Powering Winch with AUX + Relay / Isolator

[EMBronco]

I have my winch set up this way and wired to aux switch #3. Others have given good reasons why they've done it, but I'll add another.

I was with a friend in his Jeep and he was winching a truck that had rolled down into a ravine. Something internally in his winch shorted and he could not shut it off. He even unplugged the controller and it didn't help. I ended up ripping the positive battery cable off the battery as it was sucking his jeep off the side of the ravine. Since then, I've always believed it was a good idea to have some type isolator for the winch. I just happen to use the aux switch, but as pointed out in prior responses there are other ways to do it.

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[vrtical]

I run a Stinger setup with the main positive power wire about 12" in length (short as possible) and have the negative to the battery. I have mine on Aux 2 as Aux 1 is taken up by OEM secondary lights on the braptor. Using an Aux switch to power the Stinger is the safest installation and operational solution. If you are worried about using up Aux switches, an isolated switch can be put anywhere.

 

[redone17]

What size wire are you guys running from AUX to Stinger? 12 AWG?

Is there any benefit to moving the control box off the winch itself outside of cleanup and/or space?

 

[orion]

I have my winch set up this way and wired to aux switch #3. Others have given good reasons why they've done it, but I'll add another.

I was with a friend in his Jeep and he was winching a truck that had rolled down into a ravine. Something internally in his winch shorted and he could not shut it off. He even unplugged the controller and it didn't help. I ended up ripping the positive battery cable off the battery as it was sucking his jeep off the side of the ravine. Since then, I've always believed it was a good idea to have some type isolator for the winch. I just happen to use the aux switch, but as pointed out in prior responses there are other ways to do it.

This too happened to me. I wonder if these isolators can fail in an on position and we still be screwed???

 

[Brian_B]

What size wire are you guys running from AUX to Stinger? 12 AWG?

Is there any benefit to moving the control box off the winch itself outside of cleanup and/or space?

I ran 16 and even at that it’s overkill - I just tend to default to 14 or 16 for most things since I have it around. The solenoid itself is much less than 1A to power. 12 wouldn’t hurt anything though if you did it

As far as relocating the winch solenoid pack - I guess it gets it out of the weather but they are supposed to be weatherized. Mostly I see it for people with tucked winches where the install space is really tight.

 

[EMBronco]

This too happened to me. I wonder if these isolators can fail in an on position and we still be screwed???

I’m sure it can, but it would take the isolator and the winch to fail. I guess if that happens, then it’s just not your day

 

[bastardsonofelvis]

Is this the diagram I should follow?

I’m dying to know where on your Bronco the outboard will be mounted. Too heavy for the swing gate!

 

[redone17]

I’m dying to know where on your Bronco the outboard will be mounted. Too heavy for the swing gate!

Wrong. I just installed the Turn Offroad HD Carrier.

 

[Alvrz]

Im installing mine today.
Im ordering the aux switch panel from Amazon and I'll be using probably switch #6.

 

[EMBronco]

Im installing mine today.
Im ordering the aux switch panel from Amazon and I'll be using probably switch #6.

That's exactly where I mounted my solenoid. It's like that bracket in front of the battery was made for it.

 

[redone17]

Alright. Parts ordered for Stinger. I am also going to hold off on the fuse for now. 12" cable and mounting in the same location as @Alvrz. Should be a safe solution. I like that Superwinch wiring is already protected with a heavy duty sheath.

 

[redone17]

@Brian_B & @Sloth - what size fuse did you use for the wire between the switch and the Stinger (assuming fuse should be as close to solenoid as possible)? Did you ground to the battery or body?

 

[Brian_B]

@Brian_B & @Sloth - what size fuse did you use for the wire between the switch and the Stinger (assuming fuse should be as close to solenoid as possible)? Did you ground to the battery or body?

Probably a 10A - I had an empty slot in my aftermarket upfitter relay box

The relay control draws very little power, so it’s just there in case the wire insulation gets nicked or something - so size to whatever size wire you use. In my case - #16, so 10A is ok. I could probably use any size from 500mA to 15A and be ok with that

My relay box grounds to body up by the cowl on the drives side - which is close to where I have the box mounted under the hood. The main winch power grounds straight to the battery though

 

[redone17]

Probably a 10A - I had an empty slot in my aftermarket upfitter relay box

The relay control draws very little power, so it’s just there in case the wire insulation gets nicked or something - so size to whatever size wire you use. In my case - #16, so 10A is ok. I could probably use any size from 500mA to 15A and be ok with that

My relay box grounds to body up by the cowl on the drives side - which is close to where I have the box mounted under the hood. The main winch power grounds straight to the battery though

Alright. I only had 12 awg laying around from my jon boat project. I know it’s overkill. Perhaps I’ll rewire it one day. So, I opted for 15a fuse. Just waiting on my 12” battery cable (1/0) which arrives tomorrow.

 

[Brian_B]

Alright. I only had 12 awg laying around from my jon boat project. I know it’s overkill. Perhaps I’ll rewire it one day. So, I opted for 15a fuse. Just waiting on my 12” battery cable (1/0) which arrives tomorrow.

No such thing as overkill

Fuse the wire not the load - so it passes the primary law of electrical

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