Champion 100129 Use and Care Manual
Contents
1. POWER EQUIPMENT OWNER S MANUAL amp OPERATING INSTRUCTIONS i Wal W Wy 4700h AOON WINCH H e 28 4 w championpowerequipment co 4700 Ib Winch ATV UTV Winch Kit yea Limited Wap Ess MODEL NUMBER 2 S a limitada e 12039 Smith Ave SAVE THESE INSTRUCTIONS Santa Fe Springs CA 90670 Important Safety Instructions MADE IN CHINA USA 1 877 338 0999 are included in this manual REV 100129 20140821 www championpowerequipment com Have questions or need assistance Do not return this product to the store WE ARE HERE TO HELP Visit our website www championpowerequipment com for more info e Product Info amp Updates e Tech Bulletins e Frequently Asked Questions e Product Registration SR Call our Customer Care Team Toll Free at 1 877 338 0999 We are always working to improve our products Therefore the enclosed product may differ slightly from the image on the cover TABLE OF CONTENTS Introduction Introduction This Booklet Accessories Manual Conventions Safety Rules Controls and Features Winch Assembly Assembling the Winch Mounting the Remote Control Winch Wiring Wiring Diagram Operation General Tips for Safe Operation Self Recovery Winching Techniques A Z Maintenance Lubrication Cable Assembly Replacement 4700 Ib Winch ATV UTV Winch Kit Specifications Performance Specifications Parts Diagram Parts List Troubleshooting Warranty Warra2. a reduce the number or cable layers on the drum as well as b reduce the load on the cable by as much as 50 When doubling the line back to the vehicle attach to the tow hook frame or other load bearing part The vehicle engine should be kept running during operation of the winch to minimize battery drain and maximize power and speed of the winch If the winch is used for a considerable time with the engine off the battery may be drained and too weak to restart the engine Get to know your winch before you actually need to use it We recommend that you set up a few test runs to familiarize yourself with rigging techniques the sounds your winch makes under various loads the way the cable spools on the drum etc Inspect the cable and equipment before each use A frayed or damaged cable shall be replaced immediately Use only manufacturer s identical replacement cable with the exact specifications Inspect the winch installation and bolts to ensure that all bolts are tight before each operation 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 way is found to be worn or operates abnormally MUST BE REMOVED FROM SERVICE UNTIL REPAIRED It is recommended that the necessary repairs be made by a manufacturer s authorized repair facility Pull only on areas of the vehicle as specified by the vehicle manufacturer Only attachments and or adapters suppl
3. cables to an anchor Strap Used to assist cable feed Mount Assembly Flatb ed mounting channel 1 25 in Hitch Adapter Assembly Adapter for front or rear end hitch receiver mounting and off vehicle storage 100129 ENGLISH Assembling the Winch This CPE 4700 Ib 2132 kg winch is designed with a bolt pattern that is standard in this class of winch Many winch mounting kits are available that utilize this bolt pattern for the most popular UTVs and ATVs If you cannot find a kit locally contact CPE and we will provide you with the name of a dealer CAUTION Mounting bolts must be SAE grade 5 or better and torque to 34 ft Ibs 1 Insert M10x20 bolts through the mounting channel holes and attach the roller fairlead to the mounting channel with the M10 lock nuts provided 2 Turn the winch upside down Place the mounting channel on the winch making sure the winch is centered in the middle of it 3 Thread the M8x25 bolts through the M8 flat and locker washers and then thread through the mounting channel Tighten the bolts DO NOT over tighten 4 Turn winch right side up Disengage the clutch by moving the Cam Ring to the Out position Release the cable and pull through the roller fairlead 5 Attach the clevis hook to the cable and then hand strap to the clevis hook ASSEMBLY CAUTION If utilizing a mounting plate ensure that the three major sections motor drum and gear housing
4. hook to the anchor point Sling chain or snatch block Do not attach the hook back onto the cable g Engage the clutch h Connect the remote control to the winch If you are going to control the winch from inside your vehicle then pass the remote through an open window to avoid the wires being pinched in the door i Start your engine to ensure power Is being replenished to the battery j Drape a blanket or jacket over the cable approximately 5 ft to 6 ft 1 5 m to 1 8 m from the hook Open the hood for added protection k Power in the cable guiding the wire under tension to draw up the slack in the wire Once the wire is under tension stand clear Never Step over the cable 1 Double check your anchors and make sure all connections are secure m Inspect the cable Make sure there are at least 5 wraps of cable around the winch drum n Clear the area Make sure all spectators stand clear and that no one is directly in front or behind the vehicle or anchor point o Begin winching Be sure that the cable 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 cable under tension p q r 5 t u v w x y Z OPERATION The vehicle to be winched should be placed in neutral and the emergency brake released Only release the brak
5. are properly aligned Proper alignment of the winch will allow for even distribution of the full rated load NOTE The type of vehicle to which the winch and mounting channel will be applied will dictate the type of mounting kit that should be used Speed Mount Hitch Adapter Standard Mounting Channel or Specialty Mounting Kit Mounting the Remote control 1 The remote control is usually installed on the left handlebar 2 Usea piece of electrical tape around the handlebar to help prevent rotation of the mount on the handlebar Do NOT tighten over any hoses or cables 3 Once the remote control is mounted you can route the wires back to the battery and winch 4 Make sure the handlebars have full range of motion and then secure the remote control s cable NOV 1 REV 100129 20140821 6 ENGLISH 100129 ASSEMBLY Winch Wiring With some applications the motor leads may need 0 CAUTION to be rotated to avoid interference with other components Never route electrical cables across any sharp P edges through or near moving parts or near parts that become hot 1 Mount the winch to your vehicle 2 FOR WINCH TO FULLY FUNCTION CONNECT ALL LEADS CORRECTLY 3 Connect the battery leads Connect the red lead to the positive terminal of the Leads default position Leads rotated 90 vehicle s 12 volt battery Connect the black lead to the negative terminal of t
