asutherland
VA7 HDT
Hi folks
After spending quite some time the other weekend, I decided to write up this quick how-to for others. First off, I don't know about the 24V Aisin winch, or the older Warn controllers... but by following the directions found at
forum.ih8mud.com
I went through many fuses trying to hook up my 12V Aisin winch and new style Warn controller.
I bought my new Warn controller and plug from Radd Cruisers in Duncan. It came as a kit for a very reasonable price. Thanks John, it works great!
In this controller, the wiring is as follows:
WARN controller wiring:
Red - POWER (source)
Brown - GND (ground to winch motor)
Black - GND (ground to exterior of motor, such as where the winch's main ground goes to. That's why the O ring on this lead is larger diameter)
White - Out Solenoid
Green - In Solenoid
AISIN 12V winch controller wiring:
White - POWER (source). - Only on when key is in ignition
Yellow w/White Stripe - power TO the relay / solenoid that provides the main power to the winch itself *See footnote below*
White w/Black Stripe - GND
Blue w/Red Stripe - In Solenoid (connect HIGH to start reeling in)
Blue w/White Stripe - Out Solenoid (connect HIGH to start reeling out)
Green - Temp. sensor, not used in the Warn remote. Just seal this one off and leave it disconnected
By using an ohm meter (in my DMM), I was able to identify that when you press the OUT button on the remote, Red and White have zero impedance. Meaning essentially they are connected. Then, when you press the IN button on the remote, Red and Green now are connected. Therefore, the Red is power in and White and Green were the outputs. Red and Brown and Red and Black never were connected, otherwise there would be a direct short (and you'll blow a fuse)
Speaking of fuses, FYI - the fuse the winch is hooked up through is a 7.5Amp fuse labelled "IGN" in the inside fuse panel, on an HDJ81 anyway.
* Confusion about the White vs. Yellow/White Strip leads on the Aisin 12V winch... The White is constant power, only while the key is in the ignition. This should help prevent someone from walking up and using your winch to pull your neighbours car through your yard. The Yellow is Power TO a relay/solenoid hidden in the engine bay. This relay/solenoid gives the winch it's MAIN power. So basically, to use the winch, you need your key in the ignition, and hook White to Yellow/White stripe. To keep the main power disconnected from the winch, I put in a simple toggle switch between White and Yellow/White Stripe and Red (on the Warn controller plug)
Step by Step
1. Remove the bumper. Take out the 4 bolts along the bottom, 1 in each side (near the tires) and possibly a couple along the top.
2. Remove the Aisin controller plug mount.
3. Disconnect the controller harness.
4. Try to unscrew the Aisin controller from the mount. 4 LITTLE rusty screws probably hold it on. I had to use some solvent and a pair of plyers to remove them.
5. Unscrew the back of the plug, and remove the protective wire covering. Cross your fingers and CUT all the wires, removing the Aisin controller plug completely. No going back now! WARNING: Please make sure you don't have the key in the ignition while doing this work! You could probably either pull the IGN fuse or disconnect the battery to be on the safe side.
6. Custom-fit your new Warn controller plug into the little plug mount. I drilled 2 holes through the plug mount and used the nuts/bolts that came with the Warn plug.
7. Using some crimps, unsheathe each of the wires except Green.
8. Put some heat shrink onto each of the wires, then solder or butt crimp each of the wires to their counterparts in the new Warn controller plug.
9 CHECK YOUR WORK. Put the key in the ignition, and try using the winch.
You can see the toggle switch I inserted here... later on, when I bought my Cruisin Off Road bumper, I moved the switch inside the cab and put it on the centre console.
10. Re-attach the plug mount and the bumper, step back and enjoy your work!
By the way, the VERY NEXT DAY we used the winch
After spending quite some time the other weekend, I decided to write up this quick how-to for others. First off, I don't know about the 24V Aisin winch, or the older Warn controllers... but by following the directions found at
AISIN AS-1000 24v winch wiring question ?
if anyone here could help with this question it would be much appreciated. thanks
forum.ih8mud.com
I went through many fuses trying to hook up my 12V Aisin winch and new style Warn controller.
