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WINCHES: Rebuilding, Parts Information, Diagrams, Testing Sites
Here are a few sites for general repair, rebuild, parts, diagrams, testing of most of the popular winches:
[URL]http://www.yotatech.com/f31/winch-rebuild-writeup-12513/[/URL]
[URL]http://www.fourwheeler.com/techarticles/electrical/129_0708_warn_winch_breakdown[/URL]
In Cab Winch Control:
[URL]http://www.4x4wire.com/jeep/tech/winch/hardware[/URL]
Rebuilding a Warn 5000: (applies to most Warn winches)
[URL]http://www.members.show.ca/macks4runner/winch.htm[/URL]
Rebuilding a Warn 8274:
[URL]http://www.pirate4x4.com/tech/billavista/8274/[/URL]
Rebuilding a Warn 9000:
[URL]http://www.jonfund.com/technical/winchteardown.shtml[/URL]
XD9000iWarn Winch Install:
[URL]http://www.stu-offroad.com/recovery/winch/warn-1.htm[/URL]
Winch Problems:
[URL]http://www.yotatech.com/f31/warn-winch-problems-291121[/URL]
Winch Troubleshooting Guide:
[URL]http://www.offroaders.com/tech/winches/winch-troubleshooting.htm[/URL]
Winching Tips and Recovery Advice
[URL]http://www.4wheeldrive.about.com/od/winchingtipsadvice4wheeling/index_r.htm[/URL]
[url]http://www.jeepforum.com/forum/showthread.php?t=488547[/url]
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Schematic 4 solenoid Warn Winches Testing Sites
Re: Winches:Rebuilds/Schematics/Warn 5000-9500
Here is a schematic for all 4 solenoid Warn winches:
Attached Images
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8274 Wiring Schematic
Here is a wiring diagram for an 8274 Winch
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Testing winch solenoids and motors
Here is a BillaVista article fro[IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-1.jpg[/IMG]m Dirt Sports that tells how:
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Warn 5000-9500 rebuild article
[IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-22.jpg[/IMG][IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-23.jpg[/IMG]
[IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-23.jpg[/IMG]
[IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-24.jpg[/IMG]
[IMG]http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-25.jpg[/IMG]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Rebuilding a Warn xd9000i:
[url]http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html[/url]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Ramsay 8000 wiring diagram:
[url]http://www.4x4wire.com/tech/winch/remote/schematic2.jpg[/url]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Thanks to Sean (1freaky1) for this information:
[FONT=Arial][COLOR=black]Winches use two types of DC motors[B], Permanent Magnet Motors [/B]and [B]Series Wound Motors[/B]. [/COLOR][/FONT][FONT=Arial]All electric DC winch motors consist of one set of coils, called an armature, inside another set of coils or a set of permanent magnets, called the stator. [/FONT][FONT=Arial,Helvetica]It is the job of the stator to produce a magnetic field which will cause the rotor (or armature) to rotate when an electric current flows through it. [/FONT][FONT=Arial] Applying a voltage to the coils produces a torque in the armature, resulting in motion. With all types of motors, the higher the horsepower rating, the more toque and power the motor will have. The winch rating is a combination of motor torque and gear train gear ratio reduction. Motor horsepower has a direct effect on both line speed & pulling power. [/FONT]
[FONT=Arial][COLOR=black][B]Permanent Magnet Motors - [/B][/COLOR][/FONT][FONT=Arial,Helvetica]In a permanent magnet motor, the stator uses permanent magnets and there are[/FONT][FONT=Arial] no field coils. [/FONT][FONT=Arial][COLOR=black]With permanent magnet motors, the drain on your battery tends to be less [/COLOR][/FONT][FONT=Arial]than series wound motors, which uses field coils in the stator rather than magnets[/FONT][FONT=Arial][COLOR=black]. Permanent magnet motors are better suited for light to medium duty winching because they tend to generate more heat and overheat. [/COLOR][/FONT][FONT=Arial]Winching time & load should be carefully monitored as they have the tendency to overheat. The magnets in permanent magnet motors can loose their field strength over time and repeated use.[/FONT]
