CARBON OFFROAD CARBON WINCH User manual

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Thank you for purchasing your Carbon Offroad electric 4x4 vehicle recovery winch.
With proper care and preventative maintenance you will maintain a dependable service life
and safe operation from your winch.
Carbon Offroad reserves the right to continuously update, make changes and improvements
without notice. Please read the instructions carefully and fully understand how to install and
operate a winch safely before attempting to install the winch. Please ensure you operate your
winch safely in accordance with these instructions.
Note; Please keep these instructions in your vehicle at all times for reference. It is highly
recommended that you undertake an off-road winch training course from a reputable company
before using the winch. This manual is not intended as a substitute for completion of an
accredited winch training course.
TABLE OF CONTENTS :
Introduction & Box Contents 04
Warnings & Safety 05
Basic Installation Guide 06
Winch Testing 07
Winch Gearbox Rotation 08
Winch Mounting 11
Winch Vehicle Mounting 12
Control Box Mounting 13
Winch Rope Preparation 15
Please see the website for the most up to date product and warranty information
For spare parts and service call 1300 780 141 carbonoffroad.com.au
For hints and tips on
installation, visit our social
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channel for supporting
content to this manual

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BOX CONTENTS PARTS LIST
Please check contents before installation
1 x Carbon Winch
1 x Synthetic winch rope
1 x Winch fairlead
1 x Winch instructions manual
1 x Winch control box with attached motor wires
1 x Wireless winch remote control installed with 2 x
23A/A23 12 volt batteries
1 x Wired winch remote control
1 x Packet of mounting hardware
4 x Square head nuts
4 x 5/8th / 16mm hex head bolts
4 x Flat washers
4 x Spring washers
2 x Longer 5/8th / 16mm hex head bolts for
alternative fairlead mount
2 x Additional nuts for control box mounting
1 x 3mm Allen key
1 x 4mm Allen key
1 x 6mm Allen key
2 x Fairlead 10mm Allen head bolts, 2 x nuts, 2 x
washers, 2 x lock washers
1 x Stubby cooler
1 x Isolator switch Inc. fitting hardware
1 x Isolator short red wire to battery cable
1 x Winch hook
1 x Wireless remote carabiner lanyard
1 x Winch hook hand saver
1 x Plastic conduit main battery cable protector
1 x black negative battery cable
GENERAL SAFETY INFORMATION
Throughout this manual, you will find notations with the following headings:
DANGER: Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury. This
notation is also used to alert against
unsafe practices.
The following symbols on the product and in the Owner’s manual are used:
WINCH INSTALLATION SAFETY WARNINGS
Correct installation of your winch is a requirement for correct operation.
It is highly recommended that the Carbon Winch
is installed by a qualified or authorised technician
who understands the importance of the safety
requirements that come with the winch installation.
CAUTION: The winch is designed primarily for
intermittent use with a maximum of
30 sec continued use with a minimum
rest period of 30 seconds . This winch is
not designed to be used in industrial or
hoisting applications and Carbon Winch
does not warrant it to be suitable for
such use. This winch is not designed to
lift, hold or transport people.
Your winch is a very powerful machine, if used unsafely
or improperly, there is a possibility that property
damage, personal injury or death could result.
- Once you have unboxed your winch, please inspect
the winch and all hardware for any transport
damage or improper manufacturing.
- Do not install the winch if you find any broken or
damaged parts. Please contact your retailer or
place of purchase immediately for replacement
parts.
- Please ensure you are mounting the winch on a flat
even surface to ensure the motor and gearbox are
aligned correctly.
- Ensure you are attaching the winch to a winch
compatible bullbar, housing or product.
- The battery used to power the winch must have
a minimum rating of 650 CCA and be in good
working order.
This winch MUST be mounted with the rope running
in the direction indicated on the end plate, Improper
mounting could damage your winch and void your
warranty.

6 7
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.

