Outer Limits 4x4 Board

I've got a Brawn 9500lb lowmount winch which has been used hard for many years until last weekend when she died.

What happened was huge current draw whilst winching up muddy hill (single line pull). Then stopped. When i tried to wind in or out it would draw large current but no go. +ve wire from battery to Albright solenoid was very hot. Braces both busted, not sure if under load or cable bunching up to one side.

It was first suspected that gearbox was seized and causing massive draw on motor, but gearbox appears to be fine.

Anyhow i've pulled it apart today and when i connected motor only the wire heated up like mad.

I can turn the motor by hand. I've tightened up all the studs.

I haven't pulled it apart mainly because i didn't have an allen key to undo the 4 plugs/screws/wotever.

It's got 4 big plug thingy's that take an allen key, 4 small screws and 2 long bolts in the end.

How do i pull it apart further and what should i be looking for? Is their some fault finding thing i should do to eliminate possibilities? Is their an auto elec. or winch guru on this forum i could take it to in Melb?

BTW, all grease is good, no signs of water or corrosion. About 8yrs old and never been pulled apart. Spent many times in water and mud both operating and not.

Thanks for your help

also under gen4x4 section
http://www.outerlimits4x4.com/viewtopic ... 29#1120429

the armature inside is probably toasted and is shorting to ground which is what is causing your excessive current draw
take the back cover off and check it out might be burnt or stinkin like its burnt

my boss's brawn done the same thing and it was 2 weeks old. change solinoids put warn 1's in it

adam penfold wrote:my boss's brawn done the same thing and it was 2 weeks old. change solinoids put warn 1's in it

I don't think it's a solenoid problem. It doesn't 'click,click,no worky'. the wires get hot as toast and the battery terminal glows red as soon as you connect it up.

BTW, has an Albright solenoid pack.

GQ Bear wrote: the wires get hot as toast and the battery terminal glows red as soon as you connect it up.

I'm guessing that you have what we in the trade call a "short circuit", probably in the field coil (NOT the rotor coil.) I reckon you need the services of a professional, preferably one with motor winding experience.

Good luck,

Scott

Check this one out, and do an on line search, there is a lot of good cheep stuff in the states, cheers.
http://cgi.ebay.com.au/Motor-for-9500lb ... dZViewItem

On the subject of winches mine also stop last Sunday whilst whinching my patrol up a hill and and now all I get is click click when I try to winch.

I presume this will be the solinoids???

All the wiring is correct and the motor was running fine until it cut out.

If so how do I determine which one or do I just replace both??

Thanks for any help that may come my way.

GQ Bear wrote:I've got a Brawn 9500lb lowmount winch which has been used hard for many years until last weekend when she died.

What happened was huge current draw whilst winching up muddy hill (single line pull). Then stopped. When i tried to wind in or out it would draw large current but no go. +ve wire from battery to Albright solenoid was very hot. Braces both busted, not sure if under load or cable bunching up to one side.

It was first suspected that gearbox was seized and causing massive draw on motor, but gearbox appears to be fine.

Anyhow i've pulled it apart today and when i connected motor only the wire heated up like mad.

I can turn the motor by hand. I've tightened up all the studs.

I haven't pulled it apart mainly because i didn't have an allen key to undo the 4 plugs/screws/wotever.

It's got 4 big plug thingy's that take an allen key, 4 small screws and 2 long bolts in the end.

How do i pull it apart further and what should i be looking for? Is their some fault finding thing i should do to eliminate possibilities? Is their an auto elec. or winch guru on this forum i could take it to in Melb?

BTW, all grease is good, no signs of water or corrosion. About 8yrs old and never been pulled apart. Spent many times in water and mud both operating and not.

Thanks for your help

also under gen4x4 section
http://www.outerlimits4x4.com/viewtopic ... 29#1120429

Bear I also have a Brawn 9500lb alas mine has not given any problems and as Brawn is no longer trading, have a look in the yellow pages for motor rewinders. They will be able to tell you what is wrong and also rewind it to a 6hp specs a bit more grunt.

Fox Shooter wrote:

GQ Bear wrote:I've got a Brawn 9500lb lowmount winch which has been used hard for many years until last weekend when she died.

What happened was huge current draw whilst winching up muddy hill (single line pull). Then stopped. When i tried to wind in or out it would draw large current but no go. +ve wire from battery to Albright solenoid was very hot. Braces both busted, not sure if under load or cable bunching up to one side.

It was first suspected that gearbox was seized and causing massive draw on motor, but gearbox appears to be fine.

Anyhow i've pulled it apart today and when i connected motor only the wire heated up like mad.

I can turn the motor by hand. I've tightened up all the studs.

I haven't pulled it apart mainly because i didn't have an allen key to undo the 4 plugs/screws/wotever.

It's got 4 big plug thingy's that take an allen key, 4 small screws and 2 long bolts in the end.

How do i pull it apart further and what should i be looking for? Is their some fault finding thing i should do to eliminate possibilities? Is their an auto elec. or winch guru on this forum i could take it to in Melb?

BTW, all grease is good, no signs of water or corrosion. About 8yrs old and never been pulled apart. Spent many times in water and mud both operating and not.

Thanks for your help

also under gen4x4 section
http://www.outerlimits4x4.com/viewtopic ... 29#1120429

Bear I also have a Brawn 9500lb alas mine has not given any problems and as Brawn is no longer trading, have a look in the yellow pages for motor rewinders. They will be able to tell you what is wrong and also rewind it to a 6hp specs a bit more grunt.

I found a bloke who sells 6.6hp motors for $165 delivered. I let a sparkie at work have a look at it and it was cactus. Armature burnt right through and feilds phucked too. Even one of the metal brushes had disintegrated.

Thanks for your help.

New motor delivered today for $165 and $20 for the cast mounting plate thingy which the gearbox mounts to. Less than one week turnaround. Will put it all back together this weekend sometime inbetween building a pergola.

here's the ebay seller's link;

http://www.thiswotidonow.com/ebay/accessories.htm