Maintenance of the Winch
Inspect winch a minimum of once
annually. If used more than once a week,
or in adverse conditions, such as salt
water areas or areas of extreme dust
and dirt, more frequent inspection is
required.
1.Carefully inspect the winch cable for
any kinks, frays, or abnormal stiffness
and replace at the first sign of damage.
Lubrication with light oil will improve the
life of the cable.
2. To replace the winch cable, it is necessary
to remove the winch cover.
a. Remove the two clutch handle screws
and the handle, and the four cover
mounting screws.
WARNING: Be sure that the power is
disconnected from the housing.
b. Lift the housing off the winch by gently
stretching it open near the lower front
corners.
c. Rotate the winch reel so theat you have
access to the rope clamp.
d. Remove the old cable and replace it
with a new cable of the same size and
type.
e. Be sure that the cable passes under
both sides of the rope clamp and that
the clamp is tightened securely.
NOTE: Cable is wound under the drum on
Model EMW1500R and EMW3000R.
Figure 7 - Cable Attachment Methods
3. With the cover removed as described
above, inspect the entire gear train and
all drive shafts for any abnormal wear or
loose bearing fits.
a. Grease all of the gears on the inside of
the winch base and apply a drop of oil
on all of the bearings in the base.
b. Very sparingly oil all of the bearings in
the clutch mechanism and place a drop
of oil on the roller clutch.
WARNING: Do not over lubricate
these areas and do not use grease in
the roller clutch. The clutch pad on
clutch gear assembly, brake pads and
brake disc must be kept clean and
oil free.
4.Check the operation of the roller clutch
by carefully rotating the brake disc and
observing the motor shaft.
a. When the disc is turned clockwise, the
motor shaft should turn with it.
b. When the disc is turned
counterclockwise the motor shaft
should not turn.
5. Check all nuts, bolts, retaining rings, etc.,
to be sure that they are tight and secure.
6. If the clutch has been slipping and
requires adjustment, the following
procedures should be used.
NOTE: The clutch is adjustable in ten
degree increments.
a. With a screwdriver and pliers, remove
the end of the clutch spring from the
hole in the winch base.
NOTE: The spring tension is quite high so
be careful to maintain a firm grip on the
spring.
b. Rotate the O-ring so that cutout
portions align with the lugs on the
spring keeper.
c. Expand the ring with a pencil or similar
object and lift the spring keeper free
from the clutch nut.(See Figure 8).
Figure 8 - O-Ring Illustration
d. Rotate the spring keeper clockwise
10 degrees and install on the next
serration in the clutch nut.
e. Reinstall O-ring and rotate slightly so
the cut-outs are not in line with the
lugs on the spring keeper. Reinstall the
clutch spring into the hole in the base
(adjustment of the clutch more than 10
to 20 degrees should normally not be
necessary).
Figure 9 - Clutch Spring Illustration
f. With only the spring pressure, the
spring lug on the spring keeper should
come to rest at approximately the 2:30
o’clock position.(See Figure 9).
NOTE: Do not forcibly tighten the clutch
mechanism.
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