Why Maintenance Is Crucial
An electric winch is a powerful tool that must perform under extreme conditions. Regular maintenance not only prevents malfunctions at critical moments but also significantly extends the lifespan of your investment.
Check 1: Cable Condition
Inspecting Steel Cable
- Broken wires: Count the number of broken wires per lay (wrap length). More than 3 broken wires? Replace immediately.
- Kinks: Bends in the cable permanently weaken it. Replace when visible kinks appear.
- Rust: Surface rust can be scraped off. Deep rust means replacement.
- Frays: Protruding wires are a sign of wear and injury risk.
Inspecting Dyneema
- Wear spots: Look for flat, shiny areas indicating friction damage.
- Discoloration: White or faded spots may indicate UV damage.
- Fuzzing: Loose fibers indicate internal damage.
- Knots: Inspect connections for tears or deformation.
Maintenance Action
- Steel cable: Lubricate with special cable grease after each use in dirt or water
- Dyneema: Rinse with clean water and let dry out of the sun
Check 2: Brake Operation
The automatic brake keeps the load in place when the motor stops. A failing brake is life-threatening.
Test the Brake
- Hoist a light load (100-200 lbs) about 3 feet up
- Turn off the motor
- The load must remain completely stationary
- Wait 30 seconds and check for settling
Warning Signs
- Load slowly drops when motor is off
- Cracking or grinding sounds when braking
- Delayed response when stopping
Action for Problems
Brake maintenance requires specialized knowledge. Contact a professional or ask for advice.
Check 3: Electrical Connections
Inspect the Wiring
- Battery connections: Check for corrosion (white or green deposits)
- Connectors: All plugs must be securely attached
- Cables: Inspect for damaged insulation, abrasion, or kinks
- Ground: The ground cable must make good contact with clean metal
Test Operation
- Operate the winch briefly in both directions
- Listen for abnormal sounds (clicking, humming without movement)
- Check that the remote control responds reliably
- Watch for sparking at the battery (indicates loose contact)
Maintenance Action
- Clean connections with contact spray
- Lubricate terminal clamps with pole grease
- Replace damaged cables immediately
Check 4: Mounting Points
The mounting is only as strong as the weakest bolt. During recoveries, extreme forces are released.
Check
- Bolts and nuts: All present and tightened?
- Mounting plate: No cracks, deformation, or rust?
- Chassis connection: Firmly connected to the vehicle frame?
- Fairlead: Properly secured and freely rotating?
Warning Signs
- Play in the winch mounting
- Rust marks around bolt holes
- Cracks in welds or sheet metal
Check 5: Drum and Guide
Drum Inspection
- Cable winding: The cable must be wound tightly and evenly
- Free space: At least 5 wraps must always remain on the drum
- Wear: Grooves or damage in the drum? Have it checked.
Guide (Fairlead)
- Rollers: Must rotate freely without play
- Wear: Grooves in the rollers mean replacement
- Alignment: The cable must run straight onto the drum
Maintenance Schedule
| Interval | Action |
|---|---|
| After each use | Visual inspection of cable, rinse if dirty |
| Monthly | Perform all 5 checks |
| Semi-annually | Completely unroll and inspect cable |
| Annually | Professional inspection or overhaul |
Need Parts?
At Superwinch Winches, we supply all original parts for maintenance and repair. From motors to switches, from cables to fairleads.
Questions About Maintenance?
Our specialists are ready to help you with maintenance questions or ordering the right parts. Contact us for personal advice.