Comeup Blazer M2 User manual

COMPETITION
WINCH

Competition Winch
1
I.Introduction
What’s in the wooden case:
The Blazer M2/M3 Competition Winch is designed and built for extreme performance and
reliability in different off-roading events. Blazer M2/M3 features a patented motor connecting
mechanism that allows external motor(s) be added to increase dynamic power.
The Blazer competition winch is available in two motor (M2) and three motor (M3) versions;
additionally, there are three different gear ratio sets allowing you to choose the best combination
of line speed and capacity to use in a specific competition.
Another breakthrough of Blazer M2/M3 is the brake system. Blazer M2/M3 is equipped with
dual braking systems: a mechanical ratchet brake in the gear box cover and air actuated brakes
at each motor. Blazer M2/M3 uses a patented Air Brake Release Mechanism. This system allows
the team to disable the air brake when there is any malfunction of the air system during competition,
yet still have mechanical brake to safely continue the event.
1. Blazer M2/M3 built to your specification.
2. Hawse Fairlead
3. Your Blazer M2/M3 Name Plate
4. Hook
5. Hardware for mounting the Blazer M2/M3
6. Hardware for mounting the hawse fairlead
7. 8mm wrench for air brake clutch adjustment.
8. Hand strap
9. Instruction Manual
10. Mounting bolt pattern template
How to mount the Blazer M2/M3
1. Mounting the Winch
(1) It is very important that the winch is installed on a
flat and solid mounting surface in order to make sure
the motor, drum and gearbox housing are aligned
correctly.
(2) Twelve (12) M12 x 1.75 pitch 12.9 grade with 137
N-m torque settings (maximum) high tensile steel
bolts must be used in order to sustain the loads
imposed on the winch mounting.

2
2 Fitting the Hawse Fairlead
(1) Hawse fairlead does not mount to the winch directly.
(2) The synthetic rope shall be wound in an under-wound orientation only.
(3) Two (2) M10 x 1.5 pitch 8.8 grade with 44 N-m torque settings high tensile steel bolts
must be used for fastening the hawse fairlead into the mounting channel.
II. Application Information
Rope
1.Blazer M2/M3 is designed to be operated using synthetic winch ropes (we do not
recommend the use of steel cables with this winch).
2.Blazer M2/M3 winch is designed to be used in the upright position and the rope should
be installed from under the drum. This is referred to as “Under wound”.
3.Blazer M2/M3 comes with 11mm x 46M synthetic rope as standard accessories.
Once the synthetic rope needs to be replaced, please follow the procedures below:
1. Synthetic Rope Replacement.
(1) Disengage the winch clutch, remove existing rope and replace the hawse fairlead if
necessary.
(2) Guide the new rope through the collar (Fig. 1) and tie a knot leaving a 20-25 cm
(8-10 in.) tail (Fig. 2 and 3).
(3) Cut the lateral side of the end by 45° and apply 3 wraps of electrical tape to hold cut
strands in place (Fig. 4).
(4) Tighten and wrap the synthetic rope around the drum (Fig. 5).
(5) A minimum of ten (10) wraps of synthetic rope around the drum is necessary to support
the rated load (Fig. 6 ).
1 2 3
4 5 6

3
Clutch Function
Operating the Blazer M2/M3
2. Tips for Rope care and use.
(1) Periodically check the rope for damage or wear.
(2) Abrasion can damage or weaken your synthetic rope, protect your rope from rubbing
against sharp objects or edges.
(3) An aluminum hawse fairlead is required (provided by factory) since it has no sharp
edges and resists damage better than a roller fairlead.
(4) Your synthetic rope clean and dry. To clean it after exposure to sand and mud, spool
out the rope, rinse it with clean water, and let it dry completely before re-spooling.
Blazer M2/M3 is fitted with an air clutch mechanism to allow driver control of the rope
free spool. The free spool function allows fast removal of the rope from the winch without
having to engage the motors. Some notes please follow when doing the free spool:
1.Connect air source to the PF-1/4”-19 fitting (see figure below.) The required air pressure
to disengage air clutch is 120psi (8.3 bar)
Once air pressure is applied to disengage the clutch, the drum is allowed to free spool.
2.Do not disengage the drum when winch is under load.
3.Release the air pressure to engage the drum. Do not attempt to pull a load until the air
clutch in the “Engaged” position.
4.Wear leather gloves and use a strap when guiding the synthetic rope on and off the drum.
Please read carefully before operating the winch
1.Blazer M2/M3 is a very powerful high-speed winch designed for competition use and
it is necessary that only experienced competitors operate the winch. Treat the Blazer
racing winch with extreme care and observe all cautions and warnings.
2.The winch capacity is rated at the first layer of synthetic rope on the drum for intermittent-periodic
duty.
3.The winch is not to be used to lift, support or otherwise transport personnel.
4.A minimum of ten (10) wraps of rope around the drum is necessary to support the rated
load.
5.Keep clear of winch, rope, hook, and fairlead while operating.
6.Synthetic rope can break without warning. Always keep a safe distance from the winch
and rope while under a load.

