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Troubleshooting

We aim to make any product as plug and play as possible, though sometimes challenges crop up right out of the box or years down the road. See below for solutions to common operational challenges.

MOTION

Issue

Checkpoint

Motion is not smooth

Confirm cable is wrapped correctly on drum

Confirm cable rigged correctly through any mule and turnaround pulleys

Confirm deck track is clear of obstructions

Check PID tuning in Spikemark.

Motor is spinning, drum is not moving

Check your chain is properly engaged

Drum/Dog moves while brake is engaged

Check the drive chain tension and adjust

RIGGING

Issue

Checkpoint

Cable not aligned with drum grooves

Re-rig so the cable exiting the pulleys is aligned with the drum groove.

Check that your drum has not shifted and re-adjust if necessary. The spokes can be tightened down with 3/16” and 1/8” allen keys after re-adjustment.

Cable is rubbing on keeper

Re-rig so the cable is on the correct side of the keeper.

Drum noise

Confirm pulley/drum alignment

Excessive cable wear

Confirm pulley/drum alignment

Confirm there is no excessive rubbing or snagging inside the cable track.

Lubrication

Like any machine, the moving parts will stay moving longer if they are properly lubricated. The "narwall spike" (the ACME rod that moves the carriage) and the drive chain should both be visually inspected prior to load in.

Any excess dirt on the ACME rod should be wiped off and reapply a synthetic grease. We use Super Lube - you can find it at your local home improvement store or industrial supply house.

Wipe any excess dirt from the drive chain and lubricate the chain. The chain should be relubricated after 8 hours of use. Since we generally don't have a timer going, lubricate the drive chain before every load in and if you are running a very demanding show, after the tech rehearsal process is over.

Use any SAE20 oil, or any high grade cahin lubricant.

Adjusting Chain Tension

The Pushstick winch has a chain stage, connecting the motor to the drum. Chain can stretch over time. Too much slack in the chain can result movement of the drum (and the scenery) when the brake is engaged.

To adjust the chain tension:

  • Drive the motor carriage up so you can reach the chain

  • Unplug the motor cable from the Pushstick

  • Loosen the four (4) 1/2" hex bolts with Nylocks holding the motor mounting plate to the motor carriage

    • Do not remove the bolts, only loosen them

  • With the bolts lose, push the motor away from the drum - keeping it parallel with the motor carriage.

    • You do not need a massive amount of tension on the chain - just take the slack out of it

    • Too much tension in the chain can result in wear on the cahin and sprockets as well as introduce noise

  • Adjust jack bolts

    • Loosen the hex nuts locking the SHCS in place

    • Use a 9/32" allen key to adjust the jack bolts to prevent the motor from moving toward the drum

  • Tighten the four (4) motor mounting bolts

  • Tighten the jack bolt hex nuts

  • Reconnect the motor cable and test motion

TECHNICAL SUPPORT

If you get stuck, we’re here to help. The best way to get in touch with a tech expert is via email - even during normal business hours - because most days we are spread around the shop and may not be near the phone. There’s someone in the office from 8:30a-5pm EST Monday - Friday and will return an email or phone call quickly. After hours, (honestly when most tech support issues arise) we have a crack team monitoring email and voicemail who will respond quickly to help get you moving.

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