WINCHES: Rebuilding, Parts Information, Diagrams, Testing Sites

[Brody]

Here are a few sites for general repair, rebuild, parts, diagrams, testing of most of the popular winches:

http://www.yotatech.com/f31/winch-rebuild-writeup-12513/
http://www.fourwheeler.com/techarticles/electrical/129_0708_warn_winch_breakdown
In Cab Winch Control:
http://www.4x4wire.com/jeep/tech/winch/hardware

Rebuilding a Warn 5000: (applies to most Warn winches)
http://www.members.show.ca/macks4runner/winch.htm

Rebuilding a Warn 8274:
http://www.pirate4x4.com/tech/billavista/8274/

Rebuilding a Warn 9000:
http://www.jonfund.com/technical/winchteardown.shtml

XD9000iWarn Winch Install:
http://www.stu-offroad.com/recovery/winch/warn-1.htm

Winch Problems:
http://www.yotatech.com/f31/warn-winch-problems-291121

Winch Troubleshooting Guide:
http://www.offroaders.com/tech/winches/winch-troubleshooting.htm

Winching Tips and Recovery Advice
http://www.4wheeldrive.about.com/od/winchingtipsadvice4wheeling/index_r.htm

http://www.jeepforum.com/forum/showthread.php?t=488547

[Brody]

Re: Winches:Rebuilds/Schematics/Warn 5000-9500
Here is a schematic for all 4 solenoid Warn winches:
Attached Images

[Brody]

Here is a wiring diagram for an 8274 Winch

[Brody]

Here is a BillaVista article frohttp://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-1.jpgm Dirt Sports that tells how:

[Brody]

http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-22.jpghttp://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-23.jpg
http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-23.jpg
http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-24.jpg
http://i273.photobucket.com/albums/jj205/brody_2008/Toyota%20Scans/Untitled-25.jpg

[Brody]

Rebuilding a Warn xd9000i:

http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html

[Brody]

Ramsay 8000 wiring diagram:

http://www.4x4wire.com/tech/winch/remote/schematic2.jpg

[Brody]

Thanks to Sean (1freaky1) for this information:

Winches use two types of DC motors, Permanent Magnet Motors and Series Wound Motors. 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. 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. 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.
Permanent Magnet Motors - In a permanent magnet motor, the stator uses permanent magnets and there are no field coils. With permanent magnet motors, the drain on your battery tends to be less than series wound motors, which uses field coils in the stator rather than magnets. Permanent magnet motors are better suited for light to medium duty winching because they tend to generate more heat and overheat. 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.
Series Wound Motors - With a series wound motor, 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. 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.
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.
Winch Ratings - 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.
Info above taken from this link; http://www.offroaders.com/tech/winch...Components.htm (http://www.offroaders.com/tech/winches/Winch-Components.htm)

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.

http://www.google.com/products?q=DC+400+amp+fuses&hl=en

[DETN8R]

Here is the M8000 rebuild article:

http://www.fourwheeler.com/techarticles/electrical/129_0708_warn_m8000_winch_breakdown/index.html

[Brody]

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:

http://www.jonfund.com/technical/winchteardown.shtml

Warn XD 9000i Number 2:

http://www.wanderingtrail.com/Repairs_Rebuilds/warn_winch/warnwinch.html

Warn M8000:

http://www.parksoffroad.com/tacomamods/m8000rebuild/m8000rebuild.htm

Warn 8274:

http://www.pirate4x4.com/tech/billavista/8274/

Warn M5000:

http://www.members.shaw.ca/macks4runner/winch.htm

Tabor 9000 (Warn's cheaper, non roller bearing winch):

http://www.cdmfabrication.com/bbb/viewtopic.php?f=11&t=61

Ramsey 200R:

http://www.cj-3a.com/rebuilding_the_ramsey_200r_winch.htm

Mile Marker H12:

http://forums.lr4x4.com/index.php?showtopic=25692

Koenig (yes, they are still around!):

http://home.off-road.com/~brentjbeissler/winch.html (http://home.off-road.com/%7Ebrentjbeissler/winch.html)

Winch information(amperage draws, etc. from 1freaky1):

www.gregsmithequipment.com/images/ebay/whichwinch.pdf

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.

