First use Guidelines

First use Guidelines - Carbon Offroad

1. Before installing your winch check the battery size in
your vehicle. Battery size must be 650cca or greater
to ensure proper and safe operation.
2. Before using your winch the winch rope must be
unspooled to the first layer on the drum and wound
back on under load. A good way to do this is to connect
to a tree with the car in neutral and apply the handbrake
slightly and winch in guiding the rope on neatly and
evenly. Failure to spool the winch rope on under load
before first use will risk damaging the rope and/or
crushing the winch drum tube.
3. Make sure all bolts and nuts are firmly secured but
not over tensioned on the winch including tiebar and
gearbox bolts.
4. Make sure the hammerlock pin is fully inserted into the hook
recess using the central retaining ring to keep it in place.
5. Make sure your winch control box black thin earth
wire is connected to the earth terminal on the electric
motor. This ensures a solid earth point for your solenoid
control. The thick earth cable from the motor MUST be
connected to the battery negative terminal. A chassis
connection is not sufficient.

6. Battery terminals which exhibit corrosion or buildup
are not suitable to be used as connection points for a
Carbon Winch. Replace with new terminals. Ensure
that the winch cables are connected directly to
the battery terminal, not bunched on top of other
accessory wiring
7. You should never winch more than 20-30 seconds
in one pull. The winch and your car battery need time
to recover and you should respect the duty cycle of
your winch and the health of your battery. Prolonged
winching can destroy your battery, winch motor and
8. If you can hear the winch struggling to pull your
vehicle on a single line pull, use a snatch block to
setup a double line pull to halve the effort. If the
winch still struggles, then you need to evaluate your
anchor placement and work on a better line for recovery.
Do not continue winching if you can see your vehicle is
not making progress during the recovery. Reassess what
you are doing and work out a better recovery setup.
9. The wireless remote controls have a fail safe device
installed, to operate the wireless remote you must
hold down both buttons until the red LED lights up. The
remote is now active. The remote will turn itself off after
a one minute thirty seconds to conserve battery.




They must have a basic level of inspection and maintenance completed to ensure reliability and longevity,
for your own safety and security.
Carbon Winches Australia have made every effort to
manufacture the winch to reduce the ingress of water, dirt and
dust into the working parts of the motor and gearbox. We have
gone to the extra effort of electroplating brush assemblies,
winch motor magnets and adding a motor breather kit. This
extends the corrosion resistance and life of the winch motor.
If your winch is exposed to full or partial immersion it is
advisable to winch out the rope fully and then winch in
fully to warm up the motor to disperse any moisture and
redistribute grease throughout the gearbox to protect the

gearsets, after the trip. This simple maintenance technique
will go a long way to protecting your winch, and will be all
you need to do to ensure that the winch motor internals are
dry at the end of a trip. You may decide to do this 2-3 times
just to be safe.
We also recommend a yearly maintenance routine to keep
your winch in good condition. These maintenance guidelines
are not required to be completed to maintain your warranty,
but are provided for your own information and guidance in
keeping your winch in good condition.

Maintenance Guidelines:
1. Free spool 20m of rope off the winch and power in
under load once a month to heat up the motor and
redistribute grease through the gearbox to displace any
condensation build up inside.
2. Remove, disassemble and clean all moving parts in the
gearbox and regrease lightly (do not pack) with quality
high pressure waterproof molybdenum grease at least
once every 12 months.
3. After returning from a trip where the winch has been
exposed to river crossings, mud, dirt or dust, Be sure
to free spool the rope out and power in under load to
displace any moisture or condensation inside the winch.
Wash the winch with a regular hose and plain water
to remove sitting mud, dirt or other debris from
the winch housing and the drum area. Do not use a
high pressure cleaner on your winch, you risk damaging
the sealing units under high pressure.
4. Check conditions of motor terminals and battery cables
for wear and tear every 3 months, install protective
conduit on wear points to reduce risk of short circuits.

5. Rope which is exposed to dirt, mud and grit will reduce
the life of the rope. After exposure, it is good practice
spool out the rope, wash with plain water, allow to dry
and then respool back on for longevity.
6. In general make sure you check, service and maintain
your winch for reliability and the confidence that
your winch will be there when you need it most.
7. To maintain your IP warranty we recommend to replace
the drum lip seals every 12 months. This is very easy to
do. Simply undo the bolts on the tiebars and remove the
gearbox from the drum. Slide the drum off the driveshaft
remove the seals on the motor side and the gearbox
side, replace with the new seals and reverse the process
to complete the seal replacement. Be careful to make
sure the driveshaft is correctly engaged with the brake
unit on the motor and with the small sun gear on the
gearbox side. The urethane drum bushings are also
keyed and need to be located in the correct position for
the assembly to bolt back in together.
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