8 9
WINCH GEARBOX ROTATION
In many cases of installation the winch clutch handle is not always accessible from the standard 12 o’clock position.
You can rotate the gearbox to locate the clutch handle to a better more accessible position. This is best done on a
bench with the winch not mounted to the vehicle.
CW-12K Gearbox Rotation
- Stand up the bare winch (without the control box
mounted) onto the motor end, secure the winch in
place so it does not fall over.
- With the supplied 6mm allen key, undo and remove
the tie bar bolts on the gear box side
(this has a handle on it)
- Lift up the gearbox and attached end plate away
from the drum and motor, there will be a shaft
attached to the centre of the gearbox so you must
lift up straight until it clears the drum.
- Place the gearbox on its bottom with the drive shaft
pointing upwards and you will see ten allen key
head bolts between where the drum and the winch
housing meet.
- Undo and remove these bolts
- You will now be able to rotate the gearbox to the
desired location.
- Do Not separate the end plate from the gearbox
housing, only turn the end plate.
- Once you have rotated the gearbox to the right
location, align the bolt holes and thread back all ten
bolts into position(finger tight) .
- Torque all ten bolts in a crosshatch star
configuration - tightening the opposites. This is to
correctly centralise the gearbox to the end plate
housing, if you fail to do this correctly the gear
box shaft will be misaligned. And will side load the
gears and cause premature failure.
- Ensure you torque the gearbox mounting bolts
to 2.26-2.82Nm of torque. and use a medium
threadlocker
- Remove the winch drum with the rope off the
motor winch end and thread over the drive shaft
centralising it into position ensuring it seats into the
bushings and seals correctly.Turn the drum while
seating into position.
- Once the drum is seated place the motor on top of
the drum verifying the location of the keyway at the
end of the driveshaft
- Turn the motor end of the winch until it drops into
the keyway on the drive shaft
- Realign the winch tie bars that you removed
previously and refit the bolts and tighten to 15 Nm
of torque and use a medium thread locker
- Check all bolts are tight and have been torqued to
specification
- Before installation check that the winch free spool
and motor operation works correctly without
any unfamiliar noises. See winch testing and
familiarisation
- If you hear any unfamiliar noises, repeat the steps
above to correctly centralise the gearbox.
Note: Do not use impact drivers as this may lead to
stripping of the threads
CW-XD Scout Pro Extreme Duty Winch
Gearbox rotation:
- Stand the winch on its motor end with the gearbox
uppermost
- Remove the 8 allen head machine screws holding
the clutch handle housing to the main gearbox
housing
- Give the clutch housing section a light tap to
release from the main housing piece, do not
separate from the main housing completely. Be
careful not to damage the sealing o-ring.
- Rotate the housing to put the clutch/free spool
handle in your desired position. DO NOT separate
the housing from the rest of the winch as the drive
shaft will separate from the primary drive gear
or motor drive. This can be quite fiddly to realign
and will require more in-depth disassembly of the
winch.
- During this process take care not to damage the
rubber sealing o-ring
- Replace machine screws and tighten in a star
pattern as you would wheel nuts.
- Torque bolts to 2.26-2.82Nm or 20-25in/lbs (inch
pounds NOT ft/lb)
- Check operation of handle and free spool
mechanism.
Note: Do not use impact drivers as this may lead to
stripping of the threads

