Winch Permanent Power Installation Checklist¶

COMEUP SOLO 12.5rs with Egis XD Flex 2 Controller¶

Vehicle: 2006 Toyota Land Cruiser (J100) Winch: COMEUP SOLO 12.5rs (12,500 lb, synthetic rope) Controller: Egis XD Flex 2 Single (Relay) with Knob - 6P DTM Priority: 🔴 CRITICAL FOR JANUARY 24, 2025 OFFROAD TRIP Last Updated: 2025-12-28

⚠️ CRITICAL SAFETY REQUIREMENT¶

250A CIRCUIT BREAKER IS NON-NEGOTIABLE

Winch draws 300-400+ amps under heavy load
Without circuit breaker, a short circuit = fire or battery explosion
The breaker protects the cable, battery, and vehicle from catastrophic failure
DO NOT connect winch permanently without a proper circuit breaker

Parts & Materials Checklist¶

Must Purchase Before Installation:¶

250A Circuit Breaker (choose one):
Blue Sea Systems 7186 187 Series 250A (~$60) - RECOMMENDED
Stinger SGP90250 250A (~$35) - Budget option
18-20 AWG wire for control circuit (measure firewall to knob location + 3 ft extra)
Heat shrink tubing assortment (adhesive-lined)
Ring terminals for 2 AWG wire (if needed for breaker connections)
Cable ties (UV-resistant)
Dielectric grease

Already On Hand:¶

Egis XD Flex 2 relay pack and control knob
Winch-supplied power cable with 6-pin DTM connector
COMEUP SOLO 12.5rs winch (mounted on front bumper)
Firewall penetration point identified

Tools Needed:¶

Crimping tool (for ring terminals)
Wire strippers
Soldering iron and solder (recommended for critical connections)
Heat gun (for heat shrink)
Multimeter (for testing)
Drill and appropriate bits (for control knob mounting)
Wrenches/sockets (for battery terminals and breaker mounting)
Safety glasses

Estimated Cost: $50-80 (primarily the circuit breaker) Estimated Time: 3-4 hours

Pre-Installation Decisions¶

DECISION REQUIRED: Egis Control Knob Location (RFI-111)¶

Select ONE location and mark with ✅:

Option A: Dashboard Blank Panel
Pros: Factory appearance, easy reach, visible
Cons: May need drilling visible surface
Option B: Center Console
Pros: Easy reach, near other controls
Cons: May interfere with cup holders or storage
Option C: A-Pillar Mount ← RECOMMENDED FOR WINCH OPERATIONS
Pros: Very accessible while watching winch, easy to reach
Cons: Less "factory" appearance
Option D: Lower Dash (Knee Panel)
Pros: Out of way, no drilling visible surfaces
Cons: Less convenient to reach during winching

Selected Location: ___ (write in chosen location)

Installation Procedure¶

PHASE 1: Engine Bay - Circuit Breaker Installation¶

Location: Near primary battery (driver side, behind driver headlight)

Step 1: Disconnect Battery¶

Put on safety glasses
Disconnect primary battery NEGATIVE (-) terminal first
Disconnect primary battery POSITIVE (+) terminal second
Secure terminals away from battery posts
Wait 5 minutes for any residual current to dissipate

Step 2: Mount 250A Circuit Breaker¶

Identify mounting location as close to battery (+) terminal as possible
Clean mounting surface on inner fender or battery tray
Mount circuit breaker with stainless steel hardware
Verify breaker is accessible for manual reset
Verify breaker is in OFF/OPEN position
Label breaker: "WINCH MAIN POWER - 250A"

Step 3: Connect Battery to Circuit Breaker¶

Measure exact distance from battery (+) terminal to breaker input
Cut winch-supplied cable or 2 AWG wire to length (keep as short as possible)
Install ring terminal on battery end (crimp + solder + heat shrink)
Install ring terminal on breaker input end (crimp + solder + heat shrink)
Connect to breaker input terminal (finger tight for now)
DO NOT connect to battery yet - save for last step
Label wire: "PRIMARY BATTERY (+) TO BREAKER"

