In-cab Winch Controller for Warn 9.5si

[jsmoriss]

I've seen a few write-ups for in-cab controllers, but not for the 9.5si. The Warn 9.5si is significantly different -- Warn sells a specific 9.5si controller with 6 pins, where-as I think the standard Warn controller is 5 pins. I tried to get some technical info from Warn, but they're un-willing to share _any_ technical info for fear that people will screw up their winch. I pushed hard and was able to get the following diagram of the controller:

http://public.mvlan.net/content/Jeep/Projects/In-cab 9.5si Winch Remote/Warn 9.5si 6 Wire Remote.pdf

Last week-end I popped the hood on the winch to check what kind of connections were available. Turns out there are none, as I expected.

I could use those little plastic taps w/ some silicone, but I don't really like them, and it's doubtful I could fit all 6 in there. So I decided to sacrifice the remote by cutting it off and using the plug and wire (a new remote should be here in 2-3 weeks). I'll leave the plug connected and run the wire to an in-cab panel. My (always handy) father-father-law has been giving me a hand, and we took the remote apart to double-check our wiring plan. No real surprise, except for a really heavy-handed splice on the blue (LED) wire. Just by touching the wire, it came apart. Considering that LED is supposed to signal error conditions, it's doubtful it would have worked. Here's a shot of the remote and the blue wire...

The odd thing is that splice on the blue wire seems to be standard on ALL the 9.5si remotes -- it's clearly shown in that PDF from Warn above. You can bet I'm going to test the new one I ordered with a multimeter and make sure that LED circuit is functional.

Next on the list is making the panel itself. I don't have much room left in my center console, so I'm getting rid of a cigarette lighter plug. It'll take some fancy work with the dremel to make something that fits around the existing buttons... I'll post a follow-up when I have the panel done.

js.

 

[cruiseroutfit]

The day I have been waiting for!

The 9.5ti uses the same 6 pin controller as the 9.5si, but for the life of me I havn't been able to fully understand the schematics and workings of the LED. I've already wired my winch for external controls, bringing just 4 wires to the cab as the 6 wires are not needed in their entirety as I can pull 12V & GRD from my dash and reduce the risk of accidental winch operation through a grounded or shorted wire.

You can read my issue here:
http://www.rockymountainextreme.com/showthread.php?t=54387

Can you take a closeup of the blue wire, specifically how it integrates into the resistor?

 

[R_Lefebvre]

Interesting. I also noticed the female spade connectors appear to be the "weatherproof" type which may have shrinkable jackets on the bottom, to seal to the wires. Only, they haven't been shrunk which is why they are flared out where the wires go in. Try heating them and see if they shrink down. If they are in fact non-shrunk shrinkable connectors... it doesn't say much for Warn's processes.

 

[jsmoriss]

...and reduce the risk of accidental winch operation through a grounded or shorted wire.

My plan is to use a switch (with solenoid and fuse) to power the winch. I'm still looking for an adequate solenoid. Cole Hersee makes a 225A continuous duty solenoid (#24812-01), but I can't find 'em in stock anywhere...

Can you take a closeup of the blue wire, specifically how it integrates into the resistor?

My father-in-law has the remote at the moment, but I can tell you the LED is connected across the 1N4007 diode (the resistor of 1000 ohms is there to drop the voltage by around 10 volts). The resistor is based on the rating of the LED.

js.

 

[jsmoriss]

My father-in-law has the remote at the moment, but I can tell you the LED is connected across a 1N4007 diode (the resistor of 1000 ohms is there to drop the voltage by around 10 volts). The resistor is based on the rating of the LED.

Kurt, keep in mind the 9.5ti and 9.5si remotes are NOT THE SAME, so although mine has a 1N4007 diode and 1000 ohms resistance, yours may not. Here's a list of Warn remotes:

http://www.warn.com/truck/accessories/remote_control.shtml

http://www.warn.com/truck/accessories/new_remote_control.shtml

For some reason, there does not seem to be a "new remote" for the 9.5si...

js.

 

[ntsqd]

Has anyone ever figured out why Warn is doing this? Isn't a simple, 4 wire switch good enough?

 

[cruiseroutfit]

Has anyone ever figured out why Warn is doing this? Isn't a simple, 4 wire switch good enough?

It is basically a 4 wire, 4 used to activate the actual solenoids and then a ground and overheat wire to function the LED. You can still use an older Warn controller on my 9.5ti, you just won't have the LED function on overheat.

 

[cruiseroutfit]

Kurt, keep in mind the 9.5ti and 9.5si remotes are NOT THE SAME, so although mine has a 1N4007 diode and 1000 ohms resistance, yours may not. Here's a list of Warn remotes:...

Not 100% sure on the diode spec, but it has the 1k resistance and the LED, I'm pretty sure the wiring diagrams are identical.

Here is the 9.5ti diagram:

Rather than hijack your thread, I'll start a new one asking for some help

 

[jsmoriss]

FYI - I finally finished installing that in-cab remote. I was waiting for a decent set of plugs. The first set we ordered didn't work out, so I finally ordered some sPod wiring harnesses.

http://expeditionportal.com/forum/showthread.php?t=12427&page=13

js.