10 11
WINCH MOTOR ROTATION
In some cases you may need to rotate the winch motor for access to the motor terminals
- Stand the winch up on its gearbox side and secure
appropriately so it doesn’t fall
- Mark the location of both the bolts in relation to
the winch end plate to make it easier to realign the
motor.
- Undo both of the winch motor end bolts with a
10mm socket and remove.
- Do not remove the end cap. If you accidentally
remove the end cap make sure the seal is aligned
correctly before putting it back together.
- You may need to gently tap the main housing to
release from the drum end plate. Gently rotate the
motor body 180 degrees to the other location
- Using your alignment marks to drop the bolts back
in, you may need to slightly turn the housing back
and forth while turning the bolts with your fingers
for realignment.
- Once both bolts have dropped into their threads,
finger tighten both bolts
- Then evenly tighten to 4.5Nm torque with a 10mm
socket
WINCH MOUNTING
Before mounting the winch ensure you have worked out the best accessible clutch handle location on the
gearbox as this is rotatable depending on bullbar/mount accessibility.
- Install mounting kit or structural support for winch
if not already fitted or included on the vehicle.
- Ensure the winch is mounted to a flat even surface
that is at least a minimum of 6.0mm thick and is
suitable for a winch mount using the supplied 4 x
square head nuts, bolts, washers and lock washers.
- These bolts must be tightened to 55 Nm of torque
and use medium grade thread locker.
- The winch must be mounted with the arrow on the
drum end plate facing forwards and the fairlead
rope must operate from an underwound orientation.
CAUTION: In some factory bullbars from Nissan
and Toyota it is mandated due to the position of
the winch in the cradle that the rope is exited off
the top of the drum to line up with the rope outlet
on the bar. In this case the winch will need to be
fitted with the arrow pointing back towards the
engine, the rope should then be fed back around
the back of the drum and over the top to exit the
winch in this manner. You must consult the OEM
winch cradle installation manual from your vehicle
manufacturer for confirmation. WARNING: Do
not unspool the rope and wind back on the other
way, this may cause damage and failure of the
automatic brake mechanism.
- Place the square nuts inside the winch feet slots on
the winch. (Pro tip - silicone the nuts into position
to prevent them from falling out when you are
mounting a winch to the plate)
- Thread the 4 x bolts with the flat and lock washers
provided into the nuts in the winch and tighten.
- Attach the fairlead to the mounting plate using
the supplied 2 bolts, nuts, flat and lock washers
provided and use a medium lock tight. Tighten to
45 Nm of torque
- The ends of the mounting bolts must not bottom
out in the winch body and must fully engage the
threads in the nuts. If this occurs add additional
washers to the bolt to prevent bottoming out.
- WARNING: Make sure there are no sharp edges
that can contact the winch rope during operation.
You must visually inspect the rope path from the
winch drum all the way through to the outlet of
the fairlead. On some bullbar models the fairlead
mounting holes are not centrally located to the rope
outlet, and you may find that when the fairlead
is mounted the rope will be touching the inside
edge of the steel rope outlet before it feeds onto
the fairlead. It is vital to ensure that the fairlead
position is such that no other component of the
bar will touch the rope from fully wound in to fully
wound out. You will note that the angle of rope
outlet off the drum changes as it is spooled in or
out, so check both extremes for clearance. The
rope will break under load if it is subjected to any
edge or component that is not the fairlead mount.
- Ensure the mounting surface for the winch is flat
for correct winch alignment and operation
Fairlead Style Mounting - In some applications it is
easier to install the fairlead into the same mounting
holes as the bottom of the winch. Use the 2 longer
mounting bolts supplied in the bolt kit for this purpose
to run through the fairlead, mounting plate and into
the winch mounting square nut mounts. Tighten to 55
Nm of torque and fasten with thread locker.
WARNING: Do not substitute any strength grade
weaker than ISO grade 8.8 bolts and nuts

12 13
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.

