Winch Technical Support

Browse our library of technical information and downloadable documentation like manuals below for reference on servicing or replacing some common components as needed.

Electric brakes are installed between the motor and the gearbox. A.G.O. currently uses KEB brakes, but previously used Stearns brakes.

Stearns electric brakes:

Stearns electric brakes are painted white and look like this:

A.G.O. winches primarily used Stearns brakes until about 2020. Serial numbers starting with 20 or higher most likely use a KEB brake if an electric brake is present. Serial numbers starting with 19 or lower most likely use a Stearns brake if an electric brake is present.

Depending on age and how well maintained a winch is, Stearns brakes may be susceptible to seizing over time. In these cases, the winch will turn on but the motor will not be able to move the drum and will usually overload. Users can attempt to manually open the seized brake pads by turning the large black knob on the side of the brake. Users may need to remove winch panelling to access the brake release knob.

Most winches with 2HP or smaller motors (typically 56C or 145TC frame sizes) used 56700 series Stearns brakes. Most winches with 3HP or larger motors (typically 182TC frame sizes) used 87000 or 87100 series Stearns brakes.

Download the Stearns electric brake documents here:

If your winch uses a Stearns brake that is no longer functioning, we recommend replacing it with a new KEB brake when possible. When not possible, we have been able to repair some Stearns brakes in house with new brake pads or other new replacement parts (e.g. brake activation coils). Contact us to review what the best course of action is for fixing your brake.

KBRC-240D motor controllers have been used on A.G.O. winches with PMDC motors since almost as long as the company has existed. KBRC-240D’s look like this:

Depending on their exact configuration, they may have additional controls installed in the front cover. A.G.O. adds additional electrical components inside such as circuit breakers and, when applicable, relays for electric brakes and emergency stop buttons.

KBRC-240D motor controllers are only used on winches with maximum 2HP PMDC motors, and can only work with either 120VAC 1-ph or 220VAC 1-ph input power. PMDC motors take either 90VDC or 180VDC supply voltage from the KBRC-240D depending on motor specifications.

Download the KBRC-240D manual here: KBRC-240D manual

A.G.O. has been using Lenze Variable Frequency Drives (VFDs) on the majority of winches with induction motors since the early 2010’s.

Early electrical systems were built with just the VFD and some basic electrical safety components like circuit breakers, but current electrical systems include more components such as dynamic braking modules to better handle the demands of electric winch applications.

Early Lenze-based electrical systems used Lenze’s gray, NEMA 4X outdoor-rated SMVector drives, which look like this:

Later Lenze-based electrical systems used the blue NEMA 1 indoor-rated SMVector drives, which look like this and are housed inside electrical cabinets on A.G.O. winches:

The NEMA 4X and the NEMA 1 SMVector drives from Lenze both use the same operating manual, which can be referred for assistance in programming or re-programming a drive following a repair or upgrade.

Download the Lenze SMVector operating manual here: Lenze SMVector manual