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WINCH VEHICLE MOUNTING
- Disconnect the vehicle’s battery to prevent
electrical shock, fire or shorts.
-
WARNING:
When installing the winch ensure
you allow ample battery cable slack between the
bullbar and the front of the vehicle to allow for
movement between the body and chassis of the
vehicle.
- Reminder - rotate the gearbox to suit your
accessibility for your bullbar or mourning system
- Please ensure that the winch rope cannot rub on
any sharp edges inside the mounting area and the
winch rope and drum are free from any electrical
wiring.
CONTROL BOX
Familiarise yourself with the control box and understand where each cable terminates before installation. It
is recommended to bench test the winch and wiring before full installation. (see winch testing section)
- Before attaching the control box cables to the
motor ensure you thread on the rubber terminal
protectors to the appropriate coloured wires.
- Black cable with the blue tab connects to the blue
tab terminal on the motor
- Black cable with yellow tab connects to the yellow
tab terminal on the motor
- The short red cable connects to the red tab
terminal on the motor
-
IMPORTANT:
The thin black cable must connect
to the earth cable terminal on the winch motor. Do
not connect to the body of the vehicle or anywhere
else. This is essential for reliable solenoid
operation.
- The thick long black cable terminates between the
negative terminal of the vehicle’s battery and the
black terminal on the winch motor. Connect this
black cable to the winch motor only at this stage,
and do not connect to the battery. This cable must
be directly connected to the negative terminal
of the battery. DO NOT bunch on top of other
accessory wires.
- The long red cable from the control box connects
to the positive terminal of the vehicle battery; but
must be used with the supplied isolator switch.
When installing this cable ensure you use the
supplied conduit to prevent shorts/fire and allow
enough slack between winch and vehicle body to
deal with body mount movement on the chassis.
- Ensure you use two 13mm spanners to tighten the
terminals, if the top terminal nut is overtightened it
can turn the lug internally of the motor and crack
the internal motor terminals. This is an incorrect
installation and not covered under warranty.
- To prevent this from happening use two spanners
one on the bottom nut to only secure it and stop
it from rotating and one on the top nut to tighten.
Tighten to 14 NM of torque.
Note:
Only turn and tighten the top nut.
Note:
if you have located the control box in a
difficult to reach location for the operation of
the wired remote. You can purchase a wired
remote plug extension kit and situate it in a
more convenient location. Part number - CWA-
PLUGEXTKIT_V2
CONTROL BOX MOUNTING
- The control box has multiple ways of being
mounted, depending on the room available and
style of bullbar.
- Standard - in the middle over the winch drum
- Offset - above the winch motor ( better access to
the winch rope and drum area)
- Rear middle - behind the drum
- Offset rear - behind the motor
- Remote mounting - You can also mount the control
box in front of the radiator support area behind the
grill ( you are supplied additional nuts if you require
them for this style of mounting)
- On top of bullbar - You can also mount the control
box on top of the bullbar and attach it to the bullbar
simply by drilling holes on the top section of your
bullbar and securing it with bolts and nuts.
- Please ensure the control box is mounted securely
to the vehicle and the cables do not rub on the
vehicle surfaces and edges as this may cause a
short/fire.
CABLE ROUTING
When routing the cables ensure you do not bend the wires sharply around corners and ensure they do not
rub on any metal surfaces as this may cause a fire or short circuit.
- Please use the supplied conduit for the positive red
cable terminating to the positive side of the battery.
- It is the best practise to conduit all cables for a
better installation and secure them with cable ties
- Make sure you leave some slack in the cable
between the bullbar/chassis mounted terminated
wires and the body.This is due to the flexible rubber
body to chassis mounts.
- Once you have terminated all the wires and
secured them. Re-check that you have wired them
correctly.
- Your last step is to connect the red cable to the
positive terminal of the battery, make sure when
you are doing this, that the isolator switch is
connected but in the off position.