14 15
ISOLATOR SWITCH INSTALLATION
The isolator switch that is supplied with your winch is a very important part of the installation. It enables
you to turn the power off to the winch in an emergency situation and also isolates power to the winch when
you are not intending to use the winch. For good risk management always turn the isolator switch to the off
position when the winch is not in use
- This has many benefits such as preventing
electrical shorts and fire.
- You must install the isolator switch to maintain your
winch warranty.
- The switch must be located nearest to the battery
under the bonnet of the vehicle
- Do not mount the isolator switch close to the winch.
- The isolator switch comes with a short lead of wire,
this is connected to the Positive terminal of the
battery.
- Choose a location close to the battery you can use
a good quality double sided tape for mounting or
bolt/screw the switch to surrounding plastics or
engine bay avoiding heat sources.
- The isolator switch has 4 x knock outs so you can
easily configure the wires
- Ensure when tightening the nuts you do so with
two spanners this will prevent you from breaking
the terminals.
- Only turn and tighten the top nut, use the other
spanner to hold the lower nut in place.
WARNING: Batteries contain gases which are
flammable and explosive. Wear eye protection during
installation and remove all metal jewelry. Do not lean
over the battery while making connections.
WINCH HOOK CONNECTION
Once you have installed your winch you will need to connect the winch hook to the winch rope.
- Make sure you do this once the rope has been
threaded through the fairlead
- Simply pull through the fairlead approx 2 metres of
rope to make it easier.
- Remove the pin from the winch hook and slip the
clevis onto the winch rope thimble.
- Replace the winch hook pin threading it through
the rope thimble then secure with the supplied
split pin.
- Push the split pin through the hole at the end of the
pin and bend back onto itself using pliers.
- Make sure the pin cannot slip out.
- Alway use a new split pin if you are removing or
replacing the hook.
WINCH ROPE PREPARATION
When you receive your new winch, the rope has not as yet been pretensioned onto the drum. It has only been
wound onto the drum during the factory test procedure. Pretensioning the rope tightly winds it onto the drum
to prevent binding, or layers of rope cutting through to below layers.
- Spool out the winch rope from your installed winch
that’s attached to your vehicle until the warning
sheath appears ensuring you have 5 winds of rope
left on the spool.
- Attach the rope to a secured object, and slowly pull
the vehicle towards the fixed point using the winch.
Ensure you do this safely with a winch damper
blanket and rated recovery gear i.e tree trunk
protector.
- Ensure there is no one in front of the vehicle or
close by for safety reasons.
- Do not loop the winch rope back around on itself
and fasten with the winch hook, this will damage
the winch rope.
- From the safety of your vehicle operate the winch
with either your wireless or wired remote and wind
the winch in.
- Ensure you apply a small amount of resistance with
your brake to make the winch rope wind tightly
onto the drum or utilise a slight incline.
- Make sure the rope is evenly distributed across the
winch drum.
- Once you have spooled the rope in, ensure you
attach the hook to a recovery point on your vehicle
or secure it by pulling it up to the fairlead. For
safety keep your hands away from the fairlead area
while guiding the rope in and always hold the hand
saver strap do not hold the hook.
- Make sure you turn off the isolator switch once you
have completed this task.
- Now your winch is ready for recovery operation.
It is recommended that you attend an accredited
winch recovery course before operating your winch
in a recovery situation.

16 17
WINCH ROPE MAINTENANCE
To prolong the life of your winch rope a few simple maintenance procedures are needed to be followed.
- If your winch has been exposed to mud and
dirt simply remove the rope from the winch and
wash then rinse in plain water, do not use soap,
detergents or bleaches or chemicals as these will
weaken the synthetic rope.
- Exposing your winch rope to prolonged sunlight will
damage your rope as the UV light will break down
and weaken the fibres. Store your winch rope away
from direct UV light.
- If your winch rope has been exposed to salt water
make sure you rinse the rope thoroughly to remove
all traces of salt water.
- Inspect your winch rope regularly for cuts,
abrasions and fraying - Do not use the winch if
any damage has occurred and replace the rope
with a new one with the equivalent ratings and
specifications.
WINCH REMOTE CONTROL OPERATION
Your Carbon Winch is supplied with two types of remote controls to operate the winch, it is always best to
keep both in the vehicle in case of failure of one or the other. The winch wireless remote receiver comes
already installed into the control box, below is an images on how this is done.
Wireless Remote
- To turn on the wireless remote simply press and
hold both buttons for 2 seconds simultaneously,
this will activate the remote. You will notice a red
light flashing indicating that ITS TURNED ON.
- To turn off the remote power, simply press and hold
both buttons for 2 seconds simultaneously and the
light will rapidly flash then turn off.
- The remote will automatically turn off after 90
seconds of no use to save batteries and provide a
failsafe if placed back into storage with it still on.
Replacement of Batteries
- If the light doesn’t flash after holding down the two
buttons you will need to replace your batteries.
- Replacement batteries requires 2 x 23A or A23 12
volt batteries
- To replace the batteries simply use a small phillips
head screwdriver and remove the screws on the
back. You can now open up the remote and locate
the two batteries.
- Both batteries face upwards with both battery
Positives + facing upwards
Storage - WARNING:
- It is imperative that you store your remote in a safe
cool dry place in your vehicle
- Ensure you don’t not store it underneath items
as this may activate the remote and may start
winching. Further preventative measure is to
always turn your isolator switch to the off position
while not in use to prevent this from happening. In
some cases garage remotes can have the same
signal as the wireless remote and can operate the
winch without you knowing.
Wired Remote
- The wired remote comes with 3.7m lead, so you
can easily operate the winch from the driver’s seat.
- For safety do not stand in front of the vehicle and
operate the winch
- The wired remote cable simply plugs into the
control box, this will be either located on top of the
bullbar or behind it depending on your installation.
- Gently lift up the rubber insulator on the top of the
control box, you will see a socket
- Gently push the winch remote plug onto this socket
and turn it to the right to lock it in
- To remove, pull up the slide lever on the side of the
plug and turn it to the left then remove
- Replace the rubber insulator to prevent water
ingress
- If you have located the control box in a difficult
position you can purchase an extension plug
and mount it in a more convenient location. Part
number - CWA-PLUGEXTKIT_V2
- Always remove and store away the wired remote
control once you have finished winching

