Champion Power Equipment T-P2500, Assembly & Operating Instructions

Page 1: ...ELECTRICAL WINCH T P2500 T P3500 T P4500 Assembly Operating Instructions ...

Page 2: ...ING 8 WINCH ACCESSORIES YOU WILL NEED 8 RIGGING TECHNIQUES 9 WINCH WORKING DEMONSTRATION 1 0 REPLACING THE WIRE ROPE 1 0 MAINTENANCE 1 1 TROUBLE SHOOTING 1 1 WINCH ASSEMBLY DRAWING T P2500 T P3500 1 2 WINCH PARTS LIST T P2500 T P3500 1 3 WINCH ASSEMBLY DRAWING T P4500 1 4 WINCH PARTS LIST T P4500 1 5 SPECIFICATION T P2500 1 6 SPECIFICATION T P2500 1 7 SPECIFICATION T P4500 1 8 ...

Page 3: ...ritten for your safety Ultimately safe operation of this device rests with you the operator This indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This notation is also used to alert you against unsafe practices This indicates a potentially hazardous situation which if not avoided could result in death or serious injury GETTING TO KNOW YOUR WIN...

Page 4: ... is a load on the wire rope A separate mechanical brake applies the braking action 8 Control System Your winch was made to provide you the ability to use it in a medley of operations The winch can be controlled by using the Power Cord Switch Assembly or through a solenoid control box 9 Free Spooling Clutch The clutch allows the operator to manually disengage CLUTCH OUT the spooling drum from the g...

Page 5: ...afe distance to the side of the cable when it is under tension WARNING The wire rope may break before the motor stalls For heavy loads at or near rated capacity use a pulley block snatch block to reduce the load on the wire rope WARNING Never step over a cable or go near a cable under load WARNING Don t move the vehicle to pull a load towing on the winch cable This could result in cable breakage W...

Page 6: ... Duration of winching pulls should be kept as short as possible If the motor becomes uncomfortably hot to the touch stop winching immediately and let it cool down for a few minutes Do not pull for more than one minute at or near the rated load CAUTION If the motor stalls do not maintain power to the winch Electric winches are designed and made for intermittent use and should not be used in constan...

Page 7: ...ecifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation Never connect the cable back to itself This will cause cable damage Always use a snatch block sling or chain of suitable strength as shown in the illustrations Store the remote control inside your vehicle in a place that it will not be damaged Any winch that appears to be damaged in any w...

Page 8: ...Make sure all spectators are back and that no one is directly in front or behind the vehicle or anchor point o Begin winching Be sure that the wire rope is winding evenly and tightly around the drum The vehicle that is being winched can be slowly driven to add assistance to the winching process Avoid shock loads keep the wire rope under tension p The vehicle to be winched should be placed in neutr...

Page 9: ...nel using 2 each of the cap screw assembly Make sure the screw is placed through the mounting channel and roller fairlead from inside the channel This will allow enough clearance for the winch to be placed in the channel without obstruction 3 Assemble the winch to the mounting channel by first pulling and releasing the clutch knob to CLUTCH OUT position Pull out a few inches of cable from the drum...

Page 10: ...n your connections are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation MOUNTING DRAWING The mounting drawing D type A type Switch Black Motor Red Motor 4 1 5 9 Black Battery Red Battery Black Motor Red Motor 5 9 1 96 Black Battery Red Battery Fixing Panel Switch OUT IN U type OUT IN Switch 5 9 Black Battery Red Battery WINCH A...

Page 11: ...o wire rope and the winch Fig 3 2 Short pulls from an angle can be used to straighten the vehicle Long pulls should be done with the wire rope at a 90 angle to the winch vehicle When pulling a heavy load place a blanket or jacket over the wire rope five or six feet from the hook In the event of a broken cable it will dampen the snap back For additional protection open the hood of the vehicle as sh...

Page 12: ...l the motor stops before reversing directions 7 When the pulling is complete remove the switch assembly From the female connector of the directional valve and replace the female connectors cover Note For D stytle winch winch operation is controlled directly not through control box REPLACING THE WIRE ROPE If the wire rope has become worn or is beginning to show signs of strands breaking it must be ...

