Warn HS9500I wiring

Can anyone provide me with a detailed wiring diagram for a Warn HS9500i
winch. I had the winch in at a local shop for repairs...... the shop
went out of business and I got everything back in pieces!

Solenoid diagram:
http://www.billhughes.com/temp/warnSolenoidsDiagram.jpg
Picture of wired solenoids:
http://www.billhughes.com/temp/warnSolenoids.jpg
Exploded view: http://www.billhughes.com/temp/WarnHS9500i.pdf
God Bless America, Bill O|||||||O


wrote:
>
> Can anyone provide me with a detailed wiring diagram for a Warn HS9500i
> winch. I had the winch in at a local shop for repairs...... the shop
> went out of business and I got everything back in pieces!

Thanks for the diagram.
I got it all wired up and all I get is "click" from the solenoids!
I removed the wiring and tested the motor for forward/ backward
rotation by connecting the battery and a jumper wire to A, F1 & F2
terminals..... all seems fine. Is this a faulty solenoid or something
along that line? I've made sure that all my connections are clean and
tight.
Any ideas?

,
wrote:
> Thanks for the diagram.
> I got it all wired up and all I get is "click" from the solenoids!
> I removed the wiring and tested the motor for forward/ backward
> rotation by connecting the battery and a jumper wire to A, F1 & F2
> terminals..... all seems fine. Is this a faulty solenoid or something
> along that line? I've made sure that all my connections are clean and
> tight.
> Any ideas?

What was it doing wrong before?

It does sound like the solenoid isn't passing power though.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

wrote:
>
> Thanks for the diagram.
> I got it all wired up and all I get is "click" from the solenoids!
> I removed the wiring and tested the motor for forward/ backward
> rotation by connecting the battery and a jumper wire to A, F1 & F2
> terminals..... all seems fine. Is this a faulty solenoid or something
> along that line? I've made sure that all my connections are clean and
> tight.
> Any ideas?

Initially, I took it into a shop that did some work on the motor, e.g.,
installed new brushes, etc. When I finally got it back it was all
disassembled except for the motor. I have since reassembled everything
and tested the motor for rotation, etc. Now it seems that I'm having a
problem with the solenoids or connections.

Mike Romain wrote:
> What was it doing wrong before?
>
> It does sound like the solenoid isn't passing power though.
>
> Mike
> 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> 88 Cherokee 235 BFG AT's
> Canadian Off Road Trips Photos: Non members can still view!
> Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> (More Off Road album links at bottom of the view page)
>
> wrote:
> >
> > Thanks for the diagram.
> > I got it all wired up and all I get is "click" from the solenoids!
> > I removed the wiring and tested the motor for forward/ backward
> > rotation by connecting the battery and a jumper wire to A, F1 & F2
> > terminals..... all seems fine. Is this a faulty solenoid or something
> > along that line? I've made sure that all my connections are clean and
> > tight.
> > Any ideas?

It'll do that if there is no direct ground connection to the battery and is
chassis grounded, but you're connecting directly to the battery, I assume.

> wrote in message
oups.com...
> Thanks for the diagram.
> I got it all wired up and all I get is "click" from the solenoids!
> I removed the wiring and tested the motor for forward/ backward
> rotation by connecting the battery and a jumper wire to A, F1 & F2
> terminals..... all seems fine. Is this a faulty solenoid or something
> along that line? I've made sure that all my connections are clean and
> tight.
> Any ideas?
>

Right now I've got it on a bench with a test battery nearby. I'm
running the ground cable from the battery to the winch mounting bracket
and grounding it that way. Is this perhaps the problem? Where should I
be running the ground cable to?

Matt Macchiarolo wrote:
> It'll do that if there is no direct ground connection to the battery and is
> chassis grounded, but you're connecting directly to the battery, I assume.
>
> > wrote in message
> oups.com...
> > Thanks for the diagram.
> > I got it all wired up and all I get is "click" from the solenoids!
> > I removed the wiring and tested the motor for forward/ backward
> > rotation by connecting the battery and a jumper wire to A, F1 & F2
> > terminals..... all seems fine. Is this a faulty solenoid or something
> > along that line? I've made sure that all my connections are clean and
> > tight.
> > Any ideas?
> >

Mike, as I've said, I had the motor taken apart by an electrical shop
and new brushes, etc. installed. I can't confirm what they actually did
in there but when I function test the motor via by-passing the
solenoids, it works in both directions.
Mike Romain wrote:
> Clicking normally means the solenoid is energizing, just the output has
> issues.
>
> Bad brushes can draw too much juice and arc out solenoid contacts. If
> your solenoids open up, they usually can be cleaned or the contact bolts
> actually flipped around to give a new surface. On some you can flip the
> main contact washer too.
>
> If you can't open them and have verified the output connections are
> clean, then you might have to replace one.
>
> I haven't had my warn HS9000i apart but if it's wired like Bill's
> diagram, then I would first suspect circuit C for dirty connections.
>
> Mike
>
> wrote:
> >
> > Initially, I took it into a shop that did some work on the motor, e.g.,
> > installed new brushes, etc. When I finally got it back it was all
> > disassembled except for the motor. I have since reassembled everything
> > and tested the motor for rotation, etc. Now it seems that I'm having a
> > problem with the solenoids or connections.
> >
> > Mike Romain wrote:
> > > What was it doing wrong before?
> > >
> > > It does sound like the solenoid isn't passing power though.
> > >
> > > Mike
> > > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> > > 88 Cherokee 235 BFG AT's
> > > Canadian Off Road Trips Photos: Non members can still view!
> > > Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> > > (More Off Road album links at bottom of the view page)
> > >
> > > wrote:
> > > >
> > > > Thanks for the diagram.
> > > > I got it all wired up and all I get is "click" from the solenoids!
> > > > I removed the wiring and tested the motor for forward/ backward
> > > > rotation by connecting the battery and a jumper wire to A, F1 & F2
> > > > terminals..... all seems fine. Is this a faulty solenoid or something
> > > > along that line? I've made sure that all my connections are clean and
> > > > tight.
> > > > Any ideas?

Clicking normally means the solenoid is energizing, just the output has
issues.

Bad brushes can draw too much juice and arc out solenoid contacts. If
your solenoids open up, they usually can be cleaned or the contact bolts
actually flipped around to give a new surface. On some you can flip the
main contact washer too.

If you can't open them and have verified the output connections are
clean, then you might have to replace one.

I haven't had my warn HS9000i apart but if it's wired like Bill's
diagram, then I would first suspect circuit C for dirty connections.

Mike

wrote:
>
> Initially, I took it into a shop that did some work on the motor, e.g.,
> installed new brushes, etc. When I finally got it back it was all
> disassembled except for the motor. I have since reassembled everything
> and tested the motor for rotation, etc. Now it seems that I'm having a
> problem with the solenoids or connections.
>
> Mike Romain wrote:
> > What was it doing wrong before?
> >
> > It does sound like the solenoid isn't passing power though.
> >
> > Mike
> > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> > 88 Cherokee 235 BFG AT's
> > Canadian Off Road Trips Photos: Non members can still view!
> > Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> > (More Off Road album links at bottom of the view page)
> >
> > wrote:
> > >
> > > Thanks for the diagram.
> > > I got it all wired up and all I get is "click" from the solenoids!
> > > I removed the wiring and tested the motor for forward/ backward
> > > rotation by connecting the battery and a jumper wire to A, F1 & F2
> > > terminals..... all seems fine. Is this a faulty solenoid or something
> > > along that line? I've made sure that all my connections are clean and
> > > tight.
> > > Any ideas?