4
Electrical
7. Retain tension on the synthetic rope before winching. A sudden winching load can result
in broken synthetic rope as well as damage to the drum.
8. Failure to adequately align, support, or attach winch to a suitable mounting base could
result in a loss of efficiency of performance or damage the winch, rope and mounting
channel.
9. The Warranty will be invalid if the operating voltage is higher than 14.5V.
Blazer M2/M3 comes prewired and ready to use. You only need to connect the power
and ground cables to the battery and connect the control wiring properly.
(Please refer to the wiring diagram in this manual)
To maintain efficient and adequate power supply required to cope with the demands
the Blazer M2/M3 will place on it the vehicle electrical system please consider the following:
(1) The main ground connection for the winch motors must go to the batteries and not
to the frame of the vehicle.
(2) The ground connections for the air solenoid must not come from the winch motor
ground connection.
(3) The positive switching for the air solenoid must be from a battery not used for the winch.
(4) The recommended battery capacity shall be at least 950 CCA.
Lubricating oil is an essential part for the winch. All moving parts in the winch are
lubricated at the time of assembly, so it is unnecessary to add lubricating oil when using
the winch first time. The lubricating oil needs to be replaced only after total 5 operating
hours or the gear box been taken apart for maintenance.
Suggested grease: Shell GADUS S2 V220 0 lubricating
Viscosity (cSt): 220 mm2 / s at 40°C; 19 mm2 /s at 100°C
Amount: 1200cc
1. Dual Brakes
The new Blazer M2/M3 is equipped with dual braking systems: a mechanical ratchet
brake and air actuated motor brake systems. Both brake systems can offer sufficient brake
force under no load and full load circumstances.
The motor brake system requires minimum 120psi (8.3 bar) air pressure to operate.
Please ensure that this system is connected to an adequate air supply. The patented
Blazer M2/M3 air brake system can easily be overridden if there is a loss of air supply in
competition or the vehicle does not have on board air.
2. Durable Mechanical brake
The mechanical ratchet brake inside the gear box cover can safely hold the full winch
capacity load in the event that the air actuated motor brakes are overridden.
1. Setup
Lubrication
Dual Brake system: (Air Brake and Mechanical Brake)

5
III. Technical Data & Technical Support
Warning:
Before operation both air brake clutches of Blazer M2 need to be in the same engaged or
disengaged state.
Before operation all three air brake clutches of Blazer M3 need to be in the same engaged
or disengaged state
(Please refer to the figure below)
Engaged Disengaged
Technical Data:
1. Wiring Diagram
3. Disengage/ Engage air brake clutch (patented)
To disengage air brake clutch: use an 8mm allen wrench (provided with Blazer M2/M3)
turn clutch nut clockwise 180°To engage air brake clutch: turn the clutch nut counter-clockwise
180°back to original position.
Blazer M2 (Remote control)

6
Blazer M2 (Push button switch)
Blazer M3 (Remote control)

7
The winch is supplied with twin/triple 8.0 hp series wound motors and twin/triple contactor
kits each, please follow the following wiring guidelines.
(1) Use 2/0 AWG (America Wire Gauge for 67-75 mm2 in area) lead (red) from the contactors
kits to the positive (+) battery terminal.
(2) Use 2/0 AWG (America Wire Gauge for 67-75 mm2 in area) lead (black) from the
grounding terminal of the motor to the negative (-) battery terminal.
(3) Use thick copper busbar of F-1, F-2 and A of the motors to the contactors.
(4) Link red wire of twin contactor in parallel for “Cable Out” operation.
(5) Link black wire of twin contactor in parallel for “Cable In” operation.
(6) Link green wire of twin contactor in parallel for grounding.
(7) The recommended battery shall be 950 CCA minimum.
(8) Recommend the use of a 100 amp 12V plus alternator.
(9) Ensure air compressor is on and the winch has air pressure to it.
(10) Air hose diameter for air clutch and air solenoid is 6mm.
Blazer M3 (Push button switch)

8
2. Exploded-view drawing
Blazer M2
Ver:01
1
5
8
7
10
18
14
19
4
6
8
12
13
20
24
26
21
17
23
27
28
29
30
25
2
16
15
22
3
9
11

