another warn wiring problem

[new2zukes]

well i have serched threw the forum for winch wiring for in cab controles but no luck on what im after. i have a warn m8000 12v winch with a 4 solonoid pack. the wiring for the switch goes as follows:

brown red brown

green yellow black

i presume brown is earth and when you switch one side it earths while yellow is 12v and converts power to black (in/out) then green (in/out) hope this doesnt seem too confusing.
my plan was to use push buttons for the yellow to black and yellow to green and run a normal switch that makes red contact brown. well hope someone can help me here. thanks

martin

[Sadam_Husain]

you just wire it off the pins that the remote plugs into, there should be only 3 wires (thats all mines got) a live pin with 12V on it and the other 2 wires are the in and out

[Swamped]

Got my diagram from google images. Checked to make sure it would all work with a meter esp the way the motor was wound and was away laughing.

[new2zukes]

ive looked on google images and there are lots of diagrams there and helpfull ones too but still doesnt give me what i need to know. i needed to know if i can use the brown cable as a switch to shut off power in/out i am presuming the brown one is earth and i still dont know what the red one is. i have push buttons im going to use for power in and out and they only have 2 terminals and i dont know if i can link the brown wire with the red as well as yellow and black (both on the same terminal. might have to do a bit of bench testing and hopefully not blow anything up

[Jerry]

Where in there do you wire in the winch cut off / master switch?

[kbushnz]

The three wire Warns, have one wire + and the other two are in and out.
The solenoids were earthed thru the case.
The + wire is picked up from the main feed cables into the solenoid pack.

Newer Warns have 4.. with the 4th being a ground wire.
Also some are now 5 wire suppling + from the truck.

I sort of have a 5 wire setup but the earth is still in the winch.

What I have done to get incab and normal plug was to interupt the power wire in the winch..and feed it from the truck via a switch (to isolate power to solenoids)
Then via my new in out switch wired to the winch control it.

I can also use the factory plug and handheld controller. But must activate the isolation switch in the cab.

Stops the kids accidentially playing with it. I also mounted another waterproof switch next to the winch so I can reset the cable and power the winch.

Note the battery feeds to the winch are not switched.

Works for me and never had any issues.

Calvin

[new2zukes]

ok so from what i can make out is that brown is earth which needs to contact the red wire to earth the solonoids but if i just run the earth wire dirrect to the red terminal on the solonoid this should work then i can just use a 3 wire setup. i will bench test it all before i hard wire it all.

[kbushnz]

Here is the typical 3 wire setup. (like mine was)



Here is the factory 5 wire.



Here is what I have done (But have two switches one incab and the other on the grill)

Note Earth is done thru winch per orignal...Newer ones have own earth path I believe due to problems later when everything gets dirty/corroded and the electrons cant get thru..
You will notice a yellow path for + going to plug. This is so I can use the factory controller. (Winch selected on in cab)
There were stories of people in the States who would get the winch cable and hook it over the roof and use paperclip to short out the pins in the plug and operate the winch. You can guess the result
With my setup there is no power to the plug until I set it.



Cheers
Calvin

[new2zukes]

well that explains it alot more clearly thanks for that. will still bench test it but now i know how to wire it up.

[darinz]

When you test it. Take the main feed to the winch off and then as you test the switch you should be able to hear the different solenoids swtiching.
I also really reconmend a switch on the main power supply to the solenoids. A $40 BEP marine switch is more than adequate. Rated at 275amp continuos (30 mintues), 450 intermitent (5 mintues) and surge of about 1000amps (30 seconds) it more than copes with anything your power supply can produce.

[SMOKEY]

Thanks Calvin, when you see a well set out wiring diagram like this it makes the whole job that much easier.

AND I LIKE THE EASY LIFE,

FITZY.

[kbushnz]

Thanks FITZY...
As they say a picture says a thousand words.
I found them on the net a few years back when I was tring to fix my Warn Xd9000i. (Took it apart and lost my notes to get it back how it was) The agent in Auckland said it was better for them to rewire it as was difficult. All I saw was $ $$$
Not wanting to let that stop me, I trolled the net....Dam useful info out there.

Cheers
Calvin

[new2zukes]

When you test it. Take the main feed to the winch off and then as you test the switch you should be able to hear the different solenoids swtiching.
I also really reconmend a switch on the main power supply to the solenoids. A $40 BEP marine switch is more than adequate. Rated at 275amp continuos (30 mintues), 450 intermitent (5 mintues) and surge of about 1000amps (30 seconds) it more than copes with anything your power supply can produce.

is that just a marine isolator switch? as i have one of them sitting in the garage that i was guna use for winch when i got round to wiring. trying to get motor running before i get winch wired but at least i can test solonoids on the bench. thanks all for your input it was great to have good info