Need help from a WARN XD9000i owner????

[xjtrailrider]

I traded a 37 year old WARN Belleview for this XD9000i even yesterday. I was told the motor was shot and the windings were shorted. I ran WARN's motor test procedure on the motor this morning and it spins free and fast in both directions with little or no amp draw (winch dis-engaged of course)

I suspect a solenoid as the issue but the PO said he replaced all 4 with brand new WARN units (The PO is a friend of mine and has a good reputation of being honest). I pulled the cover off of the solenoid pack and found one lead loose. But before I reconnect everything I would like for some one to check the wiring to make sure he has everything connected properly. I am unable to find a wiring diagram for this winch on the net. Here are some pics

As you can see but it may be hard to make out, F] is connected to the second solenoid from the left(facing the front of the winch), F2 and A are connected to the 3rd solenoid from the left and the positive lead from the battery is connected to the last solenoid on the right. My question is; Are the Buss bars in the right places? Are the leads to the motor in the right places? And are the leads to the remote in the right places? I suspect that there is something crossed up somewhere and I want to make sure its right before i throw power to it and burn up a winding or armature.

TIA

 

[WrenchMonkey]

<Edit> Nevermind, sorry...

 

[xjtrailrider]

I was able to get a schematic of the wiring from a local wheeler and went over the routing. I found a loose buss bar and a loose connection at the "field 2" terminal. The only issue i have now is the motor will run just fine and then stop suddenly but if I wiggle the connection at "F2" it will run just fine. I'm going to pull the motor off and check the internal connections. I think the winch is just fine otherwise and the motor runs very good.

 

[OverlandZJ]

The only issue i have now is the motor will run just fine and then stop suddenly but if I wiggle the connection at "F2" it will run just fine..

That sounds as if the stud was overtightened and broken inside the solenoid.

If you pull it apart clean and grease up the collar for the freespool lever.. mine started sticking up as the old grease turned to mud.

 

[xjtrailrider]

That sounds as if the stud was overtightened and broken inside the solenoid.

If you pull it apart clean and grease up the collar for the freespool lever.. mine started sticking up as the old grease turned to mud.

BINGO! You are dead on Overland, except on the motor "F2" stud. I found the problem, the connection at F2 is broken to the stator and needs repaired. I think I will turn it over to a expert to fix this. My next door neighbor does this stuff for a living. I want to make sure it will hold up when I get the winch hot on a pull.

Here is a couple of pics with the motor and armature removed.

 

[xjtrailrider]

The motor is repaired, cleaned, the com was polished and its back on the winch. Works great!!!

The best part is, my neighbor didn't charge me a dime for the repair, so as of right now I have a nice winch for little to no money.