How to test an Aisin AI-1000 winch off the car?

[t00manyuserz]

Trying to verify if my Aisin winch rebuild worked well, but when I connect it to the car, it's not rotating. This happens:

1) With key in ACC, no power to the remote.
2) With ignition on (but engine off), Power light is barely on, nothing happens.
3) With engine on and revs high, power light is bright green, but when pressing IN/OUT it turns off and motor does not rotate.

Two questions:

1) First off, any ideas why this would be happening? Winch was working fine when I took it off a couple of months ago for restore/maintenance, so I don't think any of the solenoids failed. I checked the drum, it spins reasonably well with gear disengaged, and I don't think I forgot to plug anything in...
2) I want to bench test to see if I screwed something up. There is a white/yellow plug that goes to the main solenoid (I think). What do I hotwire that to to attempt to run this thing off a battery sitting on my floor?

Thanks!

 

[fjbj40]

Is the main relay energized and closed?

Trying to verify if my Aisin winch rebuild worked well, but when I connect it to the car, it's not rotating. This happens:

1) With key in ACC, no power to the remote.
2) With ignition on (but engine off), Power light is barely on, nothing happens.
3) With engine on and revs high, power light is bright green, but when pressing IN/OUT it turns off and motor does not rotate.

Two questions:

1) First off, any ideas why this would be happening? Winch was working fine when I took it off a couple of months ago for restore/maintenance, so I don't think any of the solenoids failed. I checked the drum, it spins reasonably well with gear disengaged, and I don't think I forgot to plug anything in...
2) I want to bench test to see if I screwed something up. There is a white/yellow plug that goes to the main solenoid (I think). What do I hotwire that to to attempt to run this thing off a battery sitting on my floor?

Thanks!

Is the main relay energized and closed?

It is what feeds power to the motor. The 2 solenoids Will be energized and click once the hand controller is plugged in, but if the main relay, called a magnet by Toyota, is not energized then the relays click and motor/spool will not turn.

The small 2 pin connector is what energized the magnet/relay.

Pay attention as that solenoid/relay/magnet easily seizes.

 

[t00manyuserz]

With the help of the most amazing @John Young , was able to debug it. Turns out that the ground was bad!

But for anyone ever looking to do this, what you need to do is bridge pin 1 of the solenoid connector (the middle one, the one that has nothing going to it if you are bench testing it) to the adjacent 12V lug to which you will attach the battery. This will activate the remote and then allow you to operate the winch on your bench.

Now I have a new problem... ATF leaks like a river from it. Originally I undertook this whole project because it dumped all the ATF on the floor of my garage, so I decided to take it apart and replace ALL the seals. I did that, loaded it up with ATF type F, and tested empty (with no rope) just to see how it's doing. Seemed OK, so I loaded up 100ft of synth rope... and as I finished, I realised I am sitting in a pool of ATF once again. The electric motor side appears to be leaking from the center of the drum.