Page 13: ...efective Switch Assembly Defective motor Water has entered motor Insert Switch Assembly all the way into the connector Tighten nuts on all cable connections Replace Switch Assembly Check for voltage at armature port with Switch pressed If voltage is present replace motor Allow to drain and dry Run in short bursts without load until completely dry Motor runs but cable drum does not turn Clutch not ...

Page 14: ...12 WINCH ASSEMBLY DRAWING T P2500 T P3500 2 17 16 15 13 14 12 10 6 8 9 4 3 5 7 2 1 11 29 7 29 27 28 18 19 20 21 22 23 24 25 26 34 33 35 30 31 32 36 32 31 30 O U T IN IN O U T 40 41 42 37 38 39 8 7 8 ...

Page 15: ...0250017 1 Roller Bearing 20 P0250018 1 Clutch axes 21 P0250019 1 Cam Clutch Gear 22 P0250020 1 Spring 23 P0250021 1 Cover Clutch Housing 24 P0250022 1 Roller Bearing 25 P0250023 1 Elastic Collar 26 P0250024 1 Clutch Handle 27 P0250025 1 Locking Washer Φ5 28 P0250026 1 Cap Screw M5 x 12 29 P0250027 4 Cap Screw M6 x 25 30 P0250028 4 Hex Flange Nut M8 31 P0250029 4 Locking Washer Φ8 32 P0250030 4 Thi...

Page 16: ...14 WINCH ASSEMBLY DRAWING T P4500 O U T IN IN O U T ...

Page 17: ...300 1 Gear Carrier Assembly Output 20 P0450400 1 Gear Carrier Assembly Intermediate 21 P0450500 1 Gear Carrier Assembly Input 22 P0450017 1 Gear Input Sun 23 P0450018 1 Gasket 24 P0450600 1 Clutch Handle Assembly 25 P0450019 4 Thick Flat Washer Φ6 26 P0450020 6 Locking Washer Φ6 27 P0450021 2 Screw M6 x100 28 P0450022 4 Screw M6 x25 29 P0450023 2 Tie Bar 30 P0450024 2 Hex Flange Nut M10 31 P045070...

Page 18: ...2 7 4 5 4 4 323mm 113mm 112mm 12 7 4 5 4 4 323mm 113mm 112mm 13 2 4 5 6 5 335mm 113mm 165mm Net weight Ibs kg 19 8 9 0 20 5 9 3 20 5 9 3 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Current A Ibs kgS 12V DC 24V DC 12V DC 24V DC 0 10 2 3 1 10 5 3 2 20 16 500 227 9 8 3 0 10 2 3 1 55 35 1500 680 7 5 2 3 9 2 2 8 95 65 2500 1134 4 3 1 3 8 2 2 5 160 100 Line Pull And Rope Capac...

Page 19: ...4 4 335mm 116mm 112mm 13 2 4 6 4 4 335mm 116mm 112mm 13 7 4 6 6 5 348mm 116mm 165mm Net weight Ibs kg 21 3 9 6 22 0 10 0 22 0 10 0 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Current A Ibs kgs 12V DC 24V DC 12V DC 24V DC 0 10 2 3 1 10 5 3 2 20 16 1000 454 8 9 2 7 9 5 2 9 75 40 2000 907 7 5 2 3 8 9 2 7 130 75 3500 1588 4 6 1 4 7 5 2 3 200 120 Line Pull And Rope Capacity I...

Page 20: ...mm 125mm 123mm 16 1 4 92 4 85 408mm 125mm 123mm 16 1 4 92 6 6 408mm 125mm 168mm Net weight Ibs kg 33 3 15 1 34 2 15 5 34 2 15 5 Pull Speed Amperes Volts First layer Line Pull Line Speed ft min m min Current A Ibs kgs 12V DC 24V DC 12V DC 24V DC 0 12 8 3 9 13 2 4 0 28 14 1000 454 9 8 3 0 10 9 3 3 80 50 2000 907 8 5 2 6 9 4 2 9 120 70 3000 1361 6 9 2 1 7 6 2 3 160 95 4500 2041 4 6 1 4 5 5 1 6 220 11...