24 Volt winch to 12 volt

[fred99tj]

I have access to a Warn XD9000 winch that is 24 volt. I found a motor cheap: http://cgi.ebay.com/ebaymotors/NEW-W...ehicleQ5fParts
is there anything else to change to make this work?

[Demus]

Originally Posted by fred99tj

i have access to a warn xd9000 winch that is 24 volt. I found a motor cheap: http://cgi.ebay.com/ebaymotors/new-w...ehicleq5fparts
is there anything else to change to make this work?

solenoid

[fred99tj]

I'd have to replace the solinoids also?

[fred99tj]

For any one whos curious heres what I found out from Warn. The Motor needs to replaced with a 12V Motor (less than $100) the Solinoids and Control Box DO NOT need to be replaced HOWEVER the controls DO NEED to be rewired. They sent me the wiring diagram and as soon as I get a motor here I am going to do the swap. I am getting the winch on trade for my Smitty Built 8000 once I do the trade. Nothing like getting a $1200 Warn XD9000I for a $250 Smitty Bilt XRC8000 and have to purchase a $89 motor

[fred99tj]

Pulled the Trigger
Well I Have a friend who has 2 x 24V Warn XD9000I winchs. Well he set one up on his trailer and the batteries were toast so we researched a bit on converting to a 12V.

Well I just ordered the 12V motor ($90 on ebay) to replace the 24V and I got the info from Warn to make the Swap.

All it requires is the new motor and rewiring the solinoids, the solinoids are the same.

So in the next 72-96 hours I should have the motor inhand, I am going to get the winch tonight and work the rewireing, remove the 24V motor and clean it up. My plan is to put the 24V motor on Ebay and hopefully get enough out of it to cover at least 1/2 the 12V motor.

So for my XRC 8000 in trade and $90 on a motor I will have a fully operational Warn XD9000I.

I will keep this updated as progress advances.

[fred99tj]

Well picked up the winch tonight and removed the 24V motor, that was probably the easiest thing I have ever done, unhook the wires and literally take out 2 bolts, done

[Ben W]

Can you post or email me the wiring diagram WARN sent you?

[fred99tj]

Ben send me an email to fsjrzdvl yahoo type and I will send you what they sent me. They are Adobe Files. There are two one for a 3 wire control box and one for a 5 wire control box

[friggnxj]

Let us know how it goes. I also got a 24v warn winch that I'm thinking about converting.

[fred99tj]

Well this is also becomeinga winch referb
removed the cable, everything turned perfectly



opened up the solinoid box and everything looked great, undid all the wires so I had bare solinoids and started from Scratch. When all was done the big difference is the 24V uses 2 less wires than the 12 V so I have to make 2 small short wires then go through and tighten everything down.

Also the PO cut the hot and ground leads so they will need replaceing, no biggy. I will get the wires I need today and throw some fresh paint on the drum (even though it doesn't need it, it's still black)

I think later today I may remove the planetary gears and clean/grease it up then re-assemble. Then its just a waitning game till the motor gets here.

When I re-string the cable I am going to coat it with a light coat of oil (like drag an oily rag over the cable as it spools) and a few squirts of WD-40 to keep it clean and moving freely

[fred99tj]

Got all the wires redone, bought new hot and ground leads, had them made 64" long, cost me $30 for the pair. SO currently sitting at $120 into this project but hope to recoup some of it from the 24v winch motor

with that said FORSALE
24V Warn XD9000I motor in like new condition $40 + shipping (weight about 30#)

[fred99tj]

Well strike 1
I got the motor today and wired everything up. Went to test the winch and it super heated the power and ground but ran the motor, VERY SLOW. Put winch on free spool and locked and it worked as should, drum turned free on free spool, and didn't on lock. I think I messed up some wires in the solinoid box. Sent an inquirery to Warn along with some new questions so we will see what they say. I am going to remove all the wires and start over tomorrow.

[Demus]

You are 100% sure you can run a 12v motor and a 24v motor off the same solenoid and just need to wire it different ??