I bought my new Warn controller and plug from Radd Cruisers in Duncan. It came as a kit for a very reasonable price. Thanks John, it works great!
In this controller, the wiring is as follows:
WARN controller wiring:
Red - POWER (source)
Brown - GND (ground to winch motor)
Black - GND (ground to exterior of motor, such as where the winch's main ground goes to. That's why the O ring on this lead is larger diameter)
White - Out Solenoid
Green - In Solenoid
AISIN 12V winch controller wiring:
White - POWER (source). - Only on when key is in ignition
Yellow w/White Stripe - power TO the relay / solenoid that provides the main power to the winch itself *See footnote below*
White w/Black Stripe - GND
Blue w/Red Stripe - In Solenoid (connect HIGH to start reeling in)
Blue w/White Stripe - Out Solenoid (connect HIGH to start reeling out)
Green - Temp. sensor, not used in the Warn remote. Just seal this one off and leave it disconnected
By using an ohm meter (in my DMM), I was able to identify that when you press the OUT button on the remote, Red and White have zero impedance. Meaning essentially they are connected. Then, when you press the IN button on the remote, Red and Green now are connected. Therefore, the Red is power in and White and Green were the outputs. Red and Brown and Red and Black never were connected, otherwise there would be a direct short (and you'll blow a fuse)
Speaking of fuses, FYI - the fuse the winch is hooked up through is a 7.5Amp fuse labelled "IGN" in the inside fuse panel, on an HDJ81 anyway.
* Confusion about the White vs. Yellow/White Strip leads on the Aisin 12V winch... The White is constant power, only while the key is in the ignition. This should help prevent someone from walking up and using your winch to pull your neighbours car through your yard. The Yellow is Power TO a relay/solenoid hidden in the engine bay. This relay/solenoid gives the winch it's MAIN power. So basically, to use the winch, you need your key in the ignition, and hook White to Yellow/White stripe. To keep the main power disconnected from the winch, I put in a simple toggle switch between White and Yellow/White Stripe and Red (on the Warn controller plug)
Step by Step
1. Remove the bumper. Take out the 4 bolts along the bottom, 1 in each side (near the tires) and possibly a couple along the top.
2. Remove the Aisin controller plug mount.
3. Disconnect the controller harness.
4. Try to unscrew the Aisin controller from the mount. 4 LITTLE rusty screws probably hold it on. I had to use some solvent and a pair of plyers to remove them.
5. Unscrew the back of the plug, and remove the protective wire covering. Cross your fingers and CUT all the wires, removing the Aisin controller plug completely. No going back now! WARNING: Please make sure you don't have the key in the ignition while doing this work! You could probably either pull the IGN fuse or disconnect the battery to be on the safe side.
6. Custom-fit your new Warn controller plug into the little plug mount. I drilled 2 holes through the plug mount and used the nuts/bolts that came with the Warn plug.
7. Using some crimps, unsheathe each of the wires except Green.
8. Put some heat shrink onto each of the wires, then solder or butt crimp each of the wires to their counterparts in the new Warn controller plug.
- Warn RED + Winch Yellow/White Stripe --> {optional toggle switch} --> Winch White
- Warn Brown --> Winch White/Black Stripe (GND)
- Warn Black --> Connect directly to GND on outside of Winch motor (ie. Chassis)
- Warn White --> Winch Blue w/White Stripe
- Warn Green --> Winch Blue w/Red Stripe
9 CHECK YOUR WORK. Put the key in the ignition, and try using the winch.
You can see the toggle switch I inserted here... later on, when I bought my Cruisin Off Road bumper, I moved the switch inside the cab and put it on the centre console.
10. Re-attach the plug mount and the bumper, step back and enjoy your work!
By the way, the VERY NEXT DAY we used the winch
Last edited:
. Just WOW. Great work.
