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Warn Winch Basic Diagnostics The following Trouble Shooting Tips are a collection of the most frequent problems that we encounter with Warn Winches. Most of these are simple electrical problems and are easily solved. We are here to answer questions and schedule Warn winch service Monday - Friday 8:00AM - 5:30PM EST. Toll Free 1-800-257-4294 1. Your Warn Winch will not operate in either direction when the remote control is activated, no sound from the solenoids. Cause: • The solenoids are not properly grounded.

• The electrical wire terminals or the battery terminals are corroded. • The motor brush holder is not grounding to the motor housing. Possible Solution: • Attach the Warn solenoid ground wire to the motor housing. On older control packs with out a ground wire attach the solenoid mounting plate to a good ground location. • Clean all electrical wire terminals and battery terminals.

All contact surfaces should be shiny. • Remove the Warn motor brush plate and clean corrosion from the edge of motor housing. Install shims for your specific winches repair kit 2. Your Warn Winch will not operate in the Power “IN” mode.

Cause: • The pins inside the remote control plug have been pushed out of position or bent, preventing contact with the corresponding receptacle in the control box. • One of the power “IN” solenoids is sticking or is damaged from prolonged use, which has overheated the solenoid. • The thermal protective switch is defective, or has tripped because the motor has over heated (old M-10000’s and industrial winches) Possible Solution: • Replace the remote control receptacle or plug, or complete unit.

• Replace the defective solenoid. • Allow the Warn winch motor to cool for about 20 minutes. The thermal switch will reset automatically.

When the remote control switch is activated there is only a “clicking sound”, and the winch does not operate in either mode. Cause: • The battery is: Not fully charged or terminals are corroded, Battery is defective or worn out. • Electrical grounding wire is not attached to the motor housing. • The motor armature is damaged or shorted, possible from incorrect wiring of the control pack to the motor, or overheating of the motor. • Water in the motor, caused by submersion or improper installation of the motor, or the motor was not allowed to drain properly, causing an electric short. • Worn or damaged brushes, caused by damaged armature commutator or normal wear.

Possible Solution: • Clean the battery terminals and wire terminals. • Attach the electric ground wire to the motor housing. • Recharge battery • Replace the motor brushes. • Replace the motor armature.

• Replace the motor. Winch runs very slow and lacks power when pulling a load, won’t pull a load, or stalls easily. Cause: • See cause and corrective action for problems 3 and 4. • Check the wire rope.

If it is spooling onto the drum in the wrong direction, it will be working against the automatic brake. Possible Solution: • Remove all the wire rope and re-spool onto the drum in the proper direction. Note: be sure to observe the drum rotation decal. Electrical sparks are seen from around the motor adapter or screw heads.

Cause: • Electric ground is not sufficient. Either the ground wire has not been installed, or the battery wires and wire terminals are corroded. Corrective action: • Install the ground wire that was supplied with the winch to the motor housing, and attach to the negative terminal of the battery. • Also see Cause and Corrective Action for problems 3,4 and 5.

Winch motor gets Hot very quickly. Cause: • Motor bushing in the winch motor end cap is too tight. • Motor armature is damaged or shorted, possibly from incorrect wiring of the control box, or overheating the motor on a previous pull. Possible Solution: • Use a emery cloth on the bushing and motor shaft. • Replace the winch motor.