I've got a Warn M12000 that was acting up. The solenoids would click loud in both directions and every once in a while the motor would engage. I took it in to have it looked at. I was told that the brushes were rusted up again even though they were new. So, an hour's labor and the motor was cleaned, lubed, reassembled and tested. I took it home and tested it on the bench by hooking up jumpers. It worked fine.
I put it in the rig hooked it up and I get the clicking again - grrrrr. So thinking that maybe the batteries aren't topped up. I start the engine and it started without a hesitation and then all of a sudden the winch started working again.
So I'm thinking, it was just a low battery state that wouldn't turn the winch motor but with the engine running, it made enough power to kick it over. I spool the cable out to re-wrap it and about 1/2 way in, (after stopping it to adjust the wrap) it starts clicking again and I cannot get it to engage the motor. This is with the engine still running.
So, I'm thinking a bad connection at that point. I had cleaned with a grinder all the cable ends and the ground contact on the bumper (which is welded to the frame). I had one connection left and that was to positive cable connection which goes to a common power post. So I pull out the battery selector switch and get to the common power post to remove the cable. It looks pretty good, but I decide to hook it up direct to the battery. Still nothing, so I throw the charger on it and it is a little weak. I let it charge to 100% and still nothing by clicks.
So I yard this puppy out AGAIN, remove the solenoid pack and hook up jumper cables to the ground and then touch the positive end to each of the positive connectors on the motor. This should bypass the solenoids and spin the motor in one direction or the other. Not a thing happens!
So, I disassemble the motor and it looks pretty good. I cleaned the stator off a little more with some 110 grit emery cloth, reassembled the motor and still NOTHING.
So I'm wondering if I am testing this wrong? There is a ground connector to connect the case to ground and then a big ground up top and two positive connectors. Am I missing something if I hook up the ground to one of the two ground posts and then touch the positive to one of the positive posts? Do I need to jumper the two grounds together? I can't believe from looking at this that there is something wrong with the motor itself.
Second, under the end cap of the motor, there is a paper insulator of some sort. I noticed that the 4 tabs that go down the side were not staying flush on the sides. These seems to be protecting the brushes for the wires from touching the case but it seems really flimsy for such a purpose. Are these little paper tabs required to keep the bare brush wire for contacting the case?
I put it in the rig hooked it up and I get the clicking again - grrrrr. So thinking that maybe the batteries aren't topped up. I start the engine and it started without a hesitation and then all of a sudden the winch started working again.
So I'm thinking, it was just a low battery state that wouldn't turn the winch motor but with the engine running, it made enough power to kick it over. I spool the cable out to re-wrap it and about 1/2 way in, (after stopping it to adjust the wrap) it starts clicking again and I cannot get it to engage the motor. This is with the engine still running.
So, I'm thinking a bad connection at that point. I had cleaned with a grinder all the cable ends and the ground contact on the bumper (which is welded to the frame). I had one connection left and that was to positive cable connection which goes to a common power post. So I pull out the battery selector switch and get to the common power post to remove the cable. It looks pretty good, but I decide to hook it up direct to the battery. Still nothing, so I throw the charger on it and it is a little weak. I let it charge to 100% and still nothing by clicks.
So I yard this puppy out AGAIN, remove the solenoid pack and hook up jumper cables to the ground and then touch the positive end to each of the positive connectors on the motor. This should bypass the solenoids and spin the motor in one direction or the other. Not a thing happens!
So, I disassemble the motor and it looks pretty good. I cleaned the stator off a little more with some 110 grit emery cloth, reassembled the motor and still NOTHING.
So I'm wondering if I am testing this wrong? There is a ground connector to connect the case to ground and then a big ground up top and two positive connectors. Am I missing something if I hook up the ground to one of the two ground posts and then touch the positive to one of the positive posts? Do I need to jumper the two grounds together? I can't believe from looking at this that there is something wrong with the motor itself.
Second, under the end cap of the motor, there is a paper insulator of some sort. I noticed that the 4 tabs that go down the side were not staying flush on the sides. These seems to be protecting the brushes for the wires from touching the case but it seems really flimsy for such a purpose. Are these little paper tabs required to keep the bare brush wire for contacting the case?