18 19
WINCH OPERATION
Winch Duty Cycles
The Carbon Winch is designed for intermittent
periodical use, as a rule of thumb you require a
winch with a maximum line pull of at least 1.5 times
greater than the combined vehicle mass including
towed items. You will also need to take into account
the surface/terrain you are winching on or in and the
incline as well.
Intermittent Duty
An electric winch is like any other motor driven power
tool such as an electric drill or saw. The electric
motor should not be allowed to become excessively
hot. Normal precautions will extend the life of your
motor. Keep the duration of pulls as short as possible
with a maximum of 30 sec continuous line pull, alway
allow the motor to cool down for a minimum of 30
seconds. If the end of the motor becomes
uncomfortably hot to touch, stop winching
and allow the motor to cool down.
The maximum working load capacity is on the
rope layer closest to the drum. DO NOT OVERLOAD.
DO NOT ATTEMPT PROLONGED PULLS AT HEAVY
LOADS. Overloading can damage the winch and/
or the synthetic rope and create unsafe operating
conditions. FOR LOADS OVER 1/2 RATED CAPACITY.
WE RECOMMEND THE USE OF A PULLEY BLOCK
TO DOUBLE LINE THE ROPE (Figure2). This reduces
the load on the winch and the strain on the rope by
approximately 50%. Attach hook to load bearing part.
The vehicle engine should be running
during winch operation. If considerable
winching is performed with the engine off, the battery
may be too weak to restart the engine.
FREESPOOL OPERATION
The clutch on this winch is a rotating ring gear style;
it has multiple holes that the pin from the clutch
handle drops into.
Rotate the clutch handle to the “Free” position as
shown in Figure 8. If there is a load on the rope, the
clutch handle may not pull out easily. Do not force the
clutch handle.
Release the tension on the clutch by pulling out some
of the synthetic rope.
Release the clutch and pull out the rope and secure
it to an anchor point or load. Check that there are
at least five (5) turns of rope left on the drum. Re-
engage the drum by returning the clutch handle to the
“Engaged” position. (See Figure 8).
CAUTION: The Clutch must be fully engaged before
winching. Never engage the clutch handle while the
drum is turning.
Figure 8
REMOTE CONTROL OPERATION
Both the wired and wireless remotes activate a
solenoid that supplies power to the winch motor.
To connect the wired controller, remove the cover on
the plug receptacle on the control box and insert the
plug end of the remote. Gently push it in and turn to
the right, when removing you will need to lift up the
latch on the side of the plug and turn to the left.
The switch trigger returns to the “Off” position when
released.
To change direction, move the toggle in the other
direction.
CAUTION: The switch assembly must be kept free of
dirt and moisture to ensure safe operation
CAUTION: To prevent unauthorised use of the winch,
remove remote control and store in a clean dry area
such as the glove box

