strands in the wire are often caused by improper use and can usually be prevented by suggestions in the winching guide.
Advice:
- Always replace kinked or damaged wire / fibre rope as soon as possible, to prevent catastrophic failure. Minimise kinking by rewinding the wire rope carefully, under a light load after each use. Refer to the winch owner’s manual for the proper procedure.
16. The winch makes a grinding noise, or jerks when pulling a load.
Possible causes:
- The drum flanges are bent outward from the wire rope stacking up on one end of the drum and forcing outward against the flange.
- The sun, or planetary gears have damaged teeth through previous misuse.
Advice:
- Have a service centre straighten the drum flanges, or replace the drum.
- Have a service centre strip and examine the gearbox, replace all of this if necessary.
17. There is a loud knocking noise from the gearbox.
Possible causes:
- The gear teeth are damaged from earlier misuse.
- A piece of metal, possibly a gear tooth, has been lodged between other gear teeth of a carrier assembly. Caused by overloading the winch, or other misuse.
Advice:
- Have a service centre strip and examine the gearbox, replace all of this if necessary.
18. There are electrical sparks from around the screw heads, or the motor.
Possible causes:
- Electrical ground / earth is not secure, or properly made.
Advice:
- Install the ground / earth wire that was supplied with the winch, to the motor housing and attach direct to the negative terminal of the battery.
19. The clutch will not operate.
Possible causes:
- The sliding clutch ring gear is damaged, or has material between the outside diameter and the inside of the gear housing.
Advice:
- Have a service centre clean the surfaces of the sliding ring gear and gear housing, coat lightly with oil.
- Have a service centre check the splines in the end housing for burrs.
20. The gear housing is cracked, or broken around the clutch lever.
Possible causes:
- This condition is usually caused by sudden engagement of the clutch whilst the winch is under a load and spooling out, creating a snatch load. Refer to item 14 above.
Advice:
- Replace the gear housing and other damaged parts. Also refer to the winching guide for correct winching practices.
21.The winch still keeps running, even after the remote control switch is released.
Possible causes:
- The remote control lead has been damaged causing a direct short, melting the small wires together in the lead.
- The remote control has been left plugged into the control box and water has entered the toggle switch, shorting it.
- The remote control has ben either submersed, or left out in the elements, allowing water to enter the toggle switch, shorting it.
Advice:
- Replace the remote control assembly.
- Refer to winch manual for proper care of remote control.
- Remote control must be unplugged and stored out of the weather when it is not in use.
