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Old 07-01-2023, 10:20 PM   #1
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Powerwinch HW277 locking up

I'm hoping someone can give me some advice on what I need to do here...

Up until today my camper top would raise and lower just fine. My battery isn't staying charged so I tried raising my top with my drill. I noticed the winch spool kept spinning but the cable wasn't moving. I got down on the ground and discovered the cable came out of the hole where the set screw holds it in place. I cut the end of the cable off and reattached it to the spool I used the power switch and wound the cable somewhat snug then the spool stopped spinning I suspect due to the weak battery. I hooked my drill up to the winch and it turned a few more revolutions and then it stopped. It's like the spool or motor are locked up. I double checked the cable and it's not an issue. I'm thinking a bearing in the motor shaft is locking up or possible something is getting out of alignment as pressure is being applied to the spool. Are there any instructional videos or literature that anyone is aware of that might give me some guidance? Glad I was doing this in the backyard and not after I traveled to a campsite! It's a 2012 model. Thank you
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Old 07-02-2023, 07:44 AM   #2
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I think you might have the cable spooling backwards and it gets stuck. Loosen the cable on the spool and wind it the other direction.
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Old 07-02-2023, 08:39 AM   #3
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Thanks, it's spooled correctly. The very end of the wire came out of the spool and I reinstalled without unwinding it so I know it's correct. The spool basically goes one direction or another about a revolution or two then locks up without tension on the wire.
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Old 07-02-2023, 10:56 AM   #4
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I just checked mine and yours is reverse spooling from mine.
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Old 07-05-2023, 11:31 AM   #5
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Wow...lots of guessing required...forgive me for the guesswork.

1. Let's say your limit switches are messed up, and that allowed your winch to keep running beyond where it should have stopped, and as it kept running, it overshot and wound the cable on the drum backwards. This goes along with MohicanJeff's comment that your cable seems to be wound backwards. No idea if this is the case or not. Something to consider.

2. Now to the limit switches. I had a 2014 HW-277. The limit switch system, in my view, is a Rube Goldberg nighmare.
Here's the manual. It's the cylindrical, plastic gear driven mechanism in front of the motor. It's about 1 1/2" to 2" in diameter and about 6" long. There are any number of reasons why it would be messed up, but most likely is that the plastic gear teeth on the limit switch have been stripped clean off, leaving you with a non-functioning switch.

The good news is that you can bypass the limit switch...with jumper wires straight from the up/down switch to the terminals on the relay(s) where the limit switch connects. If I recall, the wires are color coded from the up/down switch, into the limit switch, and out of the limit switch to the relay connections. I believe they are red and black. Couldn't be easier. If in doubt, get a multi-meter and learn how to do a continuity (ohms) test to trace the circuits while the winch is in the middle of it's functioning travel (not stopped).

When the limit switches are "closed" the switch is just like a straight piece of wire. When they open, they essentially cut the wire in half...disconnecting it. Very simple. A straight jumper wire between the up/down switch and the relay bypasses the limit switch.
Of course, without the limit switches, you must be observant to stop the winch when you have the roof fully raised. There should be a red cable on the driver's side front corner between the roof and the tub to tell you when to stop. When lowering, stop when the roof is solidly able to contact the tub when clamped.

The limit switch is an idiot proof device, but common sense and basic attention are all that are needed to operate the roof without it.

If you test with jumper wires and it works, replace the jumper wires with a more permanent solution. You can use crimp connectors on the ends of plain wire to make permanent jumper cables. This is light duty wire, because it only operates the relays...the real switch...heavy wires are attached to the output side of the relays.

CAVEAT: if you have young kids who might mess with the up/down switch, that's the real purpose of the limit switch. You can buy a replacement limit switch, and it will instruct you on installation and adjustment, or you can cover the up/down switch.

I did not replace my limit swich. The plastic gear is DUMB, and that's just the start of it. I disassembled mine to look it over, and it's a nightmare of worm gears and plunger switches and tabs on the worm gears. Insanely complex, but it's not terribly expensive if you feel you need it.

3. As for the wind on the winch drum, look at the manual to ensure yours is right. I can't tell the POV from your photo, but the manual shows how the cable is wound on the drum.

Good luck.
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Old 07-07-2023, 04:53 PM   #6
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Thanks for the reply. I think I figured this one out, if the rain will stop long enough to verify I will know for sure. I have a model 55000 winch. I believe I can run the winch to take the slack out of the line and remove the locking bolt in the switch plate and spin the switch plate down to the stop position on the lower (right) side and reattach the bolt and it should allow me to run my top all the way up. See pic below...

Before, when I ran the winch to take the slack out of the cable the switch plate was about 1/4 of the way towards the top limit switch, and when I raised the roof it hit the top limit switch before the roof was all the way up. Hope this makes sense... Thanks for the advice.
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Old 07-08-2023, 09:41 AM   #7
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I repaired it. I started the cable on the spool and ran the winch until the slack was out of the cable. From the top I removed the locking bolt and spun the switch plate until it reached the lower limit switch. I then reinstalled the locking bolt and ran the unit. I had to remove the upper limit switch bolt from the switch plate in order to spin the switch plate until it made contact with the lower limit switch so I reinstalled the upper limit switch bolt then readjusted it. Happy to have this thing working. I did notice that the wire has some rough spots, I'm going to add replacing the wire to my future to-do list after the season. Thanks for the help.
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