Behavior of Problem

Cause of Problem

Solution (Instructions or see reference)

Neither winch nor hoist will respond or is weak

Control pendant disconnected or defective

Disconnect and reconnect control pendant.

Check pendant plug to make sure all (5) pins are not bent, broken, or pushed back.

12V DC power disconnected

Check all power and ground terminal connec-tions

Check for and replace blown fuse (25A) 

Check wire harness connections at junction box

Dirty hydraulic fluid

Check filters, flush and refill hydraulic fluid

Remove valve, clean to ensure it is not plugged 

Hoist will not raise or lower

Lack of hydraulic fluid flow 

Check for leaks or clogged in-line filters

Check for blockage in the Bucher valve manifold

Fill the hydraulic tank with Grade 32 hydraulic fluid (such as ATF-Dextron II or Mobile DTE 13)

Broken or cut hydraulic line

Repair leaks or dry-rot cracks in hydraulic lines

Body prop rod is engaged or is in the “UP” position

Disengage body prop rod and return to the “DOWN” position

Foreign obstruction between top frame and bottom frame of the hoist.

Remove any tools, wires, hoses, or other for-eign object from the hoist system

Winch will not move in either direction

Battery(s) is disconnected

Check 25A fuse

Replace fuse if blown

Reconnect battery

Malfunctioning stop switch

(Winch will not winch in)

Check wiring to stop switch

Replace winch stop switch assembly

Winch motor is defective

Replace the winch motor

Winch spools out under load

Winch brake clutch slipping

Replace brake clutch in winch

Winch gears damaged

Contact your dealer

Hoist system is acting sporadically

Defective diodes in junction box 

Use a multimeter to determine which diode is defective

Replace defective diode(s)

Loose junction box connection

Check/ Tighten power and ground connectors at junction box

Neither winch nor hoist will respond or is weak

Control pendant disconnected or defective

Disconnect and reconnect control pendant

Check pendant plug to make sure all (5) pins are not bent, broken, or pushed back

12V DC power disconnected

Check all power and ground terminal connections

Check for and replace blown fuse (600A) 

Check wire harness connections at junction box

Weak vehicle batteries

Test vehicle batteries with voltmeter and replace if needed

Ensure vehicle battery requirements are satisfied

Hoist will not raise or lower

Bad ground wire connection

Check ground connections at vehicle battery, hoist junction box, winch, pump motor, and hoist frame to chassis

Defective coil

(black-box coil, qty 2)

Swap with other coil to determine which one may be defective

Replace defective coil

Weak/ no hoist operation

Pump motor not functioning

Replace Bucher pump motor or hydraulic pump assembly

Winch will not move in either direction

Vehicle battery(s) disconnected

Check 600A fuse

Replace fuse if blown

Reconnect vehicle battery

Defective Warn relay block

Replace Warn relay block

Malfunctioning stop switch

(Winch will not winch in)

Check wiring to stop switch

Replace winch stop switch assembly

Warn winch motor is defective

Replace Warn winch motor

Hoist system is acting sporadically

Defective diodes in junction box

Use a multimeter to determine which diode is defective

Replace defective diode(s)

Breather cap pops off hydraulic tank

Pump was dead headed

Load too heavy

Dirty fluid

Flush and replace fluid 3/4 full

Do not over fill

Replace breather cap

Hoist is moving slowly or is weak

Undersized PTO or Clutch Pump

Disconnect and reconnect control pendant.

Check pendant plug to make sure all (5) pins are not bent, broken, or pushed back.

No filter installed by the dealer

Clean fluid

Check valve assembly for blockage and clean

Install inline filter

Not cleaning the lines causes dirt or metal shavings to get into the system

Ensure new hydraulic lines are clean prior to installation

Check valve assembly for blockage and clean

Neither winch nor hoist will respond or is weak

Control pendant disconnected or defective

Disconnect and reconnect control pendant.

Check pendant plug to make sure all (5) pins are not bent, broken, or pushed back.

12V DC power disconnected

Check all power and ground terminal connections

Check for and replace blown fuse (25A) 

Check wire harness connections at junction box

Dirty hydraulic fluid 

Check filters, flush and refill hydraulic fluid

Remove valve, clean to ensure it is not plugged 

Hoist will not raise or lower

Lack of hydraulic fluid flow 

Check for leaks or clogged in-line filters

Check for blockage in the Bucher valve manifold

Fill the hydraulic tank with Grade 32 hydraulic fluid (such as ATF-Dextron II or Mobile DTE 13)

Broken or cut hydraulic line

Repair leaks or dry-rot cracks in hydraulic lines

Winch will not move in either direction

Battery(s) is disconnected

Check 25A fuse

Replace fuse if blown

Reconnect battery

Malfunctioning stop switch

(Winch will not winch in)

Check wiring to stop switch

Replace winch stop switch assembly

Hoist system is acting sporadically

Defective diodes in junction box 

Use a multimeter to determine which diode is defective

Replace defective diode(s)

Loose junction box connection

Check/ Tighten power and ground connectors at junction box