I'm wondering if anybody knows of a way to test the motor on a Warn XD 9000 Winch before I go burn money. I just have to confirm my beliefs that my Winch is in fact a DEAD DOG. My model has the external wrap around Heat Sink and remote mountable-4 Solenoid Control Box which uses NAPA ST 81 solenoids. Just replaced the solenoids in the box and they engage in both directions but the Drum does not move in either direction. Somebody help me! :smokin:

carefully pull it apart and check the gears to see if any of them have binded/broke, you said that you recently replaced the brushes, but I'd check those... There really isn't that much to them, so I take it completely apart and see if you can penpoint the problem... Had a simular prob with a ramsey and it turned out to be a dirty contact patch where the brushed are... could be simple, might not... and if it's off the rig test it with the motor rinning and use jumper cables to the winch.... I first tried it with just the bat, but it needs more amps.....

Also you may post it on the Colo4x4 BB (http://colorado4x4.org/cgi-bin/ubb/ultimatebb.cgi) and see if anyone near you has done the same thing that they may be physicaly able to help you out....

Good luck!
-Jerry-

Man that pic helps a lot! :rolleyes: :rolleyes: :flipoff2:

So you have tested the motor by bypassing the solenoid's? The motor with out a load doesn't pull many amps.

This is the model I have

http://www.dsiwarn.com/parts_breakdowns/xd9000_348579.pdf

I forgot to mention it didn't just break but rather has not worked since I purchased the vehicle. I initially thought it was the solenoids and plug assembly but now that those have been replaced I'm thinking I have bigger problems.

thanks going out to http://www.ih8mud.com for the PDF Link.

take it apart and dont be afaid. winches are very simple! make syre your brushes are good. clean commutator bars with fine sand paper and put 200-300 amps too it. Dc motors hardly ever go bad!

Ok. I didn't replace the brushes. I replaced and cleaned the solenoids and plug assembly in the control box. I have not tested the motor at all. I just tried using the winch after replacing the solenoids in the control box as I thought that was my main problem. Apparently it was just one of the problems.

CAN SOMEBODY DESCRIBE IN DETAIL THE PROCEDURES FOR TESTING OR PUTTING STRAIGHT POWER TO THE WINCH? I DON'T WANT TO BLOW ANYTHING UP OR ELECTRICUTE MYSELF.

NEVER INTEDED THE PIC TO BE HELPFUL. IT'S JUST A PIC. DON'T TAKE IT TOO SERIOUSLY. MAYBE THE PDF I POSTED WILL HELP DETERMINE HOW TO TEST MY MODEL.

http://www.dsiwarn.com/parts_breakdowns/xd9000_348579.pdf

Originally posted by GEARSINMYHEAD
Ok. I didn't replace the brushes. I replaced and cleaned the solenoids and plug assembly in the control box. I have not tested the motor at all. I just tried using the winch after replacing the solenoids in the control box as I thought that was my main problem. Apparently it was just one of the problems.

CAN SOMEBODY DESCRIBE IN DETAIL THE PROCEDURES FOR TESTING OR PUTTING STRAIGHT POWER TO THE WINCH? I DON'T WANT TO BLOW ANYTHING UP OR ELECTRICUTE MYSELF.

NEVER INTEDED THE PIC TO BE HELPFUL. IT'S JUST A PIC. DON'T TAKE IT TOO SERIOUSLY. MAYBE THE PDF I POSTED WILL HELP DETERMINE HOW TO TEST MY MODEL.

http://www.dsiwarn.com/parts_breakdowns/xd9000_348579.pdf

This page should help you out: http://www.rightcoastcrawler.com/billaVista/8274/8274.htm

GEARSINMYHEAD---ya....you need to hook power directly to the motor terminals to really determine if the motor needs work....I just can't remember the switching arrangement at the moment for the 3 posts.

Originally posted by imrtoy
take it apart and dont be afaid. winches are very simple! make syre your brushes are good. clean commutator bars with fine sand paper and put 200-300 amps too it. Dc motors hardly ever go bad!

Unless of course, the motor got burnt up.

When my 9500i went south, first it was 2 of 4 solenoids, then it was the brake, followed by the motor being burnt up. what mine did was click, and ocasional the motor would work by pulling some cable out which I think just moved the brushes move a part of the motor good enough to get current flowing.

These things are EASY to take apart. The motor though, if its the 4.6HP one, is about $200.