Winch install: Project Overkill

[YBABRAT]

Sorry to make this thread in Blog fashion, but it's how I think, in not being distracted by too many questions at once. I placed details 1st as I go. Until I complete my Install then you will see how things are installed and function.

1st the basics.... I have two variants but only using one on this thread. It is the simplest to setup and requires no physical alterations to make the system work. All utilize a smart battery control module and heavy duty contactor / solenoid. Once everything is setup, you will have a fully protected cabling, charging system and battery, from winch malfunction, from various issues. A compromised winch power cable, crossed connections or shorted out motor.

Many will say what I am doing is not needed. Thus my thread heading Project Overkill.


This is my circuit that I will install...

I included an optional override switch in case the XY-CD63 should fail.

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[Deleted User 38384]

I feel if your winch isn't rated to pull at least 60,000 lbs, then you need to change the thread title!

 

[YBABRAT]

1st item the solenoid....

Yes it is over kill but being surplus old stock and made in the USA, with silver internal contacts instead of copper... I could not pass it up. There are others out there, yet I like thus style, due to the isolation between contacts. This ohmed out to a little over 8 ohms. Current is a wee bit over 2A. Very powerful on its throw. Unfortunately I will not be testing it's design effectiveness. Meaning it is not intended to switch on a live connection like a light switch. There are differences between closed contacts in a live circuit vs an open circuit. Live will provide the greatest chances of voltage arc at contact points. Contacts are not 100% effective until full closure. That is why this solenoid is used as a power enable before winch is activated.

You could probably scout a U-Pull-It and get a F250 Super Duty starter solenoid and do the same.

 

[Flip]

If you're using an on/off switch what is the purpose of the solenoid?

 

[YBABRAT]

2nd... The brains of the system.

I chose to show the XY-CD63 with a common light switch cover. Being plastic, one can cut, heat mold or even graft plastic material using plastic weld epoxy. I made an adapter plate that is hidden behind the light switch plate. I may obtain a stamped metal sheet switch cover and work with that as to trim down size. Another option is to remove the plastic housing and mount flush to the switch cover. It's all dependant on your own capabilities and creativity.

 

[YBABRAT]

If you're using an on/off switch what is the purpose of the solenoid?

No, just gave an option if the XY-CD63 fails. The circuit sort of shows where to jumper if no optional switch is used.

 

[Flip]

Mine came with a switch so I installed it. My previous winch (Badland) didn't come with one, never a problem but I've read in case the winch shorts out it's good to have so it doesn't drain the battery. Easy enough.

 

[Flip]

A marine fuse was also recommended. I thought that was a good idea.

 

[YBABRAT]

I was going to post the instruction sheet to the XY-CD63, but it is translated from Chinese. It's done OK, but can confuse some on operation. I will have to make an entry on the XY-CD63 setup. Once you go through the functions, the adjustment and operation will be fairly easy to remember. At the time of testing, I never bothered about making an instruction. There is a few videos from an English chap, but his videos can be... let's say I did better on my own.

 

[YBABRAT]

A marine fuse was also recommended. I thought that was a good idea.

This idea was for simple operation and millisecond response to protect from an unknown catastrophic issue. They are rare but as long as a charging system and battery are used together to provide maximum power to winch, your battery and charging system can be compromised. My circuit protects before damage can be done... if setup within safe limits.

 

[YBABRAT]

Mine came with a switch so I installed it. My previous winch (Badland) didn't come with one, never a problem but I've read in case the winch shorts out it's good to have so it doesn't drain the battery. Easy enough.

Understood with simplicity. Though I removed the need for manual interaction under hood.

 

[Deleted User 38384]

Mine came with a switch so I installed it. My previous winch (Badland) didn't come with one, never a problem but I've read in case the winch shorts out it's good to have so it doesn't drain the battery. Easy enough.

Understood with simplicity. Though I removed the need for manual interaction under hood.

I'm going to drill another hole in my hood this weekend and install an on off switch on the exterior of the Jeep.. it'll be the school heavy duty manual metal switch sitting on top of my hood. It should look pretty ridiculous, but it'll be functional

It's marine grade so it should hold up fine!

 

[YBABRAT]

So far the Orange and Pink wire is for Aux 3... partially installed the XY-CD63 battery controller to my console, right under the aux switches.

A little trimming and a few additional panels to cover open areas for fitment. Once fitting is done, a covering of fiberglass and final shaping before paint.

Tested function having shifter in park... no issues adjusting buttons.

Set aux 3 to function when ignition is on and reset when ignition is off. When Aux 3 is active the XY-CD63 is on and ready to winch, as long as voltage is set. You will need to adjust battery voltage depending on temprature and charging system operation.

The read out Is live readings.... all the Jeep features are delayed by CAN bus and ECU driving the charging parameters. ECU will show random pulses of voltage, but actual voltage at battery will be more steady.

 

[Flip]

So far the Orange and Pink wire is for Aux 3... partially installed the XY-CD63 battery controller to my console, right under the aux switches.

A little trimming and a few additional panels to cover open areas for fitment. Once fitting is done, a covering of fiberglass and final shaping before paint.

Tested function having shifter in park... no issues adjusting buttons.

Set aux 3 to function when ignition is on and reset when ignition is off. When Aux 3 is active the XY-CD63 is on and ready to winch, as long as voltage is set. You will need to adjust battery voltage depending on temprature and charging system operation.

The read out Is live readings.... all the Jeep features are delayed by CAN bus and ECU driving the charging parameters. ECU will show random pulses of voltage, but actual voltage at battery will be more steady.

Nice job, I thought it was stock at first glance.

 

[YBABRAT]

Solenoid install... very tight with this mofo. Have to flip it upside down and use a bracket to mount to the fender frame. Luckily there is ground studs near by for the ground terminal.

No obstruction nor open contacts to short the solenoid terminals.

After thinking about cabling... it may be worth moving cables for different battery case styles.

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