Outer Limits 4x4 Board

hi all last week 4 wheel driving my winch smoked up nearly burnt my car to the ground 5 hours up the bush, not shure whats wrong yet have to pull it apart later this week to check solonoids and motor. question i have is if solonoids ar stuffed should i replace with ebay solonoid for 225 dollars or get originals anyone have a better idea? and the motor if its burnt out what should i replace it whith 6 hp warn or 7.8 other name. can winch handel 7.8 hp it was fully re built 5 mohnts ago with fill and drain plugs its 20 years old warn hi mount thanks a lot.

G'day mate. The 7.8hp superduty winch motor is the one that we are distributing in Australia now. Your high mount can most certainly handle the power.

These motors are designed as a direct bolt on and even come with spacers to get the correct armature --> brushes alignment correct for 100% efficiency.

There is a little more info on these motors here at our website:

http://www.4h.com.au/webcontent6.htm - you can buy directly off here as well.

The motors haven't had one armature failure in NZ winch challenge comps in 3.5yrs. Thats a big call but the motors have been specifically designed to handle a longer duty cycle and more extreme conditions than the warn 6hp.

If you have any questions we would be more than happy to help you out with fixing your winch. Give us a call on (03) 5975 5533.

Cheers
Dan

It is a very simple decision to make. If you are running 12v then the 6hp Warn motor is a stronger more reliable motor. If you are running 24v then the Superduty is a stronger more reliable motor.
Alot of guys ran the 12v 7.8hp Superduty motor when they were first released n NZ in 2005 and then were OK but the 6hp performed better. The 24V Superduty is a different story and they are still being used and the only faster option is the 6hp with 24v powering it but that isn't as reliable. I have the orignal 7.8hp that I got from the first shipment into NZ (in 2005) and it is still running on my winch. I have replaced the brushes and some insulation but otherwise it has never missed a beat. I now run 2 of these with a Flammin Fabs adapter. I also have 6hp Warn motors (well one at present) and they are qute a bit faster with 24v but don't handle the heavy winching we do in NZ. Great for dry weather but not for the wet.

So yes a high mount can handle 2 of these as I have been running Waza's adapter and twin 7.8's for over a year now.

would these be affected by voltage drop .. I imagine a 6hp motor pulling to it's potential would eat up quite a bit of power very very quickly.
If you didnt have mega cable to the winch, massive batteries and big chargeing system ... would you actually be better off with a smaller less hungry motor ?

6hp with 24v takes a huge amount of power!
To run my winch setup I have a 70amp 24v alternator and twin 25 plate 925cca batteries. I also have the batteries right next to the winch behind the cab and 95mm cable for everything.

A 6hp draws 480amps at full load according to the Warn specs. This puts the 7.8 (12v) at well over 600amps at peak load.

Voltage drop only happens if you have a poorly setup winch. The places it normally happens is at cable connections. All of mine are crimped, soldered and sealed to keep then clean and stop any deteriation due to soldering. A straight crimp can fill up up with water and mud and start to corode causing problems.
The other place for voltage drop is at any terminals. You will have huge cable but how much suface area is actuaclly available where the cable is connected to the winch and solenoids? All of my conects have have the surfaced filed flat and then they are also coated with copper coat to ensure a large conatct area is maintained. I also remove all split washers etc as they have a the potential to cause problems as well. And all conections are undone, cleaned, checked and reconnected after every comp! The one time this wasn't done I fried a motor due to a loose conection causing power drop. This on turn fried the motor which direct shorted and set fire to the cutout swicth I have in the cab! Not a lot of fun!

if you are to run these motors take note of the max amps under full load. things can get ugly/expensive when these stick on due to solonoids that aren't rated as high. just a thought.

I've been running standard Premier / Come Up solenoids for the past 4 years with both the 7.8 and 6hp with no solenoid problems at all. I have one set per motor and apart from one that just stopped working 3 years ago I've had not failures etc. The current ones are 3 years old!

And run kill switches, you just need to make sure they are rated high enough but you can buy marine switchs with the right rated for $120.
ie 600amp continous, 900amp for 5 minutes or 2750amp for 10 seconds.

hi just pulled motor off all burnt!!! asked bursons for price off ironman winch solonoid 270 dollars but the complet winch only costs 650 dollars go figure. so what motor shoud i get? thanks

I would visit Hobzees online ebay shop and get yourself a 6hp (tapped with breather) and a sealed solenoid pack and you wont have to muck around with it again.

Do you know why it burnt out??? were you winching for ten minutes without a break???, overloding it???? or was it just old????

weve all been there when you know you should stop and give the winch a rest but you keep your finger on the button just a bit longer and longer and longer then doh!!!!
So you need to work out why it happend or it will happen again.

the bigger hp motor will require a better electrical system.

I previously had (a now ancient) 2.5 hp motor on my highmount. Had 1 good battery and never had a drama.

After upgrading to a 6HP motor I started having flat battery problems and had to add another battery to the system to keep up with demands.

Go to our website www.4h.com.au.

We have both the 6hp motor and sealed solenoid packs in our online store under Winch Accessories category. These motors do deserve solid, clean and tight connections and good current from a decent battery.

You are asking yourself for trouble if you are running anything under a 550cca battery with one of these motors. We would recomend upwards of 650cca for any winching operation plus a decent alternator to recharge as well.

Cheers

Dan

Do you know why it burnt out??? were you winching for ten minutes without a break???, overloding it???? or was it just old????


So you need to work out why it happend or it will happen again.[/quote] was winching the day before a 75 tray back fully loaded up a steep slimy hill used all 46m of cable all in one go no snatch block only stoped for a few min in betwene motor was still thoucablle at end. did lots of river crosings after that. then had to winch a tree out of river we used 2 snatch blocks winched on/off 15min then it smoked up and stoped. was a old 2.5hp so may be over used it.

just got a old 2.5hp motor will fit for now and get 6hp warn if i got more money. thanks