The Dutch stole all 5-speed diesels! (nsfw?) HJ60 and BJ40

[hj 60]

A lot of stuff suddenly going on




Grease, no tooth missing, gears turn fine and no play:

 

[hj 60]

 

[hj 60]

Next is the check of the winch motor tomorrow, before I short the thing out I want to know what the wires do, so reading the manual and stuff.

 

[hj 60]

Getting to the point where I think buying a second hand winch is like buying a second hand birfield

But cleaned and removed as much bad stuff as possible, the grease smells terrible, but first it needs to be working and on the car.

 

[hj 60]

The point were I could test the motor, it rolls fine and free

 

[hj 60]

And after so much info made this testinone picture thing, the motor tested fine and with 24Volt and two batteries on chargers the winch is working both ways, solenoids are fine

So time to fix it to the bumper and fix the incab switch and something outside,
24 volt winch control 3 wire | eBay

Maybe the cheap (wireless) remote is dangerous because I dont want to loose my fingers, this is a mighty piece of equipment.

The albright contractor extra duty 24Volt replaces the 4 crappy solenoid so a must have:
DC88-556PL24V

Albright Contactor - Extra Duty 24V

Asked the if she fancy's a trip to England: South Molton, Devon to pick one up 450 km from Folkestone ferryport, or Caen to Portsmouth

So I tested it again for a minute free spooling in and then 1 minute out, no problem, really fast.

Lubed the two small rollers, they shine like a tit!

 

[hj 60]

Better pictures and tomorrow Winch buildin day, and when it is finally fixed test it and remove to clean and re grease properly.

Used this piece of iron to hammer them out:

 

[hj 60]

 

[hj 60]

 

[hj 60]

Finally the type! WARN M12000 46980 KM1

 

[hj 60]

With a new motor this is how it starts forward and reverse:

two white cables come from the motor and are overheat protection @204 Celsius cut out.

right green to the white on the left of green and it spools out
that white with the white left of that white to it spools in.

So it works on the work bench, now time to test in under load, I will drill the rivets to open up the solenoid to clean them, and no problem to replace with albright.

But I gave them a little pepper in ass by shorting them with ground, just to burn them clean again...

See if this works or burns

 

[hj 60]

Let the game continue

 

[hj 60]

The bracket we made for the winch support:

 

[hj 60]

 

[hj 60]

 

[hj 60]

Opened the motor this weekend and very lucky with no rust, new interior so very happy again with the non existing problems that could have ruined this buy, the bolt was replaced and looks bad but no problem:

 

[hj 60]

The overheating clixon 24v stop switch that seems to be recalled by Warn USA.
And the carbon brushes, parts in Europe still hard to find (gasket, a few nuts/bolts, carbon brush, clixon)

thermal switch WAR78354 on type WARN 9.5 and 16.5 TI (if that thermal switch fails only winch out and not in: bypass it)
Warn_Thermometric Cut Out Switch WAR78354 thermal
In my motor I found a thermostat clixon # 63TM0110045 (no google...)

length 22x 9 high x18 wide mm is the brush size,

This is the replacement cut out switch:

 

[hj 60]

Opened WARN solenoid, the little iron should be attached, when shorted this piece just burns away,
Dangerous if they stick in closed position (winch unstoppable spooling in)
Spooling in errors: have read this so many times (Dutch, German, Spanish, English and USA forums) it is a huge danger factor with batteries and engines melting away.

Rivets have to be drilled out enough or plastic wil break:

 

[hj 60]

The sticky part, dangerous so ordered albright solenoid to replace this:

 

[hj 60]

The corn is gone and another year has past.