The example what had happened in strike 1 is what would happen if we use a 24v solenoid on a 12v winch ,,very hot and slow.,,,,also did you lengthen the leads this also can make a difference if not correct gauge leads ,,,,very hot ,,not enough power.


Paul

[zukitough]

this winch sounds like the ones that are on military HUMMV's which are 24v models. that may be why u got such a smoking deal on the trade. is the winch legit?

[MuddyV8YJ]

what made you decide to spend all this time and money swapping the motor instead of getting a dual battery setup installed and running the 24v?

[fred99tj]

You are 100% sure you can run a 12v motor and a 24v motor off the same solenoid and just need to wire it different ??
Warn responded to that question and they said the Solinoids are not different. They were the ones who said the wire pattern is the only difference, so 95% sure. Even Warn can be wrong

did you lengthen the leads this also can make a difference if not correct gauge leads ,,,,very hot ,,not enough power.
this is possible. I replaced the power and ground lead with a standard parts store 4 guage battery line 54" long. the warn original wires were 2 guage????? got me thinking on this

what made you decide to spend all this time and money swapping the motor instead of getting a dual battery setup installed and running the 24v?
$120 is not alot to spend on a good winch, however the time has been a bit. Don't want to run two (actually 3) batteries in the jeep just to run a winch amd this will be a good learning experiance

this winch sounds like the ones that are on military HUMMV's which are 24v models. that may be why u got such a smoking deal on the trade. is the winch legit?
The 9000's didn't come on HMMWV's however I am not100% sure it wasnot a military application.

[zukitough]

why would you need to run 3 batteries for 24v? only need two, 12v+12v in series =24v for the winch and run the same two batteries in parallel for 12v jeep system or just run off one battery.

9000s did come on the up armor vehicles as a rear extraction winch and on some of the older models before being switched over to the mile marker hydralic ones. thats why each vehicle cae with a warn extraction kit with a snatch block to double the pulling power.

[fred99tj]

I would run 2 for a 24 V then a 3rd for the Vehicle 12 V but either way I m dead set now on getting this to work

[zukitough]

Originally Posted by fred99tj

I would run 2 for a 24 V then a 3rd for the Vehicle 12 V but either way I m dead set now on getting this to work

well if u decide to revert back to original 24v design, i or any number of people here can draw up a easy diagram to show u how u can use it with only 2 batts instead of 3.

[RRRAAAYYY2]

There are solenoids that will work on either 12 or 24volts. If they pull in on 12volts, you can consider them working. Try performing a voltage drop test on them. Put a lead of a multimeter on the post on each side. Then engage the winch. The reading on the meter will be how much voltage is lost through the solenoid's contacts. More than .2 volts and I would replace it.

From your description, I am pretty sure you either have a bad motor or it wired wrong. Your 4ga cable is a little on the lightside, but shouldnt be causing your issue that badly. Add a set of booster cables if you want to quickly check that it is not the problem. But as I said, I would look at how it is wired, especially the connections from the motor to the solenoid set.

[Ben W]

Originally Posted by zukitough

well if u decide to revert back to original 24v design, i or any number of people here can draw up a easy diagram to show u how u can use it with only 2 batts instead of 3.

Lets see it.

[zukitough]

Originally Posted by Ben W

Lets see it.

here is the most simplistic way to explain it just so ya'll know what i meant using the serial design. i am horrible at drawing in paint. only one battery would get charged at a time and only primary battery would start the vehicle. i imagine with diodes a parallel dual battery setup could be used in conjunction. i started to test this out with some bench top electronics but got sidetracked by work. also instead of the dpdt i believe there is a electronic smart module. disclaimer: this is just an illustration for clarity not a wiring diagram.

[fred99tj]

I called warn and they told me how to test the motor when I did so the motor was bad

[Muddy Oval]

Warn motor or eBay special?

[gte719p]

I don't know about the one listed but you can get good winch motors from DB electrical cheap. I haven't used them for winch motors, but I've bough solinoids and started for my 7.3 idi and powerstroke from them and everything has been top notch. There starters are 10x better then OEM.

http://www.db-starter-alternator.com/Winch%20Motor/