Locked? Wiring up Rocker Switch in place of Oven Switch on Winch

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GoldenNugget
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2011/09/30 17:30:53 (permalink)

? Wiring up Rocker Switch in place of Oven Switch on Winch

I have an old 2000 lb Warn winch that has the Oven Style Switch as a controller... A buddy gave me a newer style Rocker Switch that mounts on the handle bars, I was wondering if you can wire the newer Rocker Switch up in place of the Oven Switch... If so, how... Thanks...

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06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
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    BridelessRacing
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/09/30 18:11:50 (permalink)
    Yes
    Through a reversing relay


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    GoldenNugget
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/09/30 18:18:43 (permalink)
    Where do I find a reversing relay and how much does it cost? I figured that I might have to get a Warn solenoid to hook it up..

    "SIZE MATTERS"
    06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
    12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
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    Jake450s
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/01 06:57:01 (permalink)
    What sort of handlebar switch?   Did you also get the contactor that goes with it?  Gonna need that.  Once you've got all the parts, then yes you can use most any winch switch for most any winch, provided that the capacity is large enough, which most are for the A2000/2500 series.
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    GoldenNugget
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/01 10:37:34 (permalink)
    I got the Warn Rocker Switch and I didn't get the contactor (assume your referring to the solenoid).. I figured that's what I was going to need also after I seen how small the wire was on the switch...
    There is 3 wires coming from the rocker switch, 2 plug into the solenoid from the looks of the connectors when I searched for a price of one ($90.00), where does the remaining wire go (I think it is red)...
     
    post edited by GoldenNugget - 2011/10/01 10:38:40

    "SIZE MATTERS"
    06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
    12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
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    Jake450s
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 11:29:16 (permalink)
    No, a solenoid is what the A2000 uses with the rotary switch, or some of the less expensive winches of the A2000's day used a big fat rocker switch with four big fat wires.  The solenoid uses two fat wires, and one or two skinny wires to disable the winch when the key is off.  A contactor is utilized with the mini-rocker switches.  That's the one with four fat wires and two skinny wires, and matches to the three wire type handlebar switch.  That's what you'll be needing to make the switch.
     
    FWIW, what the atv winch makers have labeled as a "solenoid" is a single pole, single throw solenoid, meaning it takes the two fat wires, and hooks them together when it's "ON", and separates them when it's "OFF".  A "contactor" is actually two individual and separate solenoids in one pack, both of which are double pole single throw.  That means in there is no "off" position, but rather at rest they activate one circuit, an when "ON" they activate a different circuit.  They're wired such that they apply battery negative (ground) to EVERYTHING when they're at rest.  When you move the rocker, it will select one or the other of those two individual solenoids within the case, that solenoid will "switch" and apply battery positive to it's associated wire, making a complete path for electricity to flow through the winch motor in the selected direction.
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    GoldenNugget
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 12:41:13 (permalink)
    Okay, I'm still not sure what I need to hook this winch up.. All I have is the Old style Warn 2000 lb and the newer style Rocker switch that mounts on the handle bars.. I think your saying that I need the contactor that has 4 stud bolt connections for the 2 large wires from the battery and 2 large wires to the winch, and it has 2 small plug connections for the Rocker switch... Is that right??? Isn't there another loose wire on the Rocker switch and where does it go?? 

    "SIZE MATTERS"
    06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
    12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
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    Jake450s
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 14:32:33 (permalink)
    Yes, that's what you're looking for.  The third wire on the mini-rocker switch goes to a key switched battery positive source, to provide the little "signal" to activate the solenoids which control the main winch power.
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    GoldenNugget
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 16:02:27 (permalink)
    Thanks for all the info and help...

    "SIZE MATTERS"
    06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
    12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
    GoldenNugget's Treasures
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    Jake450s
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 19:21:38 (permalink)
    When you get your parts rounded up, if the contactor doesn't have directions (which it might well not..... ) post back with a clear picture of it.  There's been several common styles, somebody will know how to hook it up.  The magic smoke comes out of them if it's not correct.  They are really just as simple to hitch up as your rotary switch, but you've gotta know where the wires go.
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    GoldenNugget
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    Re:? Wiring up Rocker Switch in place of Oven Switch on Winch 2011/10/02 19:53:14 (permalink)
    I actually think I have one in my shop that works, just have to find it... I think it is marked on the side of the post where the wires go with a + , - , input , output.. If not I will post a picture for some help.. I don't like the "smoke test" theory...

    "SIZE MATTERS"
    06' Honda Foreman 500 / 4x4 / HL 2" Lift / 25" Mud Lites / 3000 Warn Winch / Stick Stoppers / Extended Rear Rack 
    12' Honda Rancher 420 / 4x4 / Power Steering / 27" XTR's / SS112 Rims / 3000 Warn Winch / Extended Rear Rack
    GoldenNugget's Treasures
    #11
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