Outer Limits 4x4 Board

Hi

I've never used the winch that was included when I bought my FJ40, and today I tested it and it would just make a clicking noise.
Its a Ramsey REP8000 with hand controller

There's voltage coming in on the controller unit (solenoids) but nothing on the winch itself.

What could be causing this issue?



Cheers

i guess you've checked for loose connections?

Check to ensure you are getting enough voltage to the relays. Had similar issue and found out it was a dud battery producing a low 12 volts

the big cables coming from the control box is wired straight on the battery +ive and -ve

the cables are all tight

can anyone confirm the wiring on the control box if its right?

the control box is a Thomas unit.

I would say you have a dodgy solonoid. Upgrade to a allbright single sealed solonoid.

Cris

all four solenoids are clicking this is by sound and touching each one of them while I press the in/out on the controller

are you sure all wiring is correct as those solinoids normaly have + & -
it apears that they are all missing 1 wire ..
those connections are either side of the feild for the solonoid to switch it
one should be POSATIVE and the other NEGATIVE

i would sudjest disconnect your main power cables from batt then test the solonoids 1 at a time applying pos and neg to each and then check across each one with a multy meter to show its switching the controled circut

the top ones have only one bolt sticking out on the body
the bottom ones have two

from the picture above the two inner big cables (red and blue taped) are the ones that goes to the winch and they dont have power even when the solenoids are clicking

anyone's got a diagram how it should be wired?

if not those single solenoid ones are good?

Have you checked if there is voltage at the motor terminals to eliminate a ceased motor?

Use some jumper leads to bypass the solenoids altogether to check if the winch motor is alive.

If it works then the issue is with the solenoids.

If it doesn't work then the issue is most likely not with the solenoids, but is more likely the motor.

Winch motor - check the carbon brushes and springs for them, check for free movement of the motor spindle (unspooling the winch cable and looking in the vent holes for movement of the spindle), sandpaper the armature winding (contact area with the carbon brushes)

Solenoids - if you can dismantle them do so and clean the contacts. They may physically be clicking, but not making good enough contact for the current they are meant to be passing.

I've tested the motor and the winch works.
It looks like theres too much hassle to open the solenoids up and take it apart as they are riveted? Need to drill it to open them up. Then have to worry about sealing them up again.

are the generic ones in fleabay should be OK or can anyone recommend a brand and where to get it?