Solenoid overheating ?

[calcrc]

Hey there, so I got my dual batteries on the cheap done and I decided to switch the old Panasonic AUX battery with a deep cycle one for the winch. I have some questions regarding my setup.

I have hooked up the winch to the AUX battery first off, is it ok or should I connect everything on the main battery and have the second only as backup ?

Also when I did the switch I touched the solenoid and I found out that it was really hot I mean you could not keep your finger on it.

( Maybe because when I did the switch up I haven't disconnected the main battery and it made the solenoid overheat !? )

So any help on insight would be appreciated

Here are some pics after all was done.

 

[calcrc]

Please help me I have the Echling 3 way solenoid. I really need to fix this before tomorrow.

 

[nglayton]

A couple things..

I wouldn't use a wire nut to connect the wires from your fuse tap.
You should either use one continuous wire all the way to the solenoid or at least solder it together. One other thing I would say is use the same gauge wire all the way as well. You aren't gaining anything by increasing the gauge two inches from the fuse.


What is the amp rating for your solenoid? That one looks pretty small, I tried to google Echling 3 way solenoid and couldn't find one that looked the same. Do you have a link?

If it's, the 80a or 85a version and your alternator is 100a or 130a that will cause heat. (and possible failure)

 

[calcrc]

Yes sir it is a 80amp. Ok I will do as you suggested and weld it. Also I will buy a better Solenoid. Thank you man.