Winch solenoid problem

Razor J · 12-16-2006, 08:06 PM

I have a Warn 9.5 series winch. I have used it 2-3 times to clear trees out of the road, but no hard pulls. The other night, I was winching in and toggling the winch to take up the final slack on the line after hooking it to the bumper. It seemed tight but when I engaged the solenoid to feed some line back out, the winch motor would not run! I can hear the solenoid engaging but no motor action. I cranked the FJ engine to increase power output from the batt. Still nothing. It was late, so I gave up until the next day. I tried it again-first 2 attempts, nothing, then it started working normally.
What happened? It causes a momentary current arc when the solenoid closes. By "bumping" the switch, did I create a small weld in the switch that fused it open, then broke loose later? Is the solenoid faulty? Was there just a little grease on the new motor brushes that prevented conduction? This wasn't a big deal since I was just snugging the line to the bumper but, if I was needing to back off a tight line in an extraction and this happened, it could be a big deal. Anyone had this type of problem? I'll probably use it some more in non critical situations before swapping the solenoid pack. I have an All pro bumper and must pull it all off to inspect the solenoids. Any thoughts/advice appreciated.

sbechtold · 12-16-2006, 08:11 PM

How old is the winch? Did it ever get hot?

Razor J · 12-16-2006, 08:29 PM

Brand new. Never got hot. Just some easy move the log out of the road 2 times previously. I was bumping the switch to get the slack out as I tightened it at the bumper. I could see the bright flashes as the solenoids closed and arced each time I did this. Weird in that it is perfectly normal now. Since it is a new unit, I wondered if it might be a brush issue (stray grease on a brush). I did not try to spooling in anymore, since the line was tight on the bumper and I wanted to loosen it a bit. Seems normal now

20Montana · 12-16-2006, 08:54 PM

Call Warn and ask them. I reread your post. Doesn't sound right.

Razor J · 12-16-2006, 09:08 PM

Thanks, I'll call Warn. I'm just afraid they will say "send the unit in and we'll check it" That would be a PITA

Razor J · 12-16-2006, 09:17 PM

I just submitted this thread to Warn by e-mail. Will post their reply next week if they have profound info. Thanks all

***4RnrJ*** · 12-18-2006, 08:58 AM

Quote:

Razor J previously said:

I just submitted this thread to Warn by e-mail. Will post their reply next week if they have profound info. Thanks all

If the solenoid isn't an integrated one, you might just be able to send that back to them. In that case, it won't be as big a PITA!

Razor J · 12-18-2006, 12:14 PM

The solenoid is not intregated but on an All pro bumper, you have to remove the front skid, then take off the whole bumper to get to the solenoid box. A draw back of this set up, I guess. Still no word back from Warn. They will probably forward my e-mail around until after Christmas anyway

Razor J · 12-19-2006, 06:48 PM

O.K. the response from Warn came back tonight. The winch is well grounded back to the battery. I will check the ground from the solenoid pack to the motor-perhaps it is loose. I tried the winch again and works fine.
Heres what they said:

Gary,
The most common cause of intermittent solenoid issues is related to a bad ground to the control pack.
This could be from either grounding the wire from the control pack to the chassis instead of the motor or running the ground wire for the winch to the chassis instead of the negative of the battery.

Michael McEwen
Warn Industries Inc.
Technical Customer Service Representative

White Rim · 12-19-2006, 08:48 PM

there is momentary heating of the contacts of the solenoid when it is engaged, and arcing (which also causes heat) when it is disengaged. Engaging and disengaging it repeatedly can (like any switch except for maybe a mercury one) heat it up a lot more than continuous use, and could concievably burn it out.