20 21
WINCH USE BASIC STEPS
Below are the basic steps to winching please read and understand all safety instructions before winching. It
is strongly advised you attended an accredited winch and 4wd recovery course before attempting a recovery.
- Turn the winch clutch handle to free spool and pull
out the rope and hook.
- Connect the hook to a suitable mounting point with
the use of rated recovery gear.
- Use a winch damper blanket for additional safety
(as close to the hook as possible)
- Turn the winch clutch handle back to the engaged
position
- Turn the isolator switch to the on position
- Use either the wired or wireless remote controls to
operate the winch
- Make sure you operate the winch from the safety of
inside your vehicle and ensure others are well clear
from the winching area.
- Make sure your vehicle is running as the winch will
drain the battery very quickly
- Proceed safely to use the winch intermittently
ensuring you do not exceed the maximum 30 sec
on, min. 30sec off. If the winch motor is labouring
and becoming hot use a pulley block to half the
strain on the winch motor, rope and vehicle chassis.
- Make sure you use the winch hand saver when
winding the winch rope back onto the drum after
the recovery.
- Turn the isolator switch back to the off position for
safety.
WARNING: The rope may break before the winch
stalls. For heavy loads, use a pulley block to reduce
the load on the rope.
WINCHING TECHNIQUES AND SAFETY
After reading and understanding this manual, please learn to use your winch by attending an accredited 4wd winch
recovery course. After installing the winch, practice using it so you will be familiar with it when the need arises.
- DO NOT ‘move’ your vehicle to assist the winch
during a winch recovery. The combination of the
winch and vehicle pulling together could overload
the rope and the winch.
- Always stand clear of the rope, hook and winch.
In the unlikely event of any component failure, it’s
best to be out of harm’s way.
- Inspect the rope and equipment frequently, a
frayed synthetic rope with broken strands must be
replaced immediately.
- Always replace the rope with the identical
replacement parts. Periodically check the winch
installation to ensure that all bolts are tight, due to
vehicle vibrations.
- Use riggers gloves or equivalent when handling
rope. DO NOT LET THE SYNTHETIC ROPE SLIDE
THROUGH YOUR HANDS.
- Never use the winch with less than 5 turns of
synthetic rope on the drum as the rope end
fastener will not withstand the full load.
- For safety of you and others keep clear of the
winch, the rope/hook during operation.
- Never put your fingers through the hook. If your
fingers become trapped in the hook, you could lose
your finger. ALWAYS USE THE HANDSAVER when
guiding the synthetic rope in or out (See figure 3)
- Never obscure the winch warning instruction labels
- Always operate the winch with an unobstructed
view of the winching operation.
- Recovery equipment such as hooks, pulley blocks,
straps, etc. should be rated for the winching task
and be inspected for damage after every use.
- Never release the free spool clutch under load
- Never work on or around the winch drum area
while the winch is under operation or load
- Do not operate the winch while under the influence
of drugs, alcohol or medication.
- Always disconnect the winch battery leads
before working in or around the winch drum
area to prevent the winch from being turned on
accidentally.
- During a winch recovery, slowly take up the rope
slack until it becomes taut. Stop, recheck all
winching connections. Be sure the hook is properly
seated. If a Winch extension or Tree strap is used,
check the attachment to the anchor point.
- When using your winch to recover another vehicle,
place the vehicle transmission into neutral, set the
vehicle brake, and chock all wheels.
- Do not use the winch to hold loads in place. Use
other means of securing loads such as rated tie
down straps.
- Use only the supplied switches, remotes and
accessories. The use of non-factory approved
components may cause injury or property damage
and could void your warranty.
- WARNING: Do not machine, weld or modify any
part of the winch. Such alterations will weaken the
structural integrity of the winch and will void your
warranty.
- DANGER: Do not connect the winch to A/C current
240V (mains power) This is an automotive 12 or 24
volt winch dependent on which type you purchased
- Electrical shock or death and motor burnout will
occur.
- DANGER: Never allow shock loads to be applied to
the winch or the rope.
WARNING: Use caution when pulling or lowering a
vehicle up and down a ramp or incline. Keep people,
pets and property clear of the path of the load and
also in the winch area danger zone between the
anchor point and the vehicle.
DANGER: Never use your winch for lifting or moving
people.
DANGER: Your winch is not intended for overhead
hoisting operations.

