Installation Instructions for Rocker Switch Retrofit Kit P/N 2233B
Contents:
Description |
Qty |
Rocker Switch |
1 |
Switch Mounting Box |
1 |
Mounting Bracket and Hardware Kit |
1 |
1/4-inch Quick Disconnect terminal |
4 |
Split Loom Tubing |
2 |
Sealed Circuit Breaker |
1 |
Battery Connection Wire |
1 |
Terminal Boots |
2 |
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Note: This kit is designed specifically for Superwinch 2.5 inch motors.
Installation:
Disconnect the black and red switch power leads at the battery. Cut the red and black switch leads close to the strain relief at the switch. Strip each cut end 1/4-inch.
Crimp a quick disconnect terminal onto the stripped end of each switch lead. Remove the red or blue and black or yellow motor leads from the rear of the switch bracket. Cut off the ring terminals from each lead. Strip each cut end 1/4 inch. Crimp a quick disconnect terminal onto the stripped end of each motor lead. Remove and discard the old switch and bracket.
Refer to the figure for wiring diagram.
3 To Motor Blue
2 red to battery (+)
1 To Motor Yellow
4 black to battery (–)
3 To Motor Blue
2 red to battery (+)
1
3 2 |
1 To Motor Yellow |
4
! WARNING |
4 black to battery (–) |
Wire terminals must be properly installed on the switch. Improper installation will result in high resistance connections that could lead to excessive heat.
2 Red
+ BAT
4 Black
1 Yellow
3 Blue
TM
87-10928 Rev - 11/12/04
Hole pattern in switch box mounting bracket allows switch box mounting in any one of several positions and orientations. Always use both box combination head mounting screws provided. Punch out the appropriate two mounting holes in the switch box. Short and long extension links are provided to elevate the switch as needed. Do not use more than one link to mount the switch box mounting bracket to the round tube clamps.
! CAUTION
ALWAYS USE THE BOX MOUNTING BRACKET, TWO SCREWS AND LOCK NUTS
PROVIDED. Screw lengths are sized for correct penetration into the switch box. Excess penetration may result in short circuits that could lead to wire overheating.
To help protect your switch, winch, and vehicle electrical systems, a new sealed Duty-Safe® breaker has been included. This breaker replaces the metal can circuit breaker. Remove and discard the old metal can circuit breaker. Connect the smaller ring terminal on short red wire supplied in this kit to the +BAT terminal of the duty safe breaker. Connect the red wire from the switch removed from the old circuit breaker to the unmarked terminal on the duty safe breaker.
Two terminal boots are supplied with this kit to insulate the terminals on the duty safe breaker. After installing the boots over the wires, the boots can be secured to a non-metal part on the vehicle to hold the duty safe breaker in place. Insulated clips, wire ties or tape may be used.
Connect the black wire from the battery to switch terminal #4. Connect the black or yellow wire from the motor to switch terminal #1. Connect the red or blue wire from the motor to switch terminal #3. Connect the red wire from the unmarked terminal of the duty safe breaker to switch terminal #2.
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Be sure that wires do not come into contact with hot or |
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WARNING |
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sharp surfaces on the vehicle. |
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Insert each wire into the loom slots on the back of the switch box. Fasten the top lid of the switch box using the supplied self-tapping screws.
Two pieces of split loom tubing are provided. Bundle the two wires to the motor in one piece of tubing and the two wires to the battery in the other piece of tubing.
! WARNING
Be sure the switch mounting position does not impede the operation of the vehicle.
Before driving the vehicle, test the vehicle control system range of motion to ensure that switch wiring does not interfere with vehicle operation.
Reconnect the red and black leads to the battery.
SWITCH OPERATION
With the switch installed as described in the previous section, the legend on the rocker will indicate
winch drum rotation as shown below.
ROPE OUT
ROPE IN
When the switch is depressed in either direction, the winch activates. “ROPE IN” winds wire rope onto the winch drum. “ROPE OUT” powers wire rope off of the drum. The switch automatically returns to the neutral “OFF” position.
The switch assembly must be kept free of dirt and moisture to ensure safe operation.
In the “OFF” position, an electrical shunt provides dynamic braking action, which reduces the possibility of the winch coasting. Thus shunt reduces the action of a load backdriving the winch. However, a load can cause the winch to creep. Do not use the winch to hold loads in place. Use other means of securing loads such as tie down straps.
Always disconnect winch power leads to battery before working in or around the winch drum so that the winch cannot be turned on accidentally. A Quickconnect (Part No. 1551) is available as an accessory to disarm the winch.
Superwinch Inc., Winch Drive, Putnam, CT 06260 • 860-928-7787 • FAX: 860-963-0811
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