winch diag help

[CheapThrillB2]

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

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

[Rover]

first off make sure you have a good ground, then make sure you have 12v going to it

im assumming you can hear/feel the relays clicking since you said you get voltage to the winch terminals

[CheapThrillB2]

good voltage and yes the solenoids are clicking

[Rover]

could you take a pic of the brushes, windings and everything for us?

[CheapThrillB2]

i planned to bring to work tomorrow and take it back apart

[Shaker]

If you haven't used it much, it is probably corrosion causing a bad connection somewhere.

If you have used it a lot, the brush pack is probably getting wore out. If you still have it together tap on the motor with a wrench or small hammer while engaging the winch. If the brush pack is wore down it may engage by tapping it just like a starter.

[CheapThrillB2]

tried above, i have had it completely apart and the brushes seem fine and not to wore out. Their was some corrision i cleaned up. But the winch did get submerged in water abit, then two weeks later i tried to use it and thats the first time it didn't work.

[CheapThrillB2]

http://i31.photobucket.com/albums/c353/cheapthrillb2/Misc/winch003.jpg

http://i31.photobucket.com/albums/c353/cheapthrillb2/Misc/winch002.jpg

http://i31.photobucket.com/albums/c353/cheapthrillb2/Misc/winch001.jpg

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.

[Yota Bill]

http://www.mcmanis.com/chuck/robotics/tutorial/h-bridge/index.html

heres a decent explanation of how the H-bridge works (switching device, reason for having 4 solenoids)

and you should read some resistance (high number = high resistance to current flow) through the windings, brushes, etc...if it read 0 ohms, that would be a dead short to ground, and infinte ohms would be an open circuit...a complete circuit will read some resistance to ground because there IS a path to ground...

[CheapThrillB2]

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.