[FONT=Arial][COLOR=black][B]Series Wound Motors - [/B] With a series wound motor, [/COLOR][/FONT][FONT=Arial]the field coils are connected in series with the armature coil. Series wound motors are powerful and efficient at high speed and generate the most torque for a given current. [/FONT][FONT=Arial][COLOR=black] A series wound motor will uses more current over a permanent magnet motor because they use field coils to generate a magnetic field.Series wound winches are heavier duty winches, and tend to be more expensive.[/COLOR][/FONT]
[FONT=Arial]A permanent magnetic motor will pull the same as a series wound motor, at at less of an amperage draw on the battery and charging system. However, as the permanent magnet motor gets warmer, the power will drop as the amperage draw will increase. The amperage draw on a series wound motor will stay the same throughout the duty cycle. [/FONT][LEFT][FONT=Arial][B]Winch Ratings[/B] - Most winch ratings are generally limited by the maximum amperage draw, with right around 400 being the cut-off point. Anymore than that would most likely damage the power source or charging system. In order to reduce the amperage usually the gear ratio will need to be increased numerically, to relive the motor from the increasing stress, however, this will also reduce the line speed at the same time.[/FONT]
[FONT=Arial]Info above taken from this link; [URL="http://www.offroaders.com/tech/winches/Winch-Components.htm"]http://www.offroaders.com/tech/winch...Components.htm[/URL][/FONT]
[FONT=Arial]Now a link to the fuse setups that will work with the winch motors. They are not cheap but cheaper than a new winch motor costs.[/FONT]
[URL]http://www.google.com/products?q=DC+400+amp+fuses&hl=en[/URL][/LEFT]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Here is the M8000 rebuild article:
[URL]http://www.fourwheeler.com/techarticles/electrical/129_0708_warn_m8000_winch_breakdown/index.html[/URL]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Here are a bunch of articles dealing with the rebuilding of many of the popular winches on the market today. Some of the articles cover the same winch rebuild, but the reason that I included these was that there was usually a lot of other information and links on that site. Many of these articles contain links to specific parts sources for winch parts and which suppliers are good or bad.
Due to the number of used winches that appear on craigslist and other places for sale, these articles will show you exactly what you are getting into buying a used winch and possibly doing a rebuild on it.
Warn XD 9000i:
[URL]http://www.jonfund.com/technical/winchteardown.shtml[/URL]
Warn XD 9000i Number 2:
[URL]http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html[/URL]
Warn M8000:
[URL]http://www.parksoffroad.com/tacomamods/m8000rebuild/m8000rebuild.htm[/URL]
Warn 8274:
[URL]http://www.pirate4x4.com/tech/billavista/8274/[/URL]
Warn M5000:
[URL]http://www.members.shaw.ca/macks4runner/winch.htm[/URL]
Tabor 9000 (Warn's cheaper, non roller bearing winch):
[URL]http://www.cdmfabrication.com/bbb/viewtopic.php?f=11&t=61[/URL]
Ramsey 200R:
[URL]http://www.cj-3a.com/rebuilding_the_ramsey_200r_winch.htm[/URL]
Mile Marker H12:
[URL]http://forums.lr4x4.com/index.php?showtopic=25692[/URL]
Koenig (yes, they are still around!):
[URL="http://home.off-road.com/%7Ebrentjbeissler/winch.html"]http://home.off-road.com/~brentjbeissler/winch.html[/URL]
Winch information(amperage draws, etc. from 1freaky1):
[COLOR=#008000]www.gregsmithequipment.com/images/ebay/which[B]winch[/B].pdf [/COLOR]
I realize that some of these are duplications and are posted in my other winch threads, but these articles, for the most part, deal exclusively with rebuilding winches.
