Winch warning - close call, near fire.

[me3@neuralfibre.com]

Short Version: If you have the older (common) 2 solenoid type winch control - I reckon you are at pretty high risk of a fire.
The field windings in that design are energised at all times, just waiting for an earth - any earth. It could be an accident that cuts a wire. In my case it was a stud in the motor that pushed through a piece of paper that was supposed to keep it insulated.
After this - I'd be making real sure you run a newer type "all in one" solenoid. These do NOT deliver any power to the winch except when energized.

Longer version:
I stripped and cleaned my Ironman winch today after finding it wasn't working after driving through the floods.
(Waterproof I found means it holds flood water inside for months)
The motor was ok. Gearbox grease disgusting. Control box a write off.

When I refitted the winch it shorted when the wires were connected and got real hot fast. I checked with a meter and the field windings where shorting to the winch body somehow. When I opened the motor I found the earth stud was too long and had rubbed through a thin piece of mica "paper" and touched the field winding. Although a minor design fault, the older control system used on most brand winches could have made this catastrophic. I was very lucky it was the movement of removing it that did the final "rub through". If it was a corrugated road - the first I would have known, could have been 2 x 120AH AGM batteries dumping into 1ga cable as it all caught fire.

I'm rewiring mine - with an all in one solenoid. That solenoid will be behind the firewall, so in an accident, there is no energized high current cables between the bullbar and radiator panels.

Catchya
Paul

[McLarryBob]

That's an interesting one. Thanks for that!

[80's_delirious]

good tip Paul, I think I will look at putting a heavy duty cutout switch on the positive +12ve cable to my winch so the power can be isolated until needed.

[oldmate]

good tip Paul, I think I will look at putting a heavy duty cutout switch on the positive +12ve cable to my winch so the power can be isolated until needed.

The iron man winch i bought a few years ago came with one. I thought all winches did.