Superwinch Winch Trouble-shooting Guide


Superwinch Winch Trouble-shooting Guide

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This guide is based on the one available from http://www.superwinch.com/UserFiles/File/troubleshoot.pdf. It has been written to help you identify and resolve the more common problems experienced with Superwinch 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 Superwinch 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 Superwinch winch, you should contact an authorised agent.

Please click the links below for more information about that problem:

  1. Motor will not operate or runs in one direction only.
  2. Winch runs backwards
  3. Motor runs but drum does not turn.
  4. Winch runs in manual mode but not with wireless.
  5. Motor runs extremely hot.
  6. Motor runs but with insufficient power or line speed.

1. Motor will not operate or runs in one direction only.

Possible causes:

  1. Connections
  2. Motor Function
  3. Defective Control Components

Advice:

  1. Check all power connections to or runs in one direction only. (including Quick Connects) winch, and solenoid for loose or broken connections.
  2. Roggle Switch: Check all wiring or runs in one direction only. (including Quick Connects) connections to switch, for loose or broken connections.
    Power Distribution Module (PDM): Check all wiring connections to PDM, for loose or broken connections.
    Solenoid: Check all wiring connections to solenoid, for loose or broken connections.
  3. If possible, connect the winch motor directly to the battery via a set of jumper cables or other means to determine if the motor is working properly. Switching the wires on the motor terminals should reverse the running direction of the motor. See Component Troubleshooting

2. Winch runs backwards

Possible causes:

  1. Motor wires reversed
  2. Switch wires reversed
  3. Switch installed incorrectly

Advice:

  1. Check all wiring
  2. Check all wiring
  3. Check switch installation

3. Motor runs but drum does not turn.

Possible causes:

  1. Freespool clutch not engaged
  2. Damaged gears

Advice:

  1. Engage freespool clutch does not turn.
  2. Replace gears or winch transmission

4. Winch runs in manual mode but not with wireless.

Possible causes:

  1. Connections
  2. Malfunctioning (PDM)
  3. Program Fault

Advice:

  1. Check battery connections to (PDM) but not with wireless. (Power Distribution Module)
  2. Check Ignition Lead Connection to PDM
  3. Check Antenna Connection to PDM
  4. Check PDM Connections to Solenoid
  5. Make sure that all of the above connections are locked into their appropriate receptacles.
  6. Troubleshoot PDM but not with wireless. (Power Distribution Module) See Component Troubleshooting
  7. Reprogram PDM See Component Troubleshooting Replace (PDM) if necessary

5. Motor runs extremely hot.

Possible causes:

  1. Long period of operation
  2. Damaged motor

Advice:

  1. Allow to cool
  2. Replace or repair motor

6. Motor runs but with insufficient power or line speed.

Possible causes:

  1. Week battery
  2. Battery to winch wires too long
  3. Poor battery connection
  4. Bad circuit breaker
  5. Poor ground
  6. Damaged motor

Advice:

  1. Recharge or replace battery power or line speed.
  2. Keep winch within distance allowed by lead wires
  3. Check battery terminals for corrosion Clean as required
  4. Pull breaker out of line and test winch with load
  5. Check and clean connections
  6. Repair or replace motor or brushes