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BASIC INSTALLATION GUIDE/PROCESS
Please read all steps before attempting installation
1. Read this manual and fully comprehend the
seriousness of winch installation and use.
2. Check you have all listed components in your
box - refer to box parts list.
3. Check over the winch and components and
ensure all bolts are tightened to specification.
4. Test the operation of the winch - installation &
familiarisation
5. Gearbox and motor rotation if required
6. Install the winch into the vehicle mount
7. Install the winch into the vehicle
8. Installing the control box
9. Install the wiring harness
10. Check all wires and mounts
11. Pretensioning the winch rope
12. Winch operation and safety
NUT AND BOLT TORQUE SETTINGS
Bolt sizes below represent the head size or socket size required
Ensure you use a medium grade thread locker for all nuts and bolts
Do not tighten any bolts with an impact wrench.
Gearbox Housing
3mm allen head bolts
2.26 - 2.82Nm
Tie bars
6mm allen head bolts
15Nm
Winch to mounting cradle bolts
5/8th / 16mm hex head bolts
55Nm
Fairlead Mount bolts
10mm allen head
45Nm
Control box bracket to winch mount
4mm allen head bolts
2.26 - 2.82Nm
Motor end plate bolts
10mm hex head
4.5Nm
Motor terminal bolts
13mm hex head
15Nm
Winch rope to drum
Allen head Bolt
15Nm
WINCH TESTING & FAMILIARISATION
It is a good practise to test the winch and understand its operation prior to completely installing it
- Secure the winch to either a bench or a suitable
strong object (the winch cradle works well) so you
can safely test its operation.
CAUTION:
Do not test
the winch unless it’s secured or mounted, as the
winch rope can grab underneath and roll forwards
and cause injury or death. See winch mounting
instructions for details.
- For this test application, bolt the control box to the
top of the winch using the metal bracket and the
two already secured bolts on the top of the motor
side of the winch housing.
- Wire the control box to the winch as per wiring
diagram and instructions. See control box
mounting.
- Turn the winch clutch handle to freespool allowing
you to manually pull the rope out, then thread
approx 1 metre of the rope out
- Turn the clutch handle back to engage, this will
click in once the winch starts turning and operating.
You can manually engage the rotating ring gear
clutch by pulling firmly on the rope, a click will be
heard, this is the clutch pin engaging into the ring
gear.
- Ensure there are no wires or body parts near the
drum and rope area
- Connect a battery (that is not connected to the
vehicle) to the winch battery leads
- Black wire to negative - and red wire to positive
+ Ensure you wire in the isolator switch as well
for added precaution to enable you to turn off the
winch.
- Cycle the winch out and in, using both the wired
and wireless remote controls(press and hold both
buttons on the wireless remote to activate)
- Familiarise yourself with how the winch works and
operates prior to installation.
-
CAUTION:
please ensure all body parts are away
from the winch drum/rope area during this test and
familiarisation process.
Summary of Contents for CARBON WINCH
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