NewHilux.net

I have a WARN XD 9000 CE winch which had not worked for about 6 months.

So over christmas I set to it and pulled it apart.

After finding half of Stockton Beach in the motor housing and the lower half of the housing covered in rust I cleaned it up.

Once clean and rebuilt I bench tested to which it worked perfectly fine (even got the wire the right way around first time.

Now a few days weeks down the track I went out to Run the cable back on the drum. Plug the remote in and all I get in the solenoids clicking and the winch not running again.

What is it I'm over looking that would causing this

it's not shorting out on the body/bullbar anywhere mate? all your leads in good shape?

A contact in a solenoid good enough to power it up with no load but won't carry enough current for the load. Put a multimeter across the terminals at the winch with it loaded up. Should be very near battery voltage obviously.

Be the negatives budd. Also had simula prob with my xp 9,5. took it back to arb and turns out they had installed it wrong at dandenong arb, upside down in the housing or something which allowed shit like mud and water entering threw the plug hole.

All the lead are in good shape.

There is/was no load on the winch when testing on the lux for the first time to day.

All the solenoids seem to be working ok will double check them. Also correct me if i'm wrong but if it was a solenoid wouldn't the winch work either in or out and not the other??

I have the same problem with the winch being mounted upside down by whom ever it was originally but have sealed the holes this time round to stop the water nad crap.

As for the earth/negatives even if the earth cable is not connected you still get the negative from the chassis anyway.

Hey James look it may not be relevant as you said you got it working on the bench, but my Warn stopped working for no apparent reason also. I opened it up cleaned greased what I could etc. I still could only get clicking, cleaned all contacts, decided to take it to OL he tol me the motor was full of sand and corrosion, connected up a spare motor and it ran fine. I ended up having to cough up for a new motor @550. He said it happens a lot FWIW. Good luck with it

jiggins wrote:Also correct me if i'm wrong but if it was a solenoid wouldn't the winch work either in or out and not the other??

True, just a suggestion. The same rules still apply. Check for power at the corresponding terminals on the winch. And I understand your comment on the earth through the body but the easiest way to check is put your positive meter lead on the winch earth and the black on the negative battery post. Any voltage shown is the voltage 'lost' through the connections.

Getting this problem now. Warn winch 9.5 xp just clicks. Voltage coming through the solenoid. Still under warranty though so taking it back. But they tell me they cant have a look at it for nearly 2 weeks.

Spot the problem:



Had this wireless kit for a couple of years but only just installed it yesterday.
Original batteries flat - dead flat 0.0V. A little odd as had not been taken out of box but not totaly unexpected
Purchased new A23 12V batts. Initial 12.45V. Installed into remote, lost 1.5 volts within 2 hours when not in use

I'm an electrical noob but can see the short and can follow good instruction
The remote is able to operate the winch - but not for long at 11V

So - whats the best way to fix this without damaging the PCB?
Easy I suspect...

Fixed this today

Excess solder bridging power to Q1
Removed excess with solder wick - thanks youtube.
Could have done this several other ways but this method was good.
Place solder wick over offending solder (hold wick with pliers)
Press 350-360 C soldering iron on top of wick
Job done

Q3 looks crap too - sharing mount pad with C3 but isnt causing any issue

4 hours later no voltage drop



Maybe no point paying extra for big brand names any more. In this case the components are poorly assembled in the same country as cheaper alternative manufacturers