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Old 01-10-2012, 09:42 PM
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Winch wiring help.

I am looking to add a power on/off switch to my winch in cab. I am looking for a wiring diagram that would allow me to add a solenoid to remotely shut off the winch via the cab so people can not short out the connections and drain my battery while I am at work. I work in downtown New Orleans so there is no telling what someone would do if they saw a winch. This is what I am thinking will work. Need to make sure before I blow something up.

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Old 01-10-2012, 09:47 PM   #2
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Originally Posted by xndrxw View Post
I am looking to add a power on/off switch to my winch in cab. I am looking for a wiring diagram that would allow me to add a solenoid to remotely shut off the winch via the cab so people can not short out the connections and drain my battery while I am at work. I work in downtown New Orleans so there is no telling what someone would do if they saw a winch. This is what I am thinking will work. Need to make sure before I blow something up.
I will start by saying I know little about wiring anything for that matter and hope I didn't get your hopes up with this reply...
but I wouldn't ground anything to the earth unless you don't plan on traveling very far (unless you have a large spool of wire in the back)

sorry for wasting your time

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Old 01-10-2012, 09:57 PM   #3
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Basically all you need to do is put a $8 switch in the power wire. All a switch does is break the circuit. Unplug the main power wire to the winch from the battery (make sure you have extra wire handy) and then you'll start to make connections. There should be either two or three prongs on the switch and follow the diagram on the switch. It really isn't difficult. Your main power wire off the winch will route all the way into your cab where the switch is, then another will run off the switch back to the battery. Then it's just a matter of grounding the switch which you may not even have to do if you don't get one with a light in it. Let me know if you need to clarify anything
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Old 01-10-2012, 10:33 PM   #4
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Originally Posted by jeepercowboy View Post
Basically all you need to do is put a $8 switch in the power wire. All a switch does is break the circuit. Unplug the main power wire to the winch from the battery (make sure you have extra wire handy) and then you'll start to make connections. There should be either two or three prongs on the switch and follow the diagram on the switch. It really isn't difficult. Your main power wire off the winch will route all the way into your cab where the switch is, then another will run off the switch back to the battery. Then it's just a matter of grounding the switch which you may not even have to do if you don't get one with a light in it. Let me know if you need to clarify anything

So are you suggesting he run the main winch cable through an $8 switch and then to the battery?

OP, you have it right with the solenoid but make sure you get solenoid that can handle the current the winch draws. If it was me, I'd probably just disconnect it at the battery when not in use.

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Old 01-10-2012, 10:35 PM   #5
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Originally Posted by Vinman

So are you suggesting he run the main winch cable through an $8 switch and then to the battery?

OP, you have it right with the solenoid but make sure you get solenoid that can handle the current the winch draws. If it was me, I'd probably just disconnect it at the battery when not in use.

Vince
Yes on second thought you probably have a point there. The winch will draw a lot of power to run through a dash switch. It may be possible with relays though.
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Old 01-10-2012, 10:41 PM
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Quote:
Originally Posted by jeepercowboy View Post
Basically all you need to do is put a $8 switch in the power wire. All a switch does is break the circuit. Unplug the main power wire to the winch from the battery (make sure you have extra wire handy) and then you'll start to make connections. There should be either two or three prongs on the switch and follow the diagram on the switch. It really isn't difficult. Your main power wire off the winch will route all the way into your cab where the switch is, then another will run off the switch back to the battery. Then it's just a matter of grounding the switch which you may not even have to do if you don't get one with a light in it. Let me know if you need to clarify anything
My original thought was to wire a switch in between the + from the battery and + to the winch but I would have to run 2 gauge wire into the cab and back out. I am trying to eliminate having to run that large of wire into the cab as much as possible. Also I would end up having to go with a pretty large switch in the cab. I was hoping to stick with the same style switch I currently have :
I know I could do this with a relay but I am not use to using any relay that can handle 200 to 300 amps. I normally use the standard 8617 automotive relays for lights and such. What I remember, at least I think I remember from my electrical class is relays are used for short term switching as solenoids are used for longer use. Are solenoids wired the same as relays?
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Old 01-10-2012, 10:43 PM
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Originally Posted by Vinman View Post
So are you suggesting he run the main winch cable through an $8 switch and then to the battery?

OP, you have it right with the solenoid but make sure you get solenoid that can handle the current the winch draws. If it was me, I'd probably just disconnect it at the battery when not in use.

