MAINTAINENCE
1. Periodically check the tightness of mounting bolts and electrical connections. Remove all dirt or corrosion and always
keep clean.
2. Do not attempt to disassemble the gear box. Repairs should be done by the manufacturer or an authorized repair
center.
3. The gear box has been lubricated using a high temperature lithium grease and is sealed at the factory. No internal
lubrication is required.
REPLACING THE WIRE ROPE
1. If the wire rope has become worn or is beginning to show signs of strands breaking it must be replaced before being
used again. To do this, remove the defective rope by free spooling. Remove the M5 x 5mm bolt on the drum and
release the rope.
2. Insert the end of new rope and secure the M5 x 5mm bolt tightly.
3. Engage the clutch and re-spool the new rope on the drum keeping tension on the rope as it spools. Ensure that the
rope is re-spooling in the under wind position.
WARNING
- Only replace the wire rope with the identical replacement part recommended by the manufacturer.
SYMPTOM
POSSIBLE CAUSE
SUGGESTED ACTION
Motor does
not turn on
-Switch Assembly not
connected property
-Loose battery cable
connections
-Solenoid malfunctioning
-Defective Switch Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the
way into the connector.
-Tighten nuts on all cable
connections.
-Tap solenoid to loosen contacts.
Apply 12volts to coil terminals
directly. A clicking indicates
proper activation.
-Replace Switch Assembly
-Check for voltage at armature
port with switch pressed. If
voltage is present replace motor.
-Allow to drain and dry. Run in
short bursts without load until
completely dry.
Motor runs but
cable drum
does not turn
-Cam Ring (clutch)
not engaged
-Move Cam Ring to the in
position. If problem persists, a
qualified technician needs to check
and repair.
Motor runs
slowly or
without normal
power
-Insufficient current or
voltage
-Battery weak, recharge. Run
winch with vehicle motor running.
-Loose or corroded battery cable
connections. Clean, tighten, or
replace
Motor
overheating
-Winch running time too
long
-Allow winch to cool down
periodically.
Motor runs in
one direction
only
-Defective or stuck
Solenoid
-Defective Switch
Assembly
-Tap solenoid to loosen contacts.
-Repair or replace solenoid.
-Replace Switch Assembly
TROUBLESHOOTING
1-800-345-4545 jegs.com