9
Item No.
Description
Part No.
Qty
1
Motor 12V
883790
2
2
Air brake kit
883791
2
3
1st shaft kit
883919
2
4
Gearbox support rack kit
883792
1
5
Transmission gear set
883920
1
6
1st gear kit A ( for 41.5:1)
883793
1
1st gear kit B ( for 33.6:1)
883794
1
1st gear kit C ( for 28:1)
883795
1
7
2nd gear kit A ( for 41.5:1)
883796
1
2nd gear kit B ( for 33.6:1)
883797
1
2nd gear kit C ( for 28:1)
883798
1
8
Ratchet stopper kit
883799
2
9
Transmitter shaft
883803
1
Transmitter shaft (for long drum)
883913
1
10
3rd gear kit
883800
1
11
Cover kit
883801
1
12
Air brake clutch kit A
883802
2
13
Drum kit
883804
1
Drum kit(for long drum)
883805
1
14
Gearbox support rack kit
883806
1
15
Tie bar kit
883807
1
Tie bar kit(for long drum)
883808
1
16
Tie bar kit A
883809
1
Tie bar kit A(for long drum)
883810
1
17
Tie bar kit
883811
1
Tie bar kit(for long drum)
883812
1
18
Clutch socket kit
882708
1
19
Air inlet cover kit
882712
1
20
Up cover kit
883813
1
21
Motor bracket kit
883815
1
22
Control pack 12V
883816
1
23
Air freespool control
883817
1
24
Grounding lead
882720
1
25
Mounting hardware
883818
1
26
Handsaver strap
880026
1
27
Synthetic rope
883240
1
28
Sling hook
882477
1
1
30
Pneumatic component kit
883911
1
1
Hawse fairlead
Hawse fairlead(for long drum)
883187
883789
29

10
Blazer M3
32
33
Ver:01
1
5
8
7
10
18
14
19
4
6
8
12
13
20
24
26
21
17
23
27
28
29
30
25
2
16
15
22
3
9
11
31

11
Item No.
Description
Part No.
Qty
1
Motor 12V
883790
3
2
Air brake kit
883791
3
3
1st shaft kit
883919
2
4
Gearbox support rack kit
883792
1
5
Transmission gear set
883920
1
6
1st gear kit A ( for 41.5:1)
883793
1
1st gear kit B ( for 33.6:1)
883794
1
1st gear kit C ( for 28:1)
883795
1
7
2nd gear kit A ( for 41.5:1)
883796
1
2nd gear kit B ( for 33.6:1)
883797
1
2nd gear kit C ( for 28:1)
883798
1
8
Ratchet stopper kit
883799
2
9
Transmitter shaft
883803
1
Transmitter shaft (for long drum)
883913
1
10
3rd gear kit
883800
1
11
Cover kit
883801
1
12
Air brake clutch kit A
883802
2
13
Drum kit
883804
1
Drum kit(for long drum)
883805
1
14
Gearbox support rack kit
883806
1
15
Tie bar kit
883807
1
Tie bar kit(for long drum)
883808
1
16
Tie bar kit A
883809
1
Tie bar kit A(for long drum)
883810
1
17
Tie bar kit
883811
1
Tie bar kit(for long drum)
883812
1
18
Clutch socket kit
882708
1
19
Air inlet cover kit
882712
1
20
Motor support rack kit
883814
1
21
Motor bracket kit
883815
1
22
Control pack 12V
883816
1
23
Air freespool control
883817
1
24
Grounding lead
882720
1
25
Mounting hardware
883818
1
26
Handsaver strap
880026
1
27
Synthetic rope
883240
1
28
Sling hook
882477
1
30
Pneumatic component kit
883912
1
31
Air brake clutch kit B
883819
1
32
M3 motor bracket kit
883820
1
33
Control pack (M3) 12V
883821
1
29 Hawse fairlead
Hawse fairlead(for long drum)
883187
883789
1
1

13
2. Upgrade Blazer M2 to Blazer M3
Step 1. Adding M3 motor kit to make Blazer M2 into Blazer M3
Step 2. Assemble motor support rack kit with air brake kit (a) and motor kit (b), then
remove hex Nuts and washers from the motor terminals (keep the nuts and
washers for Step 5). Figure (B)
Step 3. Remove M10 x 20L screw x 4pcs, and remove cover kit. Figure(C)
Step 4. Assemble M3 motor kit (Figure B) with Blazer M2, and fasten with
M10 x 30L screw x 4pcs. Figure (D)
Step 5. Install M3 motor bracket kit (a) by fastening with M6 x 15L screw x 2pcs (b),
and re-assemble the terminal hex nuts and washer removed from motor(c).
Then install M3 control pack (d) by fastening with M6 x 12L screw x 4pcs with
spring washer (e). Figure (E)
Step 6. Install power panel (f) to connect M2 and M3 control pack (+Ve). Figure (E)
Step 7. Connect air hose from pneumatic component kit (g) to the air brake of M3
motor kit. Figure (E)
For more detailed technical support, please contact Comeup Industries Inc:
[email protected]

