Instructions for LED Installation

Parts in the kit:

2- Clear LED’s short leg is (-)

2- LED Holders use a 21/64ths drill for mounting holes

2- 330 Ohm ½ Watt Resistors 

3- 5/16ths Mounting Lugs for the solenoid

 

Other items you may need and not supplied:

18 gauge hookup wire red and black 2’ of each depending on your winch

Heat Shrink: Yellow and Green Dubro worked for me

Low Watt soldering Iron, electrical flux, and Rosin Core electrical solder

 

The typical winch situation is at the right.  The positive (long) leg of the LED always is towards POS battery terminal.  The LED negative (short leg) of the LED goes towards the motor terminal.  This assumes you have battery negative grounded to the winch frame.  The resistor can go on either leg of the LED but to keep it looking like the diagram put the resistor on positive leg of the first LED from battery positive terminal and on the negative leg of the second LED.  To test the LED once resistor is on the leg, you just put across 12 volts.  It will light if polarity is correct.  You will not hurt it if resistor is in place.

 

A special thanks to Andrew E. Mileski for his technical help and picture.

Assembly Order:

1-     Assemble LED into holder.  Remove the rubber stopper, and put the LED legs through the hole in the stopper.  Put the LED and stopper into holder from the threaded end.  Once seated well put a small pin between the stopper and wall of the holder put in a small drop of thin CA.

2-     I bend over the short negative leg slightly to remind me it is negative.  Working on the first LED closest to battery positive cut the negative leg down to about Ό”.  Solder a length of hookup wire to it (black).  Slip some green heat shrink (3/32”) over the wire and up to the base and shrink it with heat gun.  Working on the second LED closest to motor terminal, cut the positive leg down to Ό”.  Solder length of hookup wire (red).  Slip some green heat shrink over it and up to the base and shrink it. 

3-     If you are going to mount the LED holders on metal or wood plate now is the time.  Drill plate with a 21/64ths drill.  Slip the LED holder in the correct hole and tighten nut onto lock washer. 

4-     Shorten remaining leg of each LED to Ό”.  Solder resistor to it.  Solder the appropriate color hookup wire to it.  If you have heat shrink use your judgment as to whether you need it over the resistor.  I just put yellow (1-1/2”) over both wires up over the end of the holder and shrank it.  I gave each one drop thin CA at heat shrink to keep it on the holder as a strain relief.

5-     Check length of hookup wire and solder a 5/16” lug on the first LED from battery positive to the red wire.  Solder a lug to second LED nearest motor terminal to its black wire. Take the negative (black wire) from the first LED and the positive (red wire) of the second LED from battery positive and solder both to center lug.  Bolt all lugs to appropriate solenoid terminals as shown in the diagram above.  Lugs maybe crimped as well if you have the tool to do it.

6-     If all else fails, email me at:  calplsf@altelco.net  I would appreciate feedback and pictures.

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