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Thread: WINCHES: Rebuilding, Parts Information, Diagrams, Testing Sites

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    Default WINCHES: Rebuilding, Parts Information, Diagrams, Testing Sites




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    Default Schematic 4 solenoid Warn Winches Testing Sites



    Re: Winches:Rebuilds/Schematics/Warn 5000-9500
    Here is a schematic for all 4 solenoid Warn winches:
    Attached Images
         

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    Default 8274 Wiring Schematic



    Here is a wiring diagram for an 8274 Winch
         

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    Default Testing winch solenoids and motors



    Here is a BillaVista article from Dirt Sports that tells how:

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    Default Warn 5000-9500 rebuild article







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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra




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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra




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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Thanks to Sean (1freaky1) for this information:

    Winches use two types of DC motors, Permanent Magnet Motors and Series Wound Motors. All electric DC winch motors consist of one set of coils, called an armature, inside another set of coils or a set of permanent magnets, called the stator. It is the job of the stator to produce a magnetic field which will cause the rotor (or armature) to rotate when an electric current flows through it. Applying a voltage to the coils produces a torque in the armature, resulting in motion. With all types of motors, the higher the horsepower rating, the more toque and power the motor will have. The winch rating is a combination of motor torque and gear train gear ratio reduction. Motor horsepower has a direct effect on both line speed & pulling power.
    Permanent Magnet Motors - In a permanent magnet motor, the stator uses permanent magnets and there are no field coils. With permanent magnet motors, the drain on your battery tends to be less than series wound motors, which uses field coils in the stator rather than magnets. Permanent magnet motors are better suited for light to medium duty winching because they tend to generate more heat and overheat. Winching time & load should be carefully monitored as they have the tendency to overheat. The magnets in permanent magnet motors can loose their field strength over time and repeated use.
    Series Wound Motors - With a series wound motor, the field coils are connected in series with the armature coil. Series wound motors are powerful and efficient at high speed and generate the most torque for a given current. A series wound motor will uses more current over a permanent magnet motor because they use field coils to generate a magnetic field.Series wound winches are heavier duty winches, and tend to be more expensive.
    A permanent magnetic motor will pull the same as a series wound motor, at at less of an amperage draw on the battery and charging system. However, as the permanent magnet motor gets warmer, the power will drop as the amperage draw will increase. The amperage draw on a series wound motor will stay the same throughout the duty cycle.
    Winch Ratings - Most winch ratings are generally limited by the maximum amperage draw, with right around 400 being the cut-off point. Anymore than that would most likely damage the power source or charging system. In order to reduce the amperage usually the gear ratio will need to be increased numerically, to relive the motor from the increasing stress, however, this will also reduce the line speed at the same time.
    Info above taken from this link; http://www.offroaders.com/tech/winch...Components.htm

    Now a link to the fuse setups that will work with the winch motors. They are not cheap but cheaper than a new winch motor costs.

    http://www.google.com/products?q=DC+400+amp+fuses&hl=en

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Here is the M8000 rebuild article:

    http://www.fourwheeler.com/techartic...own/index.html

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Here are a bunch of articles dealing with the rebuilding of many of the popular winches on the market today. Some of the articles cover the same winch rebuild, but the reason that I included these was that there was usually a lot of other information and links on that site. Many of these articles contain links to specific parts sources for winch parts and which suppliers are good or bad.

    Due to the number of used winches that appear on craigslist and other places for sale, these articles will show you exactly what you are getting into buying a used winch and possibly doing a rebuild on it.

    Warn XD 9000i:

    http://www.jonfund.com/technical/winchteardown.shtml

    Warn XD 9000i Number 2:

    http://www.wanderingtrail.com/Repair...warnwinch.html

    Warn M8000:

    http://www.parksoffroad.com/tacomamo...000rebuild.htm

    Warn 8274:

    http://www.pirate4x4.com/tech/billavista/8274/

    Warn M5000:

    http://www.members.shaw.ca/macks4runner/winch.htm

    Tabor 9000 (Warn's cheaper, non roller bearing winch):

    http://www.cdmfabrication.com/bbb/vi....php?f=11&t=61

    Ramsey 200R:

    http://www.cj-3a.com/rebuilding_the_...200r_winch.htm

    Mile Marker H12:

    http://forums.lr4x4.com/index.php?showtopic=25692

    Koenig (yes, they are still around!):

    http://home.off-road.com/~brentjbeissler/winch.html

    Winch information(amperage draws, etc. from 1freaky1):

    www.gregsmithequipment.com/images/ebay/whichwinch.pdf

    I realize that some of these are duplications and are posted in my other winch threads, but these articles, for the most part, deal exclusively with rebuilding winches.

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Here is a winch troubleshooting guide link:

    http://www.4x4grace.com/vBulletin/sh...d.php?p=140307

    And more information regarding winches:

    http://www.off-road.com/offroad/arti....jsp?id=285616

    And another good rebuild article:

    http://macquarie4x4.com.au/cmsimages...hMaintTech.pdf

    Testing solenoids. A BillaVista article:

    http://www.pirate4x4.com/tech/billav...&A1_signed.pdf

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra




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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Here is the link for Ramsey Winch Manuals for downloads:

    http://www.ramsey.com/automotive/manuals.html



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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Here is the wiring diagram for a Superwinch Husky Winch:
         

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Warn winch wiring diagram-inside the solenoid box:
         

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    SuperWinch wiring outside to remote plug:
         

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    Default Re: WINCHES: Rebuilding, Parts Information, Diagra



    Just about everything you want to know about rating, comparing and buying winches can be found on this site along with some helpful recovery and other winch how to information:

    http://4wheeldrive.about.com/od/winc..._4Wheeling.htm

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    Default



    Dual Motor Warn 8274:








    Thanks Roland!

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