I replaced the rocker switch to no avail, when it quit working it went out just alittle then quit and back in then quit so... the way i figure that the contacts must be dirty. I have never taken a winch apart befor so any advise would be great!

Thanks


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Brad

99'FOREMANes, 26" BUGS, A.P. bash plate and stick guards, winch, and soon to have a high performance kit! ohhYA...

 

Brad,
Its not a big deal at all... I don't even disconnect the wiring from the switch or battery.
Just unbolt the winch and get enough slack to set it on your front rack (plywood) Take the two screws out of the rear of the electric motor. After removing those, pull the case of the electric motor, along with the rear plate (wires coming from switch are attached to the rear plate) and the electric motor shaft away... Then take thoes coupled pieces apart. (you will FEEL the magnetic field holding the shaft inside the motor case) There are one or two small brass washers on the rear of the shaft where it engages the rear plate. Dont lose them..
Clean your brushes up with emory cloth (crocus cloth, sandpaper) LIGHTLY.. just enought to make them shine. Everything that looks nasty that I can't clean with sandpaper( I like to use my dremel tool), I spray with contact cleaner. On the main motor shaft where the brushes ride against it.. that area should be cleaned and "de-glazed"
Basically, just clean everything up and put it all back together..
I noticed it was easier for me to get the brushes and springs back in place on the shaft easieer by assembling the shaft to the rear plate (and getting the brushes all in place.. DONT forget those brass washers!!!) Then HOLD it together and slide the main motor case over the shaft and down to the rear plate.. I stress HOLD the shaft against the rear plate because the magnetic field will want to pick the shaft up faster that you can get it down in place.
If you decide you want to re-pack the gearcase while you have it off, I can help you with that too.. just let me know...
My Superwinch 1500 acted like that when it got nasty inside too... but cleaning it out fixed it every time.
Good Luck...

 

Thanks MUD
I think I will wait on the repacking of the gear grease until next time... is there anything I can do while I have it apart to help prevent it from happening again? like silicone up any areas where stuff might get in? will this even help. i know there not designed to be water tight but.....

thanks again



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Brad

99'FOREMANes, 26" BUGS, A.P. bash plate and stick guards, winch, and soon to have a high performance kit! ohhYA...

 

You could ooze some silicone in around all the seams and maybe slow the water down and hold out alot of the dirt... They don't have any actual gaskets or seals, but it couldn't hurt to try...
Does that 1500 do OK pulling your 450 out of the mud?.. I'm shopping right now for a winch, but I'm gonna use the "if some is good, more must be better" theory and buy a Rule 3300... When I get the $$$$ that is..
I just don't think the 1500 or 2000 would last long on a 650lb. machine (Magnum 500)

 

i have a superwinch 1500 on my mag 325, i had it on my timberwolf, and just swaped it over when i got rid of the twolf, it worked great on the wolf, i don't plan on using it to pull me out of mud pits on the mag cause it is so heavy, i more a less use it to pick up my plow, and pull out the 2x4 quads on the muddy trail rides.lol

 

It has yet to fail in pulling me out of the mud. The only thing I did not like about it when I got it was the 25' of cable that came on it, so I went to a local industrail supply store and bought a spool (200') of aircraft cable for $14. I put 50' on the winch then made another 50ft section that I have zipped tied on the back of my quad. A local saw shop mounted my hook and looped the ends on my spare cable. The only time it has failed to do what I wanted was when I was winching a 35' log out of a pond (14" dia) even then it pulled it out just not once it got on dry ground. (and boy was it water logged, I would hate to think what that weighed!) For the $120 bucks that I paid I have zero complaits. Just recently I bought a block and tackle and a tree strap just for the sake that I would rather have way more than enough than needed.


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Brad

99'FOREMANes, 26" BUGS, A.P. bash plate and stick guards, winch, and soon to have a high performance kit! ohhYA...

 

My buddy with a 450s with 27" Mud Bugs had a 1500lb winch like you. But after it couldn't pull his quad out of mud that was only frame deep he took it off.

 

I hate to say it.. I pulled it apart (mud: i did not have any copper washers in it anywhere ??????maybe thats my problem ) and still nothing... not even a little grirrr.. so I cleaned every thing inside, which by the way was pretty muddy, I slightly sanded the brushes till they were shiny, then I wiped every thing down reel clean, and polished the brass contact ring, then put it back together and .... nothing!!

So now I'm back to square one..

Just to make sure.. the way I hooked the wires up to the rocker switch is so that the battery + and - are in the middle and the winches +/- are on the sides, so that when one side of the switch is pressed the winch wire on that side lights up (with a tester) I tried several comboes this is the one that made since to me (but I am no electrician!)

any info/ help is GREATLY APPRICIATED

thanks


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Brad

99'FOREMANes, 26" BUGS, Maier full chasis skid plate, A.P. bash plate and stick guards, winch, and soon to have a high performance kit! ohhYA...

 

ForemanES, the rocker is a REVERSING switch, both supplying the winch with electrical power and controlling its motor's rotation direction. When the rocker is in the middle, the switch is off. When the switch is rocked to one side, terminal "a" is connected to the positive battery terminal; terminal "b" is connected to ground. Rock the switch the other way, and terminal "b" becomes the positive connection, and "a" supplies the ground to the winch. A light bulb connected between the terminals will burn, regardless of the direction the switch is rocked.

If this tutorial is of no help, I strongly suggest you telephone SuperWinch (860) 928-7787; ask to speak with Mr. Jolly, the technical service representative.

Good luck!

Tree Farmer

 

Foreman,
Ok, try this... take all the contacts lose from the switch. You should have a black coming from the negative battery terminal, a red coming from the positive battery terminal (thru the inline fuse) and a red and a black going to the winch.
Hold the red to the other red and touch the black to the other black.. The winch should go one direction. swap the wires,(go red to black and black to red) and the winch should go the other direction. If this doesn't happen, clean your contacts at the battery, bypass the fuse for this little test and try it again. If still nothing, run an OHM'S test on the wiring coming from the battery. Superwinch should be able to tell you the rated OHM'S on the winch...
If any of the above helps and the winch DOES work, either you have a bad switch, dirty contacts, switch wired wrong, or a bad fuse.
Oh, another thing.. if you have a multimeter, (you can buy one cheap at Radio Shack) Check the voltage coming into the switch, and the voltage when you try to operate the winch.. Then check it going out of the switch....
If all else fails.... Take a large ball pein hammer and.......lol