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  #11  
Old 01-20-2008, 09:22 PM
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Sorry but should I ground the plate that the selonioids attach to? Or each selonoid?

I gotta still check the grounds too.

I had a big day watchin' football.
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  #12  
Old 01-20-2008, 09:41 PM
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The winch mounting bolts should have a good ground, you can verify this using a voltmeter with the ohm measurement. Meausre the battery neg terminal to chassis and verify a good ground.
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  #13  
Old 01-21-2008, 07:01 PM
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hey drew,

you might want to run down to lowes, get some plexi glass and cut disks to fit over the new hellas. i have run those stuck on there with a little velcro (4 small velcro 1/2" disks at the edges) to keep them on and it has kept them from breaking.. yours are mounted kinda low and i might worry about a rock killing one..

-Marco
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  #14  
Old 01-21-2008, 07:37 PM
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Thanks, got some of those fancy clear covers... we'll see how long they last.

Red lock-tight on the bolts
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Rezarf <><
My rig... "Maude"
1976 FJ40 with some stuff and some leaks.

2001 Sequoia Limited with heated seats

My camping trailer build up thread.

"You 80 guys are just a Sawzall away from nirvana." -Red Chili
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  #15  
Old 01-21-2008, 09:53 PM
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look at the bright side... the winch may not work but the lights look cool as hell....

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  #16  
Old 05-09-2008, 04:23 PM
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I am back on this winch thing. I am still getting nothing. My winch is wired straight from the battery to the winch (both pos and neg), and I am hearing a "click" when throwing the switch into forward or reverse.

I am going to check the little solenoid mounting plate for ground.
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My rig... "Maude"
1976 FJ40 with some stuff and some leaks.

2001 Sequoia Limited with heated seats

My camping trailer build up thread.

"You 80 guys are just a Sawzall away from nirvana." -Red Chili
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  #17  
Old 05-09-2008, 05:01 PM
leiniesred leiniesred is offline
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There is more than 1 solenoid in that box on my 2 way winch. They both have to work for the cable to move. I dunno whatcha got in the box, but I bet it is a bad solenoid.
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  #18  
Old 06-10-2008, 03:08 PM
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Bummer, I jumped the wires with jumper cables and still can't get it to fire. I need to figure out how to get this thing working again. If anyone knows how I can isolate each solenoid to find out if I have a bad one, I would welcome the help
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My rig... "Maude"
1976 FJ40 with some stuff and some leaks.

2001 Sequoia Limited with heated seats

My camping trailer build up thread.

"You 80 guys are just a Sawzall away from nirvana." -Red Chili
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  #19  
Old 06-10-2008, 04:13 PM
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I don't have my manual in fort of me, so I'm going by memory.

Warn black boxes have a fail safe system, where power and ground are controlled by solenoids. Should one solenoid stick the other will disrupt the circuit shutting down the winch when you release the switch.

Look in the box and you should see 4 solenoids marked 1, 2, 3 & 4. On the motor there should be 4 studs labeled F1, F2, A & GND.

(Going by memory here) When winching in solenoid 1 & 4 close and current flows form the Pos cable thru "1" to "F1", thru the field, than back to the box from "F2" to "4", back to the motor via "A" thru the armature to ground.

When winching out, polarity of the field is reversed when 2 & 3 close. Form "Pos" thru "2" to "F2" to field, back from "F1" to "3" then to "A" thru the armature to "Gnd" (clear as mud?)

The control switch is a DPDT center off type switch. When winching in or out it not only energizes the solenoids but also makes or breaks the ground for the solenoids (another fail safe).

Hope this helps.

*edit* Neither the solenoids nor the metal mounting plate need to be grounded. Grounding of the solenoids is done thru the control switch.

*edit2* Just looked up the wiring diagram on Warn's site for your model. Solenoids 1 & 4 close while 2 &3 are open for in and visa-versa for out. edited text to avoid confusion.

Last edited by Seldom Seen; 06-10-2008 at 10:45 PM.
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  #20  
Old 06-11-2008, 12:19 AM
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Seldom Seen Seldom Seen is offline
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Default Low Amp "Control" Circuit

OK I'm home and have the manual.

When you open the box the 1st thing you'll notice is the 4 solenoids. They are ganged together by copper bars in a square, with the 4 wires (Pos, F1, F2 & A) connected to it's respective lug on the solenoid (see above).

The low amp or control side of the system is quite simple. There is a white (~16ga) wire connected to the same lug as the Pos (red batt cable) this is where the control picks up power. White goes to the female plug. You'll see a green wire connecting solinoids 1 & 3 and a black connecting 2 & 4. Both the black & Green go to the plug. This is the in and out control. The switch connects the White to either Black or green to energize the solenoids and make the winch spool in or out.

There should be a Brown wire that daisy chains all the solenoids together and than goes to the plug. The Brown is solenoid "ground". Brown goes to the gnd side of the control switch. The switch is wired so that it's either on or off. (center is off and in OR out is on) Warn does this as part of their safety system in case of a switch failure.

NOW HERE IS THE TRICKY PART the gnd side of the switch connects the brown wire to a RED wire. The red wire runs back thru the plug and is connected to a chassis GROUND.

You read that right. THE RED 16ga WIRE FROM THE PLUG GOES TO A GROUND!!!

Last edited by Seldom Seen; 06-11-2008 at 12:44 AM.
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