PHASE 2: Engine Bay - Egis Relay Pack Installation¶

Location: Near battery, behind driver headlight area

Step 4: Mount Egis Relay Pack¶

Identify mounting location on inner fender or frame rail
Verify 6-pin DTM connector from winch can reach relay pack
Verify control wire can route to firewall penetration
Clean and prep mounting surface
Mount Egis relay pack with vibration-resistant hardware (use lock washers)
Ensure relay pack is protected from direct water splash
Label relay pack: "EGIS WINCH RELAY"

Step 5: Wire Circuit Breaker to Egis Relay Pack¶

Measure distance from breaker output to Egis relay power INPUT terminal
Cut 2 AWG wire to length
Install ring terminals both ends (crimp + solder + heat shrink)
Connect to breaker OUTPUT terminal
Connect to Egis relay POWER INPUT terminal (check Egis manual for correct terminal)
Secure wire with cable ties (avoid sharp edges, heat sources, moving parts)
Label wire: "BREAKER TO EGIS RELAY"

Step 6: Ground Connection for Egis Relay¶

Decide on ground point:
Option A (Recommended): Direct to primary battery (-) terminal
Option B: Chassis ground bolt near battery (must clean to bare metal)
Measure distance from Egis relay GROUND terminal to selected ground point
Cut 2 AWG wire to length
Install ring terminals both ends (crimp + solder + heat shrink)
If using chassis ground: Remove paint/corrosion to expose bare metal
Connect to Egis relay GROUND terminal
DO NOT connect to ground point yet - save for later
Label wire: "EGIS RELAY GROUND"

Step 7: Connect Winch to Egis Relay¶

Route winch-supplied power cable from winch to Egis relay pack
Verify 6-pin DTM connector orientation (check for alignment pins)
Connect 6-pin DTM connector to Egis relay OUTPUT
Push connector firmly until you hear/feel the lock engage
Verify connector is fully seated and locked
Apply dielectric grease to DTM connector exterior
Secure cable with cable ties along routing path
Protect cable from sharp edges with split loom or edge guards
Label at relay pack: "TO WINCH MOTOR"

PHASE 3: Firewall Penetration - Control Wire Routing¶

Step 8: Route Control Wire Through Firewall¶

Measure wire length: Egis relay → firewall → control knob location + 3 feet extra
Cut 18-20 AWG wire to length (check Egis manual: may need 2-conductor or single)
Label engine bay end: "EGIS CONTROL - ENGINE BAY"
Label cab end: "EGIS CONTROL - CAB KNOB"
Route from Egis relay to identified firewall penetration point
Feed wire through existing firewall grommet
Seal penetration with silicone or RTV sealant
Secure wire in engine bay away from:
Heat sources (exhaust manifolds, turbo if equipped)
Moving parts (belts, pulleys, fan)
Sharp edges (use split loom protection)
Coil excess wire in engine bay and secure with cable ties

PHASE 4: Cab Installation - Control Knob Mounting¶

Step 9: Prepare Mounting Location¶

At selected location from Pre-Installation Decisions:

Verify access to backside for mounting
Mark exact center point for mounting hole
Check Egis manual for required hole diameter
Verify no obstructions behind mounting surface (wiring, HVAC ducts, etc.)
Measure control wire routing path from firewall to this location
Confirm wire length is sufficient

Step 10: Mount Control Knob¶

PHASE 5: Final Connections & Testing¶

Step 11: Connect All Power Connections (IN THIS ORDER)¶

CRITICAL: Follow this exact sequence to avoid sparks near battery

Verify all connections are tight (tug test on every terminal)
Verify circuit breaker is OPEN/OFF
Verify control knob is in center OFF position
Connect Egis relay ground wire to selected ground point
If battery (-): Attach to terminal with dielectric grease
If chassis: Attach to bolt, apply dielectric grease
Connect circuit breaker input wire to primary battery (+) terminal
Apply dielectric grease to terminal
Torque to manufacturer spec (typically 10-13 ft-lbs for battery terminal)
Connect primary battery (-) terminal ← LAST CONNECTION
Apply dielectric grease
Torque to spec

