Warn ProVantage 3500 reported failure

With the recent Episodes covering contactor, motor & transmission testing, stripdown & inspection, yes, you guessed it, a viewer sent in their winch for me to take a look. The customer advised that it just didn't work. They had tried fitting a new contactor (solenoid) block but it made no difference, the winch just refused to spool in or out...
So, more winch stuff...
Enjoy
Andy
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Thanks for all your support, until next time...
Andy

[@kenmuggli4613]

Thanks Andy, good information and entertainment.

[@snickersman81]

Love the disassembly, nice looking design of that switch.
Just a little tip regarding soldering: When you turn off the soldering iron, put some solder prior to that on it, helps preserve the tip. Always clean the tip before adding solder, removes burnt stuff from it and helps solder adhere to the tip better and transfer heat better. When you heat joints, add some solder, the flux in the solder will make it flow better and prevent snotty looking solder following the solder tip :D
As for the fault it sounds like the coil wire insulation has broken down and when it heats up it shorts, making the magnetic field weaker and therefore not switching. You should be able to see that in the current to the green wire :)

[@georgebonney90]

I like the winch videos, thank u sir👍

[@simonrawle7885]

so true andy . the mrs come in from work a few weeks back and said why is there a set of coils on the radiator

[@AndyMechanic]

Lol!

[@m9ovich785]

Technically it is Crossover Relay. The Solenoid(s) are just a part of the Moving mechanism inside.
Just a Note Die-Electric Grease is NON-CONDUCTIVE Thus the Letters Die. only use the stuff after electrical connections have been made, then coat the completed connection. It is pitiful how miss-used that stuff is.
Those contacts points need to be clean & dry..
After a Year is that relay still working ??
Mike M

[@nigelfewster]

Hello, why didn’t you just apply 12v to the solenoid whilst you had it out and leave it for 5 mins so it held the contacts and heated up then the fault may have shown itself again? The design looks better than the other one you did even though it failed intermittently. Enjoy the autopsy videos keep them coming.