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Old 08-22-2021, 04:56 PM   #1
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Electric winch not working

I knew I would refer the electric winch but it was standard on my pop up. It worked fine for about a year now it is intermittent. Push the switch and nothing happens. Sometimes if you work the switch several times it will start to work. It can be working then stop to tuck the canvas in and it won’t start again. There is power to the switch and the switch tests good. Any idea why it might be workin intermittently?
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Old 08-22-2021, 05:23 PM   #2
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Quote:
Originally Posted by ekskp View Post
I knew I would refer the electric winch but it was standard on my pop up. It worked fine for about a year now it is intermittent. Push the switch and nothing happens. Sometimes if you work the switch several times it will start to work. It can be working then stop to tuck the canvas in and it won’t start again. There is power to the switch and the switch tests good. Any idea why it might be workin intermittently?
Most likely the limit switches. Maybe they're loose and intermittent.
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Old 08-22-2021, 08:59 PM   #3
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Quote:
Originally Posted by ekskp View Post
I knew I would refer the electric winch but it was standard on my pop up. It worked fine for about a year now it is intermittent. Push the switch and nothing happens. Sometimes if you work the switch several times it will start to work. It can be working then stop to tuck the canvas in and it won’t start again. There is power to the switch and the switch tests good. Any idea why it might be workin intermittently?
Assuming its a forest river camper and you are comfortable with a resistance/continuity or voltage tester you can test the switch wither for its function with a continuity tester.

After the switch there is a double relay board on the underside of the winch motor exposed by removing the lower cover that the switch controls. Both parts together are about $75

looking from the tongue towards the back on the underside of the lift motor you will see something like this with a bunch of wires attached to the blades sticking out of the board:

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Old 08-22-2021, 09:14 PM   #4
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Quote:
Originally Posted by ekskp View Post
I knew I would refer the electric winch but it was standard on my pop up. It worked fine for about a year now it is intermittent. Push the switch and nothing happens. Sometimes if you work the switch several times it will start to work. It can be working then stop to tuck the canvas in and it won’t start again. There is power to the switch and the switch tests good. Any idea why it might be workin intermittently?
exactly how old is this unit and where is it stored when not in use?...

intermittent electrics can be the hardest things to troubleshoot...

I ask about the storage because damp/wet locations can create corrosion on switch internals and corroded connections to the switch and the motor... sometimes the connection is GOOD ENOUGH sometimes NOT. Deterioration over time tells me it is a corrosion problem due to humid and damp storage conditions.

It is going to require you to get into the workings of the wires and switches and connectors and find the one or more that are creating the problem. A visual inspection and twisting and pulling on the wires and taking apart and cleaning the connections are going to be required.

I recommend using the spray below which will help clean internal switch contacts ( providing you can get the liquid inside the switch as you cannot just spray the outside and expect it to work). Spray the connections and contact points after cleaning any rust or corrosion you find and reassemble. THe spray will help keep more corrosion from happening. This spray is good for any connection point of electrical wires.
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Old 08-23-2021, 01:36 PM   #5
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I had the same issue with our HW277. Our issue turned out to be the toggle switch to the winch. The best resolution I found was to clean the contacts on a fairly regular basis with WD-40. As long as I kept those contacts clean, the winch behaved itself nicely.
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Old 08-26-2021, 08:10 AM   #6
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First I want to say that the below video and instructions assume that you have already made sure all of the blade connectors are clean and corrosion free either by using a chemical cleaner sandpaper or just wiggling it a bunch to make a clean connection.

The Winch has a single pole double throw (SPDT) switch that is used to control up or down movement of the roof. The switches actually just control relays on a double relay board that switch the actual battery power to the winch motor. My video explains the use of a simple 12V auto light tester but you can apply the same logic for more complex test methods up to and including a volt meter.

If you want some tips on how to use a test light you can google it or watch the first part of my video to see how it works. If you are using a voltmeter I hope you know how it works.....

First Test:
The one thing I don't cover is the breaker that is on the battery + terminal that provides power to the winch and uses a breaker rather than fuse to cut power if you are drawing too much. It looks something like this:




They are supposed to auto reset when they cool down if tripped. If you are not getting power to the system at all start there and use your test light by having the clip on the negative terminal or body of the frame and touch the sharp probe lead to both sides of the breaker. You should see light on the side connected to the battery terminal and the other end that has a wire that goes down to the double relay board. If you aren't getting light on either side of the relay, your battery may be bad or the connection to it badly corroded and power is not flowing (also check the negative connection just in case). If you get light on the battery side but not on the other end connected to the wire going down to the relay board then you may have just found your problem in the breaker. You can temporarily hook the wire directly to the battery to bypass a bad relay to test but DO NOT leave it hooked up that way else you could start a fire if it ever shorts out.

I will share the below image of my winch upper cover off showing the motor, limiter and back side of the switch. Please note the big black alligator clip is from the test light and is clipped to the tow hitch lock arm. You just need a clean spot to get a good connection to the negative power for your battery. If the light lead reaches and is easily accessible you can feel free to use the battery negative terminal. Using the point on the test light you should be able to tap the center blade on the backside of the switch and see light. This tells you the switch is receiving power. Flip the switch up and down and you should see the light light up on one of the outer blades depending on which way you flip the switch. The switch blade that receives power will be the opposite one from the direction you moved the switch. It is better explained in the video but here is the photo:

https://ibb.co/JrQD0Z0

Finally here is the video that hopefully explains best what the switch does and how it works, as well as the double relay pack you can find if you remove the cover underneath the winch motor and how to test them for proper function.
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