Need a Winch Whisperer

[Eck]

I have a Warn 5687 or also known as a Belleview. It came with the Bronco and I am trying to figure out how to get this thing up and running. It did not come with any cable controls to the dash and so I would love some help figuring this out.

Here is a link to what the controls looked like: http://www.ih8mud.com/tech/oldwarn.php

This is a detailed link to the schematics and tech info:
http://www.ih8mud.com/tech/warn5687.php

I have done a lot of research to see what people have done to either modify or try to improve on some of the functions of this 40 year old beast. What I can best deduce is that I using continuous heavy duty solenoids attached to a power toggle switch on the dash would be the best way to turn the power on/off. I have also read that you can get heavy duty tractor cable with a T handle from a NAPA to run for the Brake. I am guessing you can also run the same cable and T handle for the Power In? Anyone have a better idea to run the power IN?

I also saw this write up on someone who wired up an air braking system to create an automatic brake: http://www.pirate4x4.com/forum/newbie-g ... brake.html

Another really good link to a rebuild of one: http://www.pirate4x4.com/forum/general- ... erid=57133

So this is the first winch I have ever had and I am electrically challenged. I would really like some help getting this back to functioning and the more I read on it, I actually really like that it is an "era correct" winch. Considering I am going to have to create my own controls, i would really love it if someone wanted to help out -- I pay well with beer and food!!

Thanks!

[RJLougee]

I have one of these winches as well. On mine, one of the control levers on the winch broke off, so I can't use the cable to control it.

I have mine set up on a removable frame and stick it in a receiver hitch at the front of my trailer. I just use a solenoid to control it pulling in and have nothing controlling the braking feature (except my hand, which works pulling stuff up on the trailer). Same for the in/out feature.

I believe I have the cables still. Shoot me a PM/call if you're interested.
Joe

[Eck]

PM sent. Anyone else have advice or want to help me semi-modernize this thing?

[Eck]

Re-visiting this. Would like to get my Warn Belleview hooked up but not entirely sure how. Would like to make this electric with remote.

Any suggestions or help appreciated.


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[landshark]

Re-visiting this. Would like to get my Warn Belleview hooked up but not entirely sure how. Would like to make this electric with remote.

Any suggestions or help appreciated.


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Are you wanting to hook it up so that you can plug in on the front of the Bronco or control it from inside? If so I have done this and happy to try and help. i also swapped out the old solenoid pack and used a more modern set and mounted it remotely under the battery. Let me know and i can help.

[Eck]

Re-visiting this. Would like to get my Warn Belleview hooked up but not entirely sure how. Would like to make this electric with remote.

Any suggestions or help appreciated.


Sent from my iPhone using Tapatalk

Are you wanting to hook it up so that you can plug in on the front of the Bronco or control it from inside? If so I have done this and happy to try and help. i also swapped out the old solenoid pack and used a more modern set and mounted it remotely under the battery. Let me know and i can help.

I am thinking of hooking up a wireless remote that would allow me to control it both outside or inside the cab. I am not going to use the old cable controls if that answers your question.

[landshark]

ah ok, shouldn't be too hard, you would just hook up a remote kit to the solenoid i would presume. You can use a modern solenoid pack if needed.

like this? https://www.amazon.com/Electric-Wireles ... B005FNCM44

[Eck]

ah ok, shouldn't be too hard, you would just hook up a remote kit to the solenoid i would presume. You can use a modern solenoid pack if needed.

like this? https://www.amazon.com/Electric-Wireles ... B005FNCM44

exactly!

[landshark]

easy peasy

[Digger]

I'm not very familiar with the Belleviews and only a little familiar with the 8274s, but certainly there are ways to modify that thing for remote operation.

Are you looking for 100% remote control with power in and power out? Or something in-between that and where it is now?


For full control, I would imagine you would need to do the following:

- retro-fit a reversable motor (modern series wound with the field contacts external to the case)
- buy a Warn remote relay pack (H-bridge) from an M8000 or 9000
- design / fabricate a solenoid that, when active, disengages the brake. Electrically tie that solenoid to the remote. You will likely need to design a lockout, so the brake has to disengage slightly before the motor engages. Sorta like how the starter gear needs to engage the flywheel before spooling up the starter. Timing would be critical so the brake doesn't disengage too early and allow a loaded winch to roll back under the tension of the rope.

A guy could try to retro-fit the auto brake from a 8274, but I imagine this would be a lot of fab work and by the time you were done, it would look so much like an 8274 that you'd be better off starting with that platform.

[Eck]

I am not really looking for full control. I am simply trying to hook up this winch so that I can use a solenoid pack to power it and a remote to run the "in" operation. I am assuming that I will have to manually use the brake function.

[Digger]

I am not really looking for full control. I am simply trying to hook up this winch so that I can use a solenoid pack to power it and a remote to run the "in" operation. I am assuming that I will have to manually use the brake function.

If all you want is power in, than you don't need a whole control pack, just a single high-amp solenoid and connect a remote to it.

[Eck]

Spoke with Landshark a little bit and put an order together to get my current winch hooked up to a solenoid with a wireless remote. I will probably keep my eyes out for a good deal on an 8274 or do a little more research if it is worth retrofitting the Belleview with an 8274 motor to give it the in/out function. Either way, should be pretty easy to swap in the 8274 over the Belleview if I find one.

