Inspection and verification
WARNING: Follow all warnings and precautions in the WARNINGS section of the winch operator's manual before and during winch operation.
WARNING: Diagnosis by substituting a component from another vehicle is FORBIDDEN. The substitution of control units does not guarantee confirmation of the fault and, moreover, may cause additional faults in the tested vehicle and/or in the vehicle from which the modules are removed.
1. Check the validity of the customer's complaint.
2. Visually inspect for obvious signs of damage and system integrity.
External examination
Mechanical |
Electric |
• Wrong installation • Electric winch motor • Reducer • Wire rope |
• Circuit breakers • Battery (minimum 650 CCA) • Loose, corroded or damaged electrical connections • Electromagnet for power interruption of the winch • Control block • Remote control |
3. If a clear cause for an observed or customer-reported issue is identified, resolve the issue before proceeding to the next steps (if possible).
Trouble symptom table
sign | Possible reasons | Actions taken |
winch not working | ||
winch not working (a click is heard when using the remote control switch) | ||
Winch lacks power, pulls slowly, stops | ||
When using the remote control, the winch only works in one direction | ||
Difficulties when unwinding the cable from the drum manually | ||
Difficulties when unwinding the cable from the drum manually | Install a new winch gearbox if necessary. For more information refer to: Winch Gear Assembly (419-12 Winch, Removal and installation). Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program | |
The winch does not hold the load | ||
Remote control malfunction | For Remote Control Circuit Tests Go to PINPOINT TEST C. | |
The included thermal indicator of the remote control (Light-emitting diode) | NOTE: If the temperature of the actuator bushings has reached 205+ C (400+ F), the thermal indicator opens and the LED of the remote control turns on Malfunction of the thermal shutdown device | |
Clutch lever failure |
PINPOINT -TEST A : BATTERY TEST |
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STATE DETAILS/RESULTS/ACTIONS |
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A1: CHECK MIDTRONICS BATTERY |
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1 Make sure the car's battery is charged, in good condition and meets specifications (minimum 650 CCA) |
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2 Using the Midtronics Handheld Tester or the Midtronics GR-1 Diagnostic Charger, perform "Midtronics battery test" according to the instructions in the battery care manual. Cm. (Service/Battery Care Manual/Service Information) |
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3 Record the result of battery diagnostics in the form provided for this |
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Has the battery gone "Midtronics battery test"? Yes Check for correct operation, see symptom table above if problem reported by customer persists No Install a new battery if necessary. Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program. Check the correct operation of the winch. |
PINPOINT -TEST B : NETWORK TESTS |
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STATUS! details/results/actions |
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B 1: WINCH POWER INTERRUPTION ELECTROMAGNET: CONNECTIONS |
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NOTE: The winch power interrupt solenoid provides power to the winch control box |
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NOTE: Ignition power is supplied to the switch to turn on the power supply to the winch power interruption solenoid |
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1 P using the wiring diagrams, check the power supply fuse winch power interruption electromagnet ((fuse14 to VIN 798535) (fuse 15, from VIN 798536)) in the passenger compartment fuse box |
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2 See winch wiring diagrams For more information refer to: Winch (419-12 Winch, description and principle of operation). |
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3 P check the correct location of , cleanliness and reliability of connections with circuits winch power interruption electromagnet (terminal 1 - power supply for the winch control unit, terminal 2 - "weight" electromagnet, terminal 3 - electromagnet supply (from C 0072-1 via switch), terminal 4 - battery power) |
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Are all electrical connections to the winch power interruption solenoid clean and secure? Yes GO to B2. No Clean and secure electrical connections. Check the correct operation of the winch. |
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B 2: WINCH POWER INTERRUPTION ELECTROMAGNET: WORKING |
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1 P with ignition on and remote control connected |
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2 Using a multimeter, check the battery voltage between terminal 1 ( winch control unit power supply ) and terminal 2 (" mass " winch power interruption electromagnet ) |
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Is battery voltage being observed? (about 12 V) |
Yes GO to B3. No Replace winch power interruption solenoid if necessary. For more information refer to: Winch Solenoid (419-12 Winch, Removal and installation). Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program. Check the correct operation of the winch. |
OT: POWER SUPPLY - CONTROL UNIT |
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WARNING: Make sure the winch clutch is in free unwind mode (see winch manual) |
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NOTE: The winch power interrupt solenoid provides power to the winch control box |
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1 With the ignition on and the remote control connected |
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2 Using a multimeter, check for battery voltage between the red power supply to the control box and "weight" car |
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Is battery voltage being observed? (about 12 V) Yes GO to B4. No Perform circuit tests to determine the cause of power loss. Remove if necessary. Check the correct operation of the winch. |
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B4: INPUT CONTROL UNIT - REMOTE CONTROL |