Vince
I currently have it disconnected and plan to leave it disconnected until I go wheeling. The thing I am worried about is I will forget to plug the thing in when I go out one day and will end up with water up to my hood trying to find the plug.
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Old 01-10-2012, 10:46 PM   #8
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Quote:
Originally Posted by xndrxw

My original thought was to wire a switch in between the + from the battery and + to the winch but I would have to run 2 gauge wire into the cab and back out. I am trying to eliminate having to run that large of wire into the cab as much as possible. Also I would end up having to go with a pretty large switch in the cab. I was hoping to stick with the same style switch I currently have :
I know I could do this with a relay but I am not use to using any relay that can handle 200 to 300 amps. I normally use the standard 8617 automotive relays for lights and such. What I remember, at least I think I remember from my electrical class is relays are used for short term switching as solenoids are used for longer use. Are solenoids wired the same as relays?
Honestly I'm not sure, I've never used a solenoid directly. And with my lights I normally use just a fuse and no relays.
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Old 01-10-2012, 11:38 PM   #9
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You could run the cables in the cab and stall a switch like this: e-Series Battery Switches - PN - Blue Sea Systems

But I would still prefer to use a heavy duty constant duty solenoid.

Or, if you're electrically inclined, open the winch solenoid pack and cut the small power wire that feeds the controller plug (inside the winch solenoid cover or box) and extend the wires into the cab and install a switch.
However, the main 2Ga cable will still be hot at the winch.

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Old 01-10-2012, 11:41 PM   #10
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You can find a good write up on how to install an in-cab controller here; In-Cab Winch Remote Control - 1
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Old 01-10-2012, 11:45 PM   #11
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Why not just go to 12voltguy.com and buy the setup for around $50?
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Old 01-11-2012, 01:08 AM   #12
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Your idea looks good just remeber that it needs to be rated above the amp rating of the winch or it will burn up.
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Old 01-11-2012, 06:07 AM   #13
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Do not wire directly to switch.... Use a relay with appropriate amperage ( solenoid might work as well, but needs to be rated for the draw)
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Old 01-11-2012, 06:17 AM   #14
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What winch do you have? Alot of the winches come with a solenoid box and a wired remote. I just tapped into those controls and wired my own switches in cab. I have an on/off switch for the ground wire, and a temporary push button switch for in, and another for out.

If youre worried about someone messing with your power cables I would install a battery cut off switch between the battery and the winch. You can get them at marine places or maybe at your local auto parts store. It would be very easy to cut the power to the winch and also very easy to turn it back on.
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Old 01-11-2012, 08:30 AM
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Originally Posted by Wheel2Work View Post
You can find a good write up on how to install an in-cab controller here; In-Cab Winch Remote Control - 1

This pretty much what I want to do, except I want the switch to cut all power to the winch from under the hood. I did not see one on 12voltguy.com that would do this.

I also am wiring a second battery. I have been crawling the internet for the best way to do this. A lot of the kits seem to be overpriced. Apparently everyone has a completely different way on wiring up dual batteries.
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Old 01-11-2012, 09:00 AM   #16
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Just an FYI, the warn xd9000i draws around 460 amps at max load. I'm not sure about other winches, just that one because I was looking at the manual the other day. An $8 switch is typically rated at 30 amps, if that.

Just from a quick search, your going to be looking at something very expensive or I couldn't find something with a high enough rating.
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Old 01-11-2012, 09:15 AM   #17
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What you have is correct except the ground wire (-battery) has to go to another terminal on the solenoid if ther is one or if the solenoid is grounder through the mounting bolts your good to go. The only reason for the - to go to the switch is it has a pilot light in it.
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Old 01-11-2012, 09:27 AM
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This is what I was planning on using for my dual battery setup. http://www.amazon.com/PAC-PAC-500-50...6295185&sr=8-1
Will this also work for the winch? My winch says it peaks at 500 amps at max load. The ratting for this states : Handles 500 amps continuous and 700 amp surges.
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Old 01-11-2012, 01:29 PM   #19
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This is what I was planning on using for my dual battery setup. Amazon.com: PAC PAC-500 500-Amp Battery Isolator Relay: Automotive
Will this also work for the winch? My winch says it peaks at 500 amps at max load. The ratting for this states : Handles 500 amps continuous and 700 amp surges.
Yes. THIS will be fine

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