[Brody]

Here is a winch troubleshooting guide link:

http://www.4x4grace.com/vBulletin/showthread.php?p=140307

And more information regarding winches:

http://www.off-road.com/offroad/article/articleDetail.jsp?id=285616

And another good rebuild article:

http://macquarie4x4.com.au/cmsimages/File/4wd_091-097_WinchMaintTech.pdf

Testing solenoids. A BillaVista article:

http://www.pirate4x4.com/tech/billavista/Q&A1/Q&A1_signed.pdf

[JeffX]

A link to Ramsey parts:

http://www.goramseywinch.com/ramsey_winch_service_parts.asp

[Brody]

Here is the link for Ramsey Winch Manuals for downloads:

http://www.ramsey.com/automotive/manuals.html


(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)

[Brody]

Here is the wiring diagram for a Superwinch Husky Winch:

[Brody]

Warn winch wiring diagram-inside the solenoid box:

[Brody]

SuperWinch wiring outside to remote plug:

[Brody]

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:

http://4wheeldrive.about.com/od/winchingtipsadvice4wheeling/Winching_Tips_Recovery_Eqiupment_Advice_For_4Wheel ing.htm

[Brody]

Excellent Warn 8000 rebuild article:

http://4x4preservation.com/forums/showthread.php?t=381

And another one:

http://www.jeepforum.com/forum/f27/how-i-rebuilt-my-warn-m8000-1260695/

Warn m8000 parts breakdown and parts list:

http://printfu.org/read/warn-ce-m8000-winch-replacement-parts-list-898f.html?f=1qeYpurpn6Wih-SUpOGumqenh8OwyLOUq6qQv6GepJaVxK66sr6Fxq21vLOss8Gr w8GFvLDIuceIsbnFvZCv2a-fn47j6oev25-ho6OQ3tvo4dLcv8bK4M2Hq-Wjn66I24-g36msmK6KzeTm2aijlezk3Jrm19filsjf35ji5tvY2JS-1ObR1cvK3dfX4sTH5-HYm7K7t8S0lNPX297gm6iamqCd5snaiqDt

Warn Winch Service Manual Downloads:

http://printfu.org/read/service-manual-5c22.html?f=1qeYpurpn6Wih-SUpOGul6mnh7-0yLu9q6qQv6q8yafBj6DfqaifltzZkq3cqKWXr4_P4eLq0uS4t dXezpCv2a-en47VmKDnop6jrIvW6Nrlp5Sb5u3cotzG0-HWz-jL59_O4N7o3qLL1N2h59HX1efZyuWew8bi3cbc5ZWTppbW39nV 0uLK55e41eTf19fL1LrG2uTX0dO_1OLdyMHcy9rhxMSzr5PkzM uSreY

[Brody]

Dual Motor Warn 8274:


http://www.youtube.com/watch?v=EVu78xN_vYI



http://www.youtube.com/watch?v=am_KsYcJZ8M


http://www.youtube.com/watch?v=Grd4LQ7sA9I

Thanks Roland!

[Brody]

HICKEY SideWinder Winch Diagram and information:

http://forum.ih8mud.com/winching-recovery/427736-rebuilding-hickley-sidewinder.html

More:

http://forum.ih8mud.com/winching-recovery/42709-hickey-sidewinder-winch.html

Replacement Motor:

http://www.piercesales.com/12-Volt-Heavy-Duty-Winch-Motor-p/ps534h.htm

Link to Pirate with information on a wiring diagram source:

http://www.pirate4x4.com/forum/showthread.php?t=302570