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WARNING: Make sure the winch clutch is in free unwind mode (see winch manual) |
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NOTE: The winch control unit controls the direction of rotation of the winch motor |
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NOTE: Unwind - remote control supplies power to remote control connector terminal 2 and terminal 1 "masses" |
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NOTE: Winding - The remote control supplies power to terminal 4 of the remote control connector and terminal 1 "masses" |
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1 See winch wiring diagrams For more information refer to: Winch (419-12 Winch, description and principle of operation). |
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2 Use a multimeter to check terminal 2 (white), terminal 4 (green) and terminal 1 (brown) |
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Are terminals 2 reacting correctly (unwinding) and 4 (winding) (nutrition) and terminal 1 (weight) when using the remote control? Yes GO to B5. No Perform circuit tests to determine the cause of power loss. Remove if necessary. Check the correct operation of the winch. |
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B5: CONTROL UNIT - OUTPUT |
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WARNING: Make sure the winch clutch is in free unwind mode (see winch manual) |
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NOTE: When in use, the winch control unit supplies power to the winch motor |
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NOTE: Unwinding - the control box energizes terminal F1 of the winch motor and connects terminal F2 to terminal A (cepfle4HMK) |
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NOTE: Winding - the control unit supplies power to the F2 terminal of the winch motor and connects the F1 terminal to the A terminal (cepfle4HHK) |
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1 See winch wiring diagrams For more information refer to: Winch (419-12 Winch, description and principle of operation). |
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2 Use a multimeter to check terminals F1, F2 |
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Do terminals F1 and F2 respond correctly when using remote control? Yes GO to B6. No Check the connections to the control unit. If all connections are clean and secure, install a new control box if necessary. For more information refer to: Winch Control Unit (419-12 Winch, Removal and installation). . Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program. Check the correct operation of the winch. |
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B6: WINCH ELECTRIC CONNECTIONS |
WARNING: Make sure the winch clutch is in free unwind mode (see winch manual) |
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1 See winch wiring diagrams For more information refer to: Winch (419-12 Winch, description and principle of operation). |
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2 Check the connections to the winch motor |
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Are all connections clean and secure? Yes GO to B7. No Clean and secure electrical connections. Check the correct operation of the winch. |
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B7: CHECK THE ELECTRIC WINCH |
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WARNING: Make sure the winch clutch is in free unwind mode (see winch manual) |
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1 Disconnect the positive cable from the battery (leave the wire attached "masses") |
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2 Attach tags to the three wires from the control box to the three pins on the winch motor and disconnect them |
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3 A, F1 and F2 are stamped next to the three pins of the winch motor. Connect test wire (suitable connecting wires) A to F1 and apply battery power to F2. The winch motor must be running |
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4 Connect test wire from A to F2 and apply battery power to F1. The winch motor must run in the opposite direction |
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Does the winch drive work in both directions? Yes Check for correct operation, see symptom table above if problem reported by customer persists No Check winch motor connections. If all connections are clean and secure, install a new winch motor if necessary. For more information refer to: Winch Motor (419-12 Winch, Removal and installation). Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program. Check the correct operation of the winch. |
PINPOINT -TEST C : REMOTE CONTROL |
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CONDITIONS! details/results/actions |
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C1: REMOTE CONTROL - CONDUCTIVITY CHECK |
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NOTE: Visually inspect remote control connector terminals for damage and repair or replace as necessary |
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NOTE: The winch remote control must be tested for continuity with a multimeter |
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1 With the winch remote control off, test for continuity as instructed below |
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2 Move the switch to "power out" (unwinding) - check conduction between terminals (1) And (3), check for continuity between the terminals (2) And (6) |
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3 Move the switch to "power in" (winding) - check conduction between terminals (1) And (3), check for continuity between the terminals (4) And (6) |
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Has the remote control passed the conductivity test? (resistance less than 1 ohm)? Yes Check for correct operation, see symptom table above if problem reported by customer persists No Install a new winch remote control if necessary. Before installing a new unit/component, refer to the Warranty and Procedures Manual to determine if a replacement requires prior authorization under any applicable special program. Check the correct operation of the winch. |
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