VII. Maintenance Schedule
14
● Ensure that a responsible person carries out all inspections as per schedule.
● Inspections are dived into Daily, Monthly and Quarterly.
Classification of check
Item Checking method Checking reference
Daily
Periodical
Monthly
Quarterly
Installation
Loosening and
center run-out of
Checking of installing
bolts
Existence of
abnormalities
Remote
control
Working
Manual
Reasonable actuation
Wearing in contact
points
Visual
Free of wear or
damage
Synthetic
rope
Broken strands Visual, measuring
Two or more adjacent
strands are cut
Decrease in rope
diameter
Visual, measuring
25% of nominal
diameter max
Fused or melted
fibers
Visual
Existence of
abnormalities
Fastening condition
of end
Visual
Existence of
abnormalities
Clutch Working
Cycle through
engaged/disengaged
state
To be free from
remarkable wear and
damage
Motor Staining, damage
Decomposition
checking
Existence of
abnormalities
Mechanical
Brake
Wearing of brake
disc
Decomposition
checking
To be free from
remarkable wear and
damage
Performance
Visual
Reasonable actuation
Air Brake
Wearing of brake
disc
Decomposition
checking
To be free from
remarkable wear and
damage
Performance
Visual
Normal
Clutch Visual
2 or 3 sets are
engaged
Gear Damage, wearing Decomposition
checking
To be free from
remarkable wear and
damage
Low oil level
Visual
Replenish oil

Competition Winch
WARRANTY
15
Limited life time Warranty for Mechanical Components
Limited One (1) Year Warranty for Electrical Components
Comeup Industries Inc. (COMEUP) warrants to the original purchaser that the mechanical components
and electrical components of the Comeup Blazer will be free of defects in material and workmanship
for one (1) year. All Comeup mounting kits and other accessories carry one (1) year limited warranty
against defects in material workmanship.
This warranty applies only to the original purchaser of the winch. To obtain any warranty service,
the purchaser under this Limited Warranty is requested to advise COMEUP or its authorized distributors
on any claim. The purchaser must provide a copy of the purchase receipt bearing the winch serial number,
date of purchase, owners name, email or Tel & Fax, address and purchaser vehicle details. Any products
that COMEUP determines to be defective will be repaired or replaced or refunded at COMEUP’s sole
discretion without charge to buyer upon buyer’s compliance with these procedures. In the event of repair
or replacement, purchaser must send the defective winch or part, with freight prepaid, to COMEUP or
its authorized distributor. COMEUP will send the serviced product back to purchaser at COMEUP’s
expense. This warranty does not cover the removal or reinstallation of the winch.
COMEUP takes the responsibility for COMEUP winch parts and components to be free from defects
in materials and workmanship, but the following portions are hereby excluded and disclaimed. COMEUP
or its authorized distributors may make reasonable charges for parts and labour for repairs or resumption
in the following portions not covered by this limited warranty.
(1). All warranties of wire rope and synthetic rope assemblies after initial use
(2). All warranties of fitness for a particular purpose
(3). All warranties of the product’s finish
(4). All warranties of merchantability
The limited warranty does not cover any failure that results from improper installation/operation,
third party part substitution, purchaser’s alteration or modification of the COMEUP winch. This warranty
is void when COMEUP serial number plate is removed or defaced.
The warranty will be invalid if the operating voltage is higher than 14.5V.
COMEUP’s liability to the purchaser under the winch warranty for any loss or damage howsoever
and whatsoever arising shall not exceed the price of the initial winch purchase receipt. COMEUP
shall not in any event be liable to the purchaser for any consequential and/or indirect loss or damage
whether for loss or for profit or otherwise, costs, expenses or other claims for consequential compensation
whatsoever and whether caused by negligence of COMEUP employees, distributors and their employees
or otherwise. COMEUP reserves the right to change product design without notice. In situations in which
COMEUP has changed a product design, COMEUP shall have no obligation to upgrade or otherwise
modify previously manufactured products.
V. Warranty

NOTES
16

PN 883909 Ver:01
Specifications subject to change without notice
COMEUP INDUSTRIES INC.
No.139, Jieyukeng Rd., Ruifang Dist., New Taipei City 22453, Taiwan
TEL:[phone] FAX:[phone]
Email: [email protected]
http://www.comeupwinch.com