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Here is a winch troubleshooting guide link:
[URL]http://www.4x4grace.com/vBulletin/showthread.php?p=140307[/URL]
And more information regarding winches:
[URL]http://www.off-road.com/offroad/article/articleDetail.jsp?id=285616[/URL]
And another good rebuild article:
[URL]http://macquarie4x4.com.au/cmsimages/File/4wd_091-097_WinchMaintTech.pdf[/URL]
Testing solenoids. A BillaVista article:
[url]http://www.pirate4x4.com/tech/billavista/Q&A1/Q&A1_signed.pdf[/url]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
A link to Ramsey parts:
[url]http://www.goramseywinch.com/ramsey_winch_service_parts.asp[/url]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Here is the link for Ramsey Winch Manuals for downloads:
[URL]http://www.ramsey.com/automotive/manuals.html[/URL]
[URL="http://images.google.com/images?hl=en&q=ramsey+winch+wiring+diagram&sourceid=navclient-ff&rlz=1B3GGLL_enUS363US363&um=1&ie=UTF-8&ei=KidoS9rdLJOgnQf12ei8Bw&sa=X&oi=image_result_group&ct=title&resnum=1&ved=0CBYQsAQwAA"]
[/URL]
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Here is the wiring diagram for a Superwinch Husky Winch:
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Warn winch wiring diagram-inside the solenoid box:
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Re: WINCHES: Rebuilding, Parts Information, Diagra
SuperWinch wiring outside to remote plug:
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Re: WINCHES: Rebuilding, Parts Information, Diagra
Just about everything you want to know about rating, comparing and buying winches can be found on this site along with some helpful recovery and other winch how to information:
[URL]http://4wheeldrive.about.com/od/winchingtipsadvice4wheeling/Winching_Tips_Recovery_Eqiupment_Advice_For_4Wheeling.htm[/URL]
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Excellent Warn 8000 rebuild article:
[URL]http://4x4preservation.com/forums/showthread.php?t=381[/URL]
And another one:
[URL]http://www.jeepforum.com/forum/f27/how-i-rebuilt-my-warn-m8000-1260695/[/URL]
Warn m8000 parts breakdown and parts list:
[URL]http://printfu.org/read/warn-ce-m8000-winch-replacement-parts-list-898f.html?f=1qeYpurpn6Wih-SUpOGumqenh8OwyLOUq6qQv6GepJaVxK66sr6Fxq21vLOss8Grw8GFvLDIuceIsbnFvZCv2a-fn47j6oev25-ho6OQ3tvo4dLcv8bK4M2Hq-Wjn66I24-g36msmK6KzeTm2aijlezk3Jrm19filsjf35ji5tvY2JS-1ObR1cvK3dfX4sTH5-HYm7K7t8S0lNPX297gm6iamqCd5snaiqDt[/URL]
Warn Winch Service Manual Downloads:
[URL]http://printfu.org/read/service-manual-5c22.html?f=1qeYpurpn6Wih-SUpOGul6mnh7-0yLu9q6qQv6q8yafBj6DfqaifltzZkq3cqKWXr4_P4eLq0uS4tdXezpCv2a-en47VmKDnop6jrIvW6Nrlp5Sb5u3cotzG0-HWz-jL59_O4N7o3qLL1N2h59HX1efZyuWew8bi3cbc5ZWTppbW39nV0uLK55e41eTf19fL1LrG2uTX0dO_1OLdyMHcy9rhxMSzr5PkzMuSreY[/URL]
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Dual Motor Warn 8274:
[video=youtube;EVu78xN_vYI]http://www.youtube.com/watch?v=EVu78xN_vYI[/video]
[video=youtube;am_KsYcJZ8M]http://www.youtube.com/watch?v=am_KsYcJZ8M[/video]
[video=youtube;Grd4LQ7sA9I]http://www.youtube.com/watch?v=Grd4LQ7sA9I[/video]
Thanks Roland!
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HICKEY SideWinder Winch Diagram and information:
[url]http://forum.ih8mud.com/winching-recovery/427736-rebuilding-hickley-sidewinder.html[/url]
More:
[url]http://forum.ih8mud.com/winching-recovery/42709-hickey-sidewinder-winch.html[/url]
Replacement Motor:
[url]http://www.piercesales.com/12-Volt-Heavy-Duty-Winch-Motor-p/ps534h.htm[/url]
Link to Pirate with information on a wiring diagram source:
[url]http://www.pirate4x4.com/forum/showthread.php?t=302570[/url]