This question is probably pretty basic, but I have no clue when it comes to electronics. Anyways, I want to install a toggle switch on my SuperWinch ATV2000 instead of installing the solenoid. Since the winch takes a maximum 118 Amps @ a 2000lb load, does this mean I have to have a switch that can handle 118 Amps? This seems awfully high, and the local auto parts store only carries switches up to 50 Amps.

Thanks.

 

Warn makes the switch you seek it is very heavy duty and available at most Warn Dealers but the not putting some sort of buffer in the system will only increase the risk of burning the stator in your charging system should and overload occur.

 

Go get a set of Ford Starter relays and you can hook a small 3 way toggle switch(on-off-on) up to them to control the motor. Connect the battery positive cable to one side of each solinoid then run the othere side one to each terminal on the winch. That will take the heavy load for the winch to wire the switch take a positve wire from the battery with a <u>in line fuse</u> to the center section on the switch now run one wire from each side of the switch to each of the solinoids and I think put it on the small post that is marked S and you will have it wired for about 20-30 bucks in supplies and you will have a small switch on your handlebars. Any questions just e-mail or PM me.

 

You want to run a solenoid to handle the heavy amp draw, however use a "constant duty" rated one, one for starter duty is rated "intermittent duty". Check your local auto parts store the can find one for you. Also search www.colehersee.com they make a complete line of electrical equipment. Make sure you use a fuse or better yet a auto reset breaker to protect the wiring.
Pullerguy

Just looked #'s up.
Cole Hersee constant duty 85amp rated, 24082 or 24106, both are double pole, single throw, DPST.
However use 2 each 24401-01 to make a wired remote switch, these are DPDT solenoids also rated 85 amp. By using either of these solenoids a standard toggle switch rated for 15 or 20 amps can be used.
Hope this helps.
Pullerguy

 

I thought the heavy duty ones where for more constant use I have seen them used any way.

 

I've got a Warn rocker switch that I bought and did not use I will sell or you can get a relay for a Warn 2500 winch and use a regular return to center double throw switch.

 

Here is a picture of my handlebar mounted winch switch. I am using the warn DPDT relay. My friend bought the warn DPDT relay that comes with the Warn A2500 kit, I think it cost him around $75. The relay, switch, and wiring are the only differences between the warn A2000 and A2500 winches (same motor, but more current = more winching force).

I think the Ford starter relays is a neat idea, don't know their rating. However, you would need 4 of them, since they are single pole, single throw, in order to get a dual pole, dual throw circuit out of them. When the toggle is pressed one way, it needs to energize 2 of them, one to provide 12v and the other for GND. When the toggle is pressed the other way (the other two relays disconnect) the other 2 relays provide the 12v and GND reversed so the winch motor goes backwards. The winch motor does not run with only 12v to one of the poles, the other pole must be grounded. If it was wired that way, the motor windings would have been much bigger, making the winch heavier.

 

I was thinking that the winch used the frame as ground there for you would only have to switch the positive from side to side. WHOOPS

 

The Cole Hersee solenoid #24401-01 is a DPDT solenoil so it would take 2 of these to switch directions of the winch, or any DC motor, the same as the Warn reversing relay. This give the option of installing a small toggle switch with SPDT momentary contact on the handle bars or with a small trailer plug make a cord to make a wired remote control.
Pullerguy