Step 12: Pre-Power Verification¶

BEFORE closing the circuit breaker:

Double-check all connections are tight
Verify 6-pin DTM connector fully seated at winch
Verify control knob is in OFF (center) position
Verify circuit breaker is still OPEN/OFF
Visual inspection: No bare wires, no wires touching sharp edges
No tools or metal objects near battery
Put on safety glasses

Step 13: Power-On Testing¶

Follow this sequence carefully:

Step 14: Functional Testing¶

Light Load Testing:

Electrical Verification:

Verify circuit breaker did NOT trip during operation
Using multimeter, check voltage at battery during winch operation
Should not drop below 11.5V during light winch operation
If drops below 11.0V: Possible high resistance connection or weak battery
Verify control knob OFF position stops winch immediately
Verify no power draw when knob is OFF (multimeter check)

Step 15: Post-Installation Tasks¶

Re-torque all electrical connections (vibration can loosen during initial use)
Apply dielectric grease to any connections that got warm
Verify all cable ties are secure
Verify no wires are touching hot or moving parts
Clean up any metal shavings or debris from drilling
Test wireless remote (if equipped) to verify it still functions
Verify Egis control knob and wireless remote don't conflict

Documentation & Final Verification¶

Step 16: Document Installation¶

Take photos of:
Circuit breaker installation and labeling
Egis relay pack installation
Control knob installation in cab
Wire routing paths (engine bay and cab)
All connection points
Update ELECTRICAL_CIRCUITS.md:
Change winch status from "⚠️ Needs permanent power" to "✅ Installed"
Update "Egis Control Knob Location" with actual location
Add circuit breaker details
Update this checklist with any deviations or notes

Safety Notes & Best Practices¶

During Installation:¶

Always disconnect battery negative first, reconnect negative last
Never connect battery until all other wiring is complete
Wear safety glasses when working with battery
Use proper crimping technique - crimp AND solder for critical connections
Apply dielectric grease to all electrical connections
Protect wiring from heat, sharp edges, and moving parts

During Use:¶

Never winch continuously for more than 60 seconds (motor overheat risk)
Allow 10 minutes cool-down between heavy winch operations
Keep hands clear of cable and hook during operation
Always use tree strap and winch damper for safety
Verify circuit breaker is accessible for emergency shutoff
Monitor battery voltage during extended winch operations
Inspect synthetic rope regularly for wear or damage

Emergency Procedures:¶

If winch doesn't stop: Flip circuit breaker to OFF immediately
If you smell smoke: Flip circuit breaker OFF, disconnect battery
If connections get hot: Stop winching, allow cooling, check for high resistance
If circuit breaker trips: Investigate cause before resetting (short circuit, overload?)

Troubleshooting¶

Winch doesn't operate:¶

Check circuit breaker is ON
Check control knob connection to Egis relay
Verify 12.6V at Egis relay power input
Check 6-pin DTM connector at winch is fully seated
Verify winch wireless remote is not interfering

Winch operates but is slow:¶

Check battery voltage under load (should be >11.5V)
Check for voltage drop across connections (high resistance)
Verify all ring terminals are tight
Check ground connection quality

Circuit breaker trips:¶

May indicate short circuit - inspect all wiring
May indicate overload - verify breaker is 250A
Check for damaged winch motor or cable

Control knob doesn't return to center:¶

Verify knob is not over-tightened on mounting nut
Check for interference with dashboard
Verify knob rotates freely before connecting wires

Completion Checklist¶

Before considering installation complete:¶

Installation completed by: _____

Date: _____

Egis control knob final location: _____

Circuit breaker model purchased: _____

Total installation time: _ hours

Issues encountered: (List any deviations from procedure)

Status: ✅ Installation Complete / ⚠️ In Progress / ❌ Not Started

Last Updated: 2025-12-28