Suggestions For Maintenance Of Your Winch; Troubleshooting Guide - Ramsey Electronics 2000 Owner's Manual

Suggestions for Maintenance of Your Winch
Spool the cable properly on the drum when storing
between each usage.
Check the oi l level in the gear box every six months.
At the same time, check eiectricai connections and
mounting bolts — tighten if necessary.
Be sure the winch has pienty of battery power
availabie.
The minimum ampere-hour rating of the vehicie
battery should be 70, and used with at ieast a 40 amp.
alternator.
Replace oil annually or more often ifwincl>:-is.used
frequently. We suggest all purpo^ SAE TAOWr worm
EP 90 weight t\Vi 90 weight oii
gear box and SAE 20 for spur gear box. Apply cup
grease to lube fitting at top of ciutch housing. Check
periodicaiiy to determine if ciutch operates freeiy. If not,
lubricate.
Should winch be submerged for a brief period, drain
oil, flush and replace oil in gear boxes. Place oil in
motor pots and ail grease zerks. On hidden winches
check periodicaiiy to determine that the ciutch cable
control operates freeiy. If not, lubricate,
if winch is not to be used for an extended period,
disconnect winch battery cable from the battery.
For best results, use only factory certified replace
ment parts.
Ramsey Electric Winches Trouble Shooting Guide
t'
CON
condition
MOTOR RUNS IN ONE
DIRECTION ONLY
MOTOR RUNS
EXTREMELY HOT
MOTOR RUNS, BUT WITH
INSUFFICIENT POWER, OR
WITH LOW LINE SPEED
MOTOR RUNS, BUT DRUM
DOES NOT TURN
MOTOR WILL NOT OPERATE
MOTOR WATER DAMAGED
CLUTCH INOPERATIVE OR
BINDS UP
CLUTCH SPRING DOES NOT
OPERATE
CLUTCH DOES NOT LOCK AT
DISENGAGED POSITION
REMOTE CABLE CONTROLLED
CLUTCH DOES NOT LOCK IN
DISENGAGED POSITION
OIL LEAKS FROM HOUSING
POSSIBLE CAUSE
(1) Defective solenoid or stuck
solenoid
(2) Defective switcfi
(3) Broken wire or bad connection
(1) Long period of operation
(2) Insufficient battery
(3) Cable from battery to wlncti
too small
(4) Bad connection
(5) Insufficient cfiarging system
(1) Ciutcti not engaged
(2) Stieared drum stiaft key
(3) Stripped bronze gear
(4) Parted sfiaft
(1) Defective solenoid or stuck
solenoid
(2) Defective switcti
(3) Defective motor
(4) Loose connections
(1) Submerged in water
CORRECTION
(1) Jar solenoid to free contacts. Cfieck by applying 12 volts
to coll terminal (It sftould make an audible click when
energized).
(2) Disengage winch ciutch or remove armature lead. Remove
switch plug from hood. Raise connector cover on hood
and with a screw driver, short the bottom two pins.
Solenoid should click. Short the two left hand pins. The
other solenoid should operate. If both solenoids operate
check for a broken wire In switch cable.
Check for loose connection on switch and switch connector.
Gooling-off periods are essential to prevent over-heating.
Check battery terminal voltage under load. If 10 volts or
less, replace or parallel another battery to it.
Check battery to ground (chassis) cable. Must be No. 2
or larger.
Check battery cables for corrosion; clean and grease.
Replace with larger capacity charging system.
(3)
(1)
(2)
(3)
(4)
(5)
(1) If ciutch engaged but symptom still exists, it will be
necessary to disassemble winch to determine cause and
repair.
(1) Dry or rusted shaft
(2) Dog point setscrew too tight
(3) Bent yoke
(4) Keys pulled out of shape by
over load
(1) Broken spring
(1) Set screw loose or worn
(1) Failure to properly secure
remote cable
(1) New seal
(2) Seal damaged or worn
(3) Too much oil
(4) Damaged gasket
(1) Jar solenoid to free contacts. Check by applying 12 volts
to coil terminal (it should make an audible click when
energized).
(2) Disengage winch clutch or remove armature lead. Re
move switch plug from hood. Raise connector cover on
hood and with a screw driver, short the bottom two pins.
Solenoid should click. Short the two left pins. The other
solenoid should operate. If both solenoids operate, check
for a broken wire in switch cable.
if solenoids operate, check for voltage at armature post;
replace motor.
Tighten connections on bottom side of hood and on motor.
(3)
(4)
(1) Allow to drain and dry thoroughly, then run motor with
out load in short bursts to dry windings.
(1)
(2)
(3)
(4)
Clean and lubricate.
Remove rubber plug from ciutch housing and rotate set-
screw outward until ciutch operates smoothly. Replace
rubber plug.
Replace yoke or shifter assembly. '
If drum shaft's keyways are rounded or damaged replace
shaft and keys. If not, file off burrs and replace keys.
(1) Replace.
(1) Remove rubber plug from clutch housing, tighten set-
screw or replace. Replace plug.
(1) See individual mounting kit Instructions for proper
adaptation of cable to ciutch assembly. See paragraph (3)
in Operating Instructions, Page 3 Owner's Manual.
(1) New seals sometimes leak until seated to shaft.
(2) Replace.
(3) Drain excess oil per lubrication Instructions.
(4) Replace.