Champion Power Equipment 100794, Operator'S Manual

Page 1: ...ns important safety precautions which should be read and understood before operating the product Failure to do so could result in serious injury This manual should remain with the product Specifications descriptions and illustrations in this manual are as accurate as known at the time of publication but are subject to change without notice REGISTER YOUR PRODUCT ONLINE at championpowerequipment com...

Page 2: ...Assembly Parts 7 Assembly 8 Assembling the Winch 8 Wiring the Winch 9 Operation 10 General Tips for Safe Operation 10 Self Recovery 10 Winching Techniques A Z 11 Maintenance 12 Lubrication 12 Steel Rope Replacement 12 Synthetic Rope Replacement Optional 12 Synthetic Rope 12 Specifications 13 Performance Specifications 13 Parts Diagram 14 Parts List 15 Wiring Diagram 16 Troubleshooting 17 ...

Page 3: ...e common sense and always err on the side of caution when operating the product to ensure no accident property damage or injury occurs We want you to continue to use and be satisfied with your CPE product for years to come When contacting CPE about parts and or service you will need to supply the complete model and serial numbers of your product Transcribe the information found on your product s n...

Page 4: ...k in the rope Shock loads can far exceed the rate capacity for the wire rope and drum Do not accelerate your vehicle while winching Loss of traction can cause a shock load on the cable WARNING Batteries contain acid and produce explosive gases Keep sparks flames and cigarettes away from batteries at all times Wear safety glasses and protect the eyes at all times Do not lean over the batteries duri...

Page 5: ...made for intermittent use and should not be used in constant duty applications CAUTION Never release the free spool clutch when there is a load on the winch CAUTION Use hook strap when handling the hook for spooling or unspooling the rope CAUTION DO NOT mix old and new batteries DO NOT mix alkaline standard or rechargeable batteries Operation Symbols Some of the following symbols may be used on th...

Page 6: ...o guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper 4 Steel rope 5 16 in 85 ft 8 mm 25 9 m galvanized aircraft rope designed specifically for load capacity of 9 000 lb 4082 kg 5 Braking System Braking action is automatically applied to the winch drum by a separate mechanical brake when the winch motor is stopped and there is a load o...

Page 7: ... 4 Lock washer Ø10 4 Lock nut M10 4 Clevis hook 1 Needle nose pliers Yellow Strap 1 Remote Control 1 8 Planetary Gear System The reduction gears convert the winch motor power into extreme pulling forces This system allows high torque while maintaining compact size and light weight 9 Remote Switch Dual switches for powering the rope in or out of your winch drum 10 Clevis Hook Provides a means for c...

Page 8: ...aligned Proper alignment of the winch will allow for even distribution of the full rated load NOTICE The type of vehicle to which the winch and mounting plate will be applied will dictate the type of mounting kit that should be used Speed MountTM hitch adapter standard mounting plate or specialty mounting kit Assembling the Winch 1 Insert 2 M10 35 bolts to the mounting channel or plate not include...

Page 9: ...cable movement 1 Connect the battery leads 1a Connect the red lead to the positive terminal of the vehicle s 12 volt battery 1b Connect the black lead to the negative terminal of the vehicle s 12 volt battery see wiring diagram black 2 Connect the quick connect leads Insert the male quick connect into the female quick connect to complete the wiring 3 Attach the remote lead to the winch and test fo...

Page 10: ... sounds your winch makes under various loads the way the cable spools on the drum etc Inspect the wire rope and equipment before each use A frayed or damaged rope shall be replaced immediately Use only manufacturer s identical replacement rope with the exact specifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Store the remote control ins...

Page 11: ...p over the wire rope Double check your anchors and make sure all connections are secure Inspect the wire rope Make sure there are at least 5 wraps of wire rope around the winch drum Drape a blanket or jacket over the wire rope approximately 5 6 ft 1 5 1 8 m from the hook Open the hood for added protection Clear the area Make sure all spectators stand clear and that no one is directly in front or b...

Page 12: ...formed by a manufacturer s authorized repair facility and that only manufacturer supplied parts be used 1 Move the clutch to the Out position 2 Extend wire rope to its full length Note how the existing rope is connected to the inside of the drum 3 Remove old wire rope and attach new one 4 Retract wire rope onto drum being careful not to allow kinking Synthetic Rope Replacement Optional 1 It is rec...

Page 13: ... KG 0 907 1814 2721 3628 4082 Line Speed 12V DC FPM 15 7 10 8 8 2 7 2 5 2 4 6 MPM 4 8 3 3 2 5 2 2 1 6 1 4 Max Current A 80 140 195 240 310 330 Run Time Minutes 1 1 1 1 1 1 Cooling Time Minutes 5 5 5 5 5 5 If the motor becomes uncomfortably hot to the touch stop winching immediately and let it cool down for 5 minutes Do not pull for more than one minute at or near the rated load Electric winches ar...

Page 14: ...100794 9 000 LB 4082 KG WINCH Specifications 14 Parts Diagram 9 30 10 29 45 43 42 4 1 2 3 26 27 24 6 25 32 28 28 7 24 22 33 8 21 20 38 39 12 13 14 15 16 17 19 18 11 31 35 36 40 34 37 44 23 46 41 5 ...

Page 15: ...Screw M4 8 1 20 P1011010 Gear Housing End Cover Seal 1 21 P1011030 Gear Housing B 1 22 P1011012 Bushing 1 23 P1011013 Thrust Washer 1 24 P1011014 Motor End Bearing Seal 2 25 P1011015 N BF End Bearing Black Flat 1 Part Number Description Qty 26 P1011016 D Lock Washer Ø6 Dacromet 8 27 P1011017 D Hexagon Socket Head Screw M6 20 Dacromet 8 28 P1011018 Thrust Disc 2 29 P1010008 Bushing Drum 1 30 P10100...

Page 16: ...100794 9 000 LB 4082 KG WINCH Specifications 16 Wiring Diagram Negative Positive Red Red Black Black ...

Page 17: ...load until completely dry Motor runs but cable drum does not turn Clutch cam ring not engaged Move cam ring to the In position If problem persists a qualified technician needs to check and repair Motor runs slowly or without normal power Insufficient current or voltage The battery is weak recharge Run winch with vehicle motor running battery should have a strong charge Loose or corroded battery ca...

Page 18: ...been misused neglected involved in an accident abused loaded beyond the product s limits modified installed improperly or connected incorrectly to any electrical component Normal maintenance is not covered by this warranty and is not required to be performed at a facility or by a person authorized by CPE Other Exclusions This warranty excludes Cosmetic defects such as paint decals etc Wear items s...