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Old July 14th, 2008, 09:45 AM   #1
CheapThrillB2
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Default winch tech questions

I bought a champion 8K winch a few years back (yeah should have bought a warn)

It no longer works...can't tell if its a motor problem or a solenoid problem.

It has 4 solenoids under the cover
on the motor their is

A. 1 lead that is the ground to negative (bolts to the case of the motor
B. 1 lead comes off the solenoids and attachs through the motor case and to the brushes
C. 1 lead attaches to the magnets in the motor through the motor case
D. 1 lead attaches to the windings around the magnets Through the motor case
E. and of cousre the positive connects to the solenoids.

When i engage the winch in either direction leads B,C, & D are powered at the same time

Shouldn't C and D switch power like a window motor depending on winch direction in/out

It also seems that i have a small amount of contiunity between leads B, C, and D to the motor case. Each lead is on a insulated type bushing through the motor case. I've tried several different thigns to elminate the contunity to the case from the bushings and when i do it still does not work the winch).

Also seemed wierd that when i pulled the motor apart, theirs 4 brushes at the end of it. But only 2 are actually hooked up, the other two are just their but not connected in any way to the elec par of the winch.

I can't afford a new winch right now, but if somebody can help me in a direction to repair my current one for awhile that would be great.




I'll get it out of the way early
yes should have bought a warn
Yes i'm a cheap ass
yes i know i bought a cheap winch
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Old July 14th, 2008, 10:38 AM   #2
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check your wiring first, if everything is good then check the solenoids individually, if those are good then it is probably your motor.

I had a problem with my winch, I thought the solenoids took a crap.... redid all of those and then assumed motor burned up.... checked the motor and it finally turned out that my in cab control was the problem... the wires leading to it were resting on the exhaust and melted through, they were both engaging when I would try to power one way or the other.

so basically double check the wiring to see that nothing is wrong and then go from there.
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Old July 14th, 2008, 10:47 AM   #3
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fwiw i did check the controller and that is only powering one side in/out

my initial thougths were that the motor was bleeding power throught the insulated contacts and in a way shorting itself out.
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Old July 15th, 2008, 09:00 PM   #4
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theirs four brushes, two are connected to the soleniods and the other two are just riveted to the housing. I am assumeing that the brushes connected to the solenoids are powered with winch operation and the other two brushes are ground through the housing. I found that when trying to use the winch, the two "Grounded" brushes get very hot and you could see where the rivets where melting through the plastic isolator thing. I drilled the rivets from these brushes and found a bit of corrision under the little isolators and replaced the rivets. Haven't tried the winch since, still need to reassemble.
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Old July 18th, 2008, 07:25 AM   #5
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i think i got it working again

found alot of corrision under the two "Dead" brushes, so i drilled the rivets and cleaned and reriveted.

Also took the clutch,planetary set apart and found that their was a set of gears that were extremeley difficult to spin. So i cleaned that all up and the winch seems to work fine now. Have to spool the cable back up on it and see what happens i guess.
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Old July 18th, 2008, 05:44 PM   #6
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Quote:
Originally Posted by CheapThrillB2 View Post
i think i got it working again

found alot of corrision under the two "Dead" brushes, so i drilled the rivets and cleaned and reriveted.

Also took the clutch,planetary set apart and found that their was a set of gears that were extremeley difficult to spin. So i cleaned that all up and the winch seems to work fine now. Have to spool the cable back up on it and see what happens i guess.
Who needs a warn I bought the same winch
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