22 23
Figure 3
Warning - Alway use the hand saver to guide the
rope back into the fairlead
Single Line or Double Line Pull
During winching operation the winch begins to
struggle due to incline, vehicle weight or terrain
(mud).Use a double line pull to assist the winch with
a pulley block that halves the load on the winch, rope
and vehicle chassis.Figure 2
Winch Hook Use
Never attach the hook back onto itself as you could
damage the synthetic rope. Use a Tree Trunk protector
strap instead. (Figure 4)
When operating the winch you must use a winch
damper blanket or jacket over the rope nearest to the
hook end when operating the winch(Figure 5). If a rope
failure should occur, the winch blanket will act as a
damper and help prevent the rope from whipping back
towards you causing injury or death. Specific damper
blankets can be purchased see website for details.
Figure 5
Avoid continuous pulls from extreme angles as this
will cause the rope to bind up on one end of the
drum (Figure 6). This can jam the rope in the winch,
causing damage to the rope or the winch.
Figure 6
WARNING: The responsibility for safe installation and
operation of the winch and prevention of personal
injury and property damage ultimately rests with you,
the installer and operator. There is no substitute for
the use of good judgment and caution in operating
a winch.
MAINTENANCE SCHEDULE
Please carry out all inspections listed below on the schedule and inspections, they are divided into before
every use, monthly and 3 monthly. Clean all connections as corrosion on electrical connections will reduce
performance or may cause a short.
Classification of check
Item Checking method Checking reference
Before
every
use
Periodical
One
month
Three
month
* Complete winch Operate the winch in
and out
Minimise corrosion
of the internal motor
components
* Installation Mounting bolts &
alignment Bolts tension & wear Tightened and aligned
*Remote
control
Working Manual Reasonable actuation
*Wearing in
contact points Visual Free of wear or damage
*
Rope
Broken strands Visual, measuring
(Monthly) Less than 10%
* * Decrease in rope
diameter
Visual, measuring
(Monthly)
7% of nominal
Diameter max
*
Deforming or corrosion
and fastening condition
of end
Visual No existence of
abnormalities
* Freespool Wear in spring Visual evidence of wear Free of wear or damage
* Motor Visual damage Visual evidence of wear No existence of
abnormalities
*
Brake
* * Performance check operation on an
incline engaged no slip
* Gearbox Damage wearing Visual / operational
evidence of wear
Free of wear or damage
and distortion
For hints and tips on
installation, visit our social
channels and Youtube
channel for supporting
content to this manual
For the most up to date
product and warranty
information please visit
the website.
For any service or warranty
claims please contact your
place of purchase.

24 25
CARBON WINCH K SERIES (CW-12K)
PARTS LIST & ASSEMBLY DIAGRAM
Part Description Quantity
1 Motor assy 1
2 Motor bracket 1
3 Braking assy 1
4 Bushing 2
5 Rubber seal 2
6 Drum 1
7 Tie rod 2
8 Drive shaft 1
9 Gearbox bracket 1
10 Gearbox seal 1
11 3rd ring gear 1
12 3rd stage carrier 1
13 2nd stage carrier 1
14 1st stage carrier 1
15 1st and 2nd ring gear 1
16 Sun gear 1
Part Description Quantity
17 Bearing 1
18 Gearbox house 1
19 Clutch assy 1
20 Wireless 1
21 Remote control 1
22 Rope 1
23 Hook 1
24 Strap 1
25 Alum.Fairlead 1
26 Pad 1
27 Connect plate 1
28 Bottom plate 1
29 solenoid 1
30 Control box 1
31 Rubber cover 1
CARBON WINCH SCOUT PRO EXTREME DUTY SERIES
(CW-XD12, CW-XD15)
PARTS LIST & ASSEMBLY DIAGRAM
Part Description Quantity
1 Motor assy 1
2 Motor bracket 1
3 Braking assy 1
4 Bushing 2
5 Rubber seal 2
6 Drum 1
7 Tie rod 2
8 Drive shaft 1
9 Gearbox bracket 1
10 Gearbox seal 1
11 3rd ring gear 1
12 3rd stage carrier 1
13 2nd stage carrier 1
14 1st stage carrier 1
15 2nd ring gear 1
16 Sun gear 1
Part Description Quantity
17 Bearing 1
18 Clutch assy 1
19 Gearbox housing 1
20 Wireless remote 1
21 Wired Remote 1
22 Rope 1
23 Hook 1
24 Strap 1
25 Alum. fairlead 1
26 Pad 1
27 Connect plate 1
28 Bottom plate 1
29 solenoid 1
30 Control box 1
31 Rubber cover 1

For premium recovery gear, suspension
and other 4x4 accessories please visit:
CARBONOFFROAD.com.au