This document describes the installation and troubleshooting of a Universal Contactor/Relay and Mini Rocker Switch Kit (5600.3060) for a winch system. The kit is designed to provide control over a winch, allowing users to spool cable in and out.
Function Description
The Universal Contactor/Relay and Mini Rocker Switch Kit serves as the control interface for a winch system. It comprises a solenoid assembly, a rocker switch, and associated wiring. The solenoid acts as a relay, managing the power flow from the battery to the winch motor based on input from the rocker switch. The rocker switch provides a simple, intuitive way for the user to control the winch's direction of operation, either spooling cable "IN" or "OUT." This system is crucial for safely and effectively operating a winch, ensuring that the motor receives power only when commanded by the user. The design aims to integrate seamlessly with existing winch and vehicle setups, providing a robust and reliable control mechanism.
Usage Features
Cable Installation:
The manual provides detailed instructions for installing the winch cable. It emphasizes the importance of proper cable routing, specifically noting that the cable should feed from the bottom of the drum. Users are advised to unwind the new cable along the ground to prevent kinking and to observe how the old cable was attached before removal. To prevent fraying, the end of the new cable should be securely wrapped with tape before installation. The process involves pushing the cable through a small hole in the drum, forming a tight loop, and then reinserting the loop end into a slotted hole. The cable is then pulled back through the small hole. When winding the cable, it's recommended to apply a light load to maintain constant tension. A length of chain or a swivel block should be used to separate the cable hook and load, allowing the cable to swivel freely.
Rocker Switch Operation:
The mini rocker switch is the primary user interface for controlling the winch. Pressing the switch toward the "IN" position will spool the cable in, while pressing it toward the "OUT" position will spool the cable out. The switch is designed for easy mounting on ATV handlebars, typically on the left side, for convenient access during operation. The switch itself is clearly labeled "IN" and "OUT" to help users quickly identify the correct direction of cable spooling, which is important for protecting the winch from incorrect operation. The manual notes that the appearance of the rocker switch may vary from the provided picture, but its functionality remains the same.
Solenoid Installation:
The solenoid assembly, which is the heart of the control system, requires careful placement. It should be mounted in a protected and dry area, preferably on a flat surface. The manual guides users to use the solenoid assembly itself as a template to mark four 7/32" holes for mounting. The solenoid is then secured using four 25 mm long bolts, #10 flat washers, and #10 locknuts, tightened to a specific torque of 60 in-lb (7 Nm) to ensure a secure and stable installation.
Wiring Installation:
Before beginning the wiring process, several preparatory steps are outlined. These include installing the mounting kit and winch, turning off the vehicle ignition, disconnecting the negative battery cable, disengaging the winch clutch, and removing any necessary hood or cowling to access the installation area. Users are instructed to locate and mark the position for the solenoid assembly, ensuring that the chosen location allows for wiring connections without altering the pre-determined wire lengths. The manual also references an optional wireless remote control kit (part number 5600.3018) for those wishing to add wireless functionality.
The wiring diagram (Figure A) illustrates the connections between the battery, the solenoid, the winch motor, and the rocker switch. The solenoid has clearly marked terminals for the battery (RED and BLACK) and the winch motor (YELLOW COVER/BLACK LINE and BLUE COVER/RED LINE). The rocker switch connects to a dedicated port on the solenoid. Crucially, the manual includes two "CAUTION" warnings regarding wiring:
- If the winch motor runs in the wrong direction, users must reverse the yellow and blue wires or reverse the positive and negative motor cables. This ensures correct operation and prevents damage.
- Users are warned not to connect the negative battery cable or engage the clutch until the entire installation is complete. This is a critical safety measure, as the winch could unexpectedly begin spooling cable, leading to injury or damage.
Rocker Switch Wiring:
The rocker switch wiring involves assembling and positioning the switch mount on the handlebars, bolting the switch in place, and adjusting it for convenience. The wire from the rocker switch should be routed down the handlebars, ensuring sufficient clearance when the handlebars are turned fully left and right. The wire is then carefully routed to the solenoid and screwed into its matching connector. It is essential to ensure that the wires are not pulled taut against any surfaces that could damage them or come into contact with the exhaust system. Cable ties are provided to secure the wires and manage any excess length.
Solenoid Wiring to Winch and Battery:
The "Bear Claw™ Electronics Package" is pre-wired, meaning only connections to the winch motor and the battery are necessary. A critical caution is provided regarding the tightening of nuts on the terminal studs: they should be tightened to 35-40 in-lbs (3-4 Nm) torque, and users are warned not to over-tighten them.
The final check on connections involves color-coded cables:
- Connect the yellow-coded power cable to the corresponding terminal on the winch.
- Connect the green-coded power cable to the corresponding terminal on the winch.
- Connect the red-coded power cable to the positive battery terminal.
- Connect the black-coded power cable to the negative battery terminal.
After these connections, users must recheck cable routing to ensure no interference with moving parts or contact with hot surfaces. Supplied cable ties should be used to secure power cables for proper placement.
Finish Installation:
The final steps involve confirming that the winch clutch is disengaged, connecting the negative battery cable to the vehicle battery (using the Black Battery Lead to connect the winch and negative vehicle battery terminal), spooling out a few feet of cable by hand, and then engaging the winch clutch. A functional test is performed by pushing the rocker switch to "OUT" (winch should spool cable out) and then to "IN" (winch should reel cable in).
Maintenance Features
The manual includes a "Trouble Shooting" section that serves as a guide for diagnosing and resolving common issues, effectively acting as a maintenance feature. This section lists various conditions, their possible causes, and corresponding corrections, enabling users to maintain the optimal performance of their winch system.
Troubleshooting Guide:
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Motor runs extremely hot:
- Possible Cause: Prolonged Operation.
- Correction: Implement cooling-off periods to prevent overheating.
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Motor runs with insufficient power or low line speed:
- Possible Cause: Low Battery.
- Correction: Test for a faulty battery.
- Possible Cause: Bad Connection.
- Correction: Check the battery cable for corrosion, clean it, and apply grease.
- Possible Cause: Insufficient Charging System.
- Correction: Replace with a larger capacity charging system.
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Motor runs but drum does not turn:
- Possible Cause: Clutch not engaged.
- Correction: If the clutch is engaged while symptoms persist, it may be necessary to disassemble the winch to determine the cause and make appropriate repairs.
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Motor will not operate:
- Possible Cause: Defective or stuck solenoid.
- Correction: Jar the solenoid assembly to free contacts. Check the solenoid by applying 12 volts to the coil terminal (an audible click should be heard when energized).
- Possible Cause: Defective Rocker Switch.
- Correction: Replace the rocker switch.
- Possible Cause: Defective Motor.
- Correction: If the solenoids operate, check for voltage at the armature post; replace the motor.
- Possible Cause: Loose Connections.
- Correction: Check all electrical leads from the battery to the motor.
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Water Damage:
- Possible Cause: Submerged in water or high-pressure car wash.
- Correction: Drain and dry thoroughly. Run the motor without a load to drain and dry the windings.
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Winch runs in opposite direction of transmitter buttons:
- Possible Cause: Motor leads crossed.
- Correction: Reverse the electrical connections to the motor.
This comprehensive troubleshooting guide empowers users to identify and rectify common operational issues, extending the lifespan and reliability of the winch system by facilitating timely and appropriate maintenance actions.
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