Ordered this solenoid: https://www.summitracing.com/parts/SPW-90-14452

Ordered this remote-- I liked that it had a POWER button so that I can keep the winch power turned off unless I am using it: https://www.amazon.com/gp/product/B00JK ... UTF8&psc=1

This rope: https://roweoffroad.com/shop/synthetic- ... -suv-jeep/

This flatlink: http://factor55.com/product/flatlink-e-expert/

This fairlead: http://factor55.com/product/hawse-fairleads/

** I had ordered a pilot toggle switch for an in cab power on switch but thinking I may not use it since the remote has a power button. Any reason I should still hardwire a switch into the cab?

[Gunnibronco]

This is a motor I understand can be used to upgrade an 8274. You might look into it, if you end up going that direction.

https://www.amazon.com/WARN-39436-12-Vo ... B000CQFVM4

[TOOLMAN]

Here's a couple of 8274's I found on Craigslist. First one looks to be kind of a deal.

https://cosprings.craigslist.org/tls/5910810468.html

https://fortcollins.craigslist.org/for/5952434233.html

[Eck]

So I've got a lead on an 8274 for $300. Is that a fair price? Also- how would I be able to test it and make sure it's not a total rebuild?


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[pgilbeau]

The Feb '17 Four Wheeler has an article on rebuilding the free spool and brake on an 8274, thought maybe the info in there could be of use

[Digger]

So I've got a lead on an 8274 for $300. Is that a fair price? Also- how would I be able to test it and make sure it's not a total rebuild?


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$300 is a good price for a functional 8274.

- Check for leaks (8274s are wet lubricated like a diff or transmission)
- power up the motor in both directions, listen for bad gears
- make sure the ratchet moves freely and brake functions
- check the free spool knob for function
- look for cracks or breaks in the case


It will be hard to fully test the winch unless it is mounted to a truck and you can test it under load, but checking the above items will be a fair indicator of condition.

[Strike2]

[quote="Eck"]So I've got a lead on an 8274 for $300. Is that a fair price? Also- how would I be able to test it and make sure it's not a total rebuild?

You could fab up at a quick receiver hitch, just to test it under a load ?

[TOOLMAN]

X2...everything Digger said. At $300, you can buy almost any part for that winch. Even if you spent $500 in repair parts, you'll still be in the black!

[landshark]

they are easy to work on and the parts are plentiful, i wouldn't be afraid to pick that one up

[Justin]

x4 or whatever. $6-700 is a common price for the 8274, so $300 is a screaming deal if it's in decent shape.

[Eck]

So I've got a lead on an 8274 for $300. Is that a fair price? Also- how would I be able to test it and make sure it's not a total rebuild?


Sent from my iPhone using Tapatalk

$300 is a good price for a functional 8274.

- Check for leaks (8274s are wet lubricated like a diff or transmission)
- power up the motor in both directions, listen for bad gears
- make sure the ratchet moves freely and brake functions
- check the free spool knob for function
- look for cracks or breaks in the case


It will be hard to fully test the winch unless it is mounted to a truck and you can test it under load, but checking the above items will be a fair indicator of condition.

Heading to take a look at it in Friday afternoon. Thanks for the to-do list. I'm not very farmiliar with winch's let alone the 8274. I've watched a couple how-to video's on how to check the motor operation with jumper cables and an extra wire. I'm not too worried about checking the solenoid pack since I ordered a new one.

I'm still unclear on the ratchet moving freely, where the brake is and how it works, and where the free spool knob is. I'll see what else I can try to find on the interweb that identifies these parts.

I can't see it not being a good deal but just want to make sure I do my homework.


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[Eck]

Ok- so I know how to check the free spool knob to make sure that works. Clearly know how to check it for leaks and cracks. I think I also have it figured out how to power the in/out of the motor.

The only thing I am not sure how to check without putting it under a load is the brake. Also, how the ratchet works? Any last minute advice before I go check it out tomorrow?

[Digger]

The ratchet pawl is straight forward. It is spring loaded to keep the pawl tight to the ratchet wheel on the exterior of the winch. This is part of the braking mechanism. Just made sure it moves freely and wants to seat against the ratchet wheel.

The brake works when the motor is engaged but not moving. If the drum tries to turn without being driven by the motor, this will drive a cam/ramp on the spur gear shaft attached to the ratchet wheel. The ramp causes the side plates on either side of the ratchet wheel to squeeze the ratchet wheel, which cannot turn because of the ratchet pawl, thus stopping the drum from spooling out.

The way to test this would be to engage the motor and try to turn the drum in the spool-out direction. This should engage the brake and stop the drum. You will likely see the side plates moving and squeezing the ratchet wheel. That whole mechanism should move freely to work properly.

It relies on two friction discs between the side plates and ratchet wheel. (Looks like a clutch friction liner) If these are worn or missing, the brake may not work properly. In that case, just make sure the side plates move properly and buy new friction discs later.

[Eck]

Well- here she is for better or for worse. Seems to have checked out. Ran power to it, hooked up the remote and was able to power in and out.

Now to get the steel cable off and get it it cleaned up. Any tips or ideas on how to try to polish it up a little?








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[Strike2]

Nice score!
To spruce up the aluminum try some 500-1200 grit sandpaper or scotchbrite and then some mothers polish.

[Eck]

Got it all cleaned up this afternoon. Wire brush, brake cleaner and a little finishing polish did a pretty good job. Hope to get it installed and wired up tomorrow.

[landshark]

looks great!

[TOOLMAN]

Nice! January 1982 winch if I read the letters right.