Winch Wiring Questions: In-Cab + Handheld Setup

[RP80]

Hi there:
I have a Warn Zeon 10-S with the 5-pin connection. I'm trying to understand how to get this set up to use in-cab controls, as well as having a handheld port on the outsdie of the vehicle. I will be using a 500A Stinger Solenoid that will be switched by an Aux switch to power the whole winch setup. I've found the below diagram to get it set up, but it doesn't address the brown and black ground wires that need to be closed by plugging in a handheld. In the example below, wouldn't a handheld NEED to be plugged in to close that loop?

To note: The winch control pack is remotely-located under the hood.

Anyone do this?

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[Chrome_Pony]

No, in your diagram the momentary and power switches are tapping the internal wiring for direction before the remote plug. The other two might be powering indicator LEDs or something on the remote. I'm not sure what the dashed line is either.

That diagram is for an M8000, so verify that your Zeon wiring diagram matches. Winches aren't as universal as they used to be. They used to be momentary ON OFF ON, with each on being a direction for the motor.

 

[RP80]

No, in your diagram the momentary and power switches are tapping the internal wiring before the remote plug.

Oh, I think this makes sense. So the winch will "know" which to use whether its the handheld plugged into port, or in-cab switches powered on?

Now, I had planned to have an Aux switch-controlled 500A solenoid to turn on the entire winch system. Would I still need to have another "power" swith to turn on the in-cab controls (as indicated in that diagram above)?

That diagram is for an M8000, so verify that your Zeon wiring diagram matches. Winches aren't as universal as they used to be.

It does seem to be the same—this is the newer-style 5-pin that Warn has been using.

 

[Bikeric]

YES, you are still required to use the handheld controller.

The Stinger will only interrupt the big red battery cable going to the winch contactor box. Yes, you can use an AUX switch to energize the Stinger to close its internal contacts and make the winch capable of being used.

You still need the provided wired controller to plug into the box to perform any movement of the winch drum. Usually that handheld controller is long enough to reach into the cab through the window.

 

[Chrome_Pony]

Also, I thought about this setup and then just bought the wireless adapter.

Now my remote works inside and out, and if the batteries die, you just plug it in and it still works.

 

[RP80]

Also, I thought about this setup and then just bought the wireless adapter.

Now my remote works inside and out, and if the batteries die, you just plug it in and it still works.

Haha, this certainly seems like the simplest solution. There is a certain allure to a hard-mounted cab switch though...

 

[Chrome_Pony]

There is a certain allure to a hard-mounted cab switch though...

This is just the remnant Toyota in your bloodstream, it will pass.

 

[RP80]

The wireless solution certainly ticks the functionality desires, but given the amount of re-wiring I need to do, I'd like to figure out a proper hard-wired solution.

The winch control "in-out" switch might end up being a momentary-control set digital display—sPod or something.

 

[Fasteddy]

Hi, you should be able to just use a SPDT momentary toggle switch connected to the three blade connectors on the warn contactor to control the winch from inside...

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