6. covers Failures due to acts of God and other force majeure events beyond the manufacturer s control Problems cause by parts that are not original Champion Power Equipment parts Limits of Implied Warranty and Consequential Damage Champion Power Equipment disclaims any obligation to cover any loss of time use of this product freight or any incidental or consequential claim by anyone from using this winch THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE A unit provided as an exchange will be subject to the warranty of the original unit The length of the warranty governing the exchanged unit will remain calculated by reference to the purchase date of the original unit This warranty gives you certain legal rights which may change from state to state Your state may also have other rights you may be entitled to that are not listed within this warranty Contact Information Address Champion Power Equipment Inc Customer Service 12039 Smith Ave Santa Fe Springs CA 90670 www championpowerequipment com Customer Service Mon Fri 8 30 AM 5 00 PM PST PDT Toll Free 1 877 338 0999 info championpowerequipment com Fax no 1 562 236 9429 Technical Service Mon Fri 8 30 AM 5 00 PM PST PDT Toll Free 1 877 338 0999 tech championpowerequipment com 24 7 Tech Support 1 562 204 1188 REV 100129 20140821 16
7. d capacity use a pulley block snatch block to reduce the load on the cable Z WARNING Do not move the vehicle to pull a load towing on the winch cable This could result in cable breakage Z WARNING Pull only on areas of the vehicle as specified by the vehicle manufacturer ENGLISH Z WARNING Do not use the winch to secure or hold a vehicle for a long period of time Do not use the winch to secure a vehicle for transport Z WARNING Disconnect the remote control and battery leads when not in use Z WARNING Avoid shock loads by using the control Switch intermittently to take up the slack in the cable Shock loads can far exceed the rate capacity for the cable and drum Do not accelerate your vehicle while winching Loss of traction can cause a shock load on the cable Z 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 during operation ENGLISH Z WARNING When re spooling the cable ensure that the cable spools in the under wind position with the cable entering the drum from the bottom not the top To re spool correctly and while wearing gloves keep a slight load on the cable while pushing the remote button to draw in the cable Walk toward the winch not allowing the cable to slide through your hands Do not le
8. der this warranty are the sole responsibility of the purchaser This warranty only applies to the original purchaser and is not transferable Do Not Return The Unit To The Place Of Purchase Contact CPE s Technical Service and CPE will troubleshoot any issue via phone or e mail If the problem is not corrected by this method CPE will at its option authorize evaluation repair or replacement of the defective part or component at a CPE Service Center CPE will provide you with a case number for warranty service Please keep it for future reference Repairs or replacements without prior authorization or at an unauthorized repair facility will not be covered by this warranty Warranty Exclusions This warranty does not cover the following repairs and equipment Normal Wear Winches need periodic parts and service to perform well This warranty does not cover repair when normal use has exhausted the life of a part or the equipment as a whole WARRANTY Installation Use and Maintenance This warranty will not apply to parts and or labor if this winch is deemed to have been misused neglected involved in an accident abused loaded beyond the winch s limits modified installed improperly or connected incorrectly to any electrical component Normal maintenance is not covered by this warranty Other Exclusions This warranty excludes The winch cable Cosmetic defects such as paint decals etc Accessory parts such as storage
9. e pedal when under full tension Avoid shock loads to the winch This can damage the winch cable and vehicle The winch is meant for intermittent use Under full load with a single line rig do not power in for more than a minute without letting the motor cool down for a few minutes and then resume the winching operation The winching operation is complete once the vehicle is on stable ground and is able to drive under its own power Secure the vehicle Be sure to set the brakes and place the vehicle in park Release the tension on the cable The winch is not meant to hold the vehicle for long periods of time Disconnect the cable from the anchor Rewind the cable Make sure that any wire already on the drum has spooled tightly and neatly If not draw out the wire and re spool from the point where the cable is tight Keep your hands clear of the winch drum and fairlead as the cable is being drawn in Secure the hook and hook strap Disconnect the remote control and store in a clean dry place Clean and inspect connections and mounting hardware for next winching operation REV 100129 20140821 10 ENGLISH 100129 MAINTENANCE The owner operator is responsible for all periodic Lubrication maintenance All moving parts within the electric winch having been lubricated using high temperature lithium A WARNING grease at the factory No internal lubrication is required Lubricate cable assembly periodically using a light penetratin
10. ech E a2 50500 BBM 200020 Tseewseeo ER aa 200020 washer toce 6 as 200019 wasrer a rit 6 else Jm id A 1 25 in Hitch Adapter 200027 BF Black Flat 250037 5 8 in Hitch Pin 250038 Retaining Pin 50 450021 Bolt M8 x 25 a 250025 BF Ge E Channel Black DESCH ER sa 2500208 Rote raiead sa 250095 washerat0 ooking 2 loggt 2 REV 100129 20140821 14 ENGLISH 100129 TROUBLESHOOTING Problem Cause Solution Motor does not turn Switch Assembly not connected Insert Switch Assembly all the way into the connector properly Loose battery cable connections Tighten nuts on all cable connections Contactor malfunctioning Tap contactor to loosen contacts Apply 12 volts to coil terminals directly A clicking indicates proper activation Defective Switch Assembly Replace Switch Assembly Defective motor Check for voltage at armature port with Switch pressed If voltage is present Replace motor Water has entered motor Allow to drain and dry Run in short bursts without load until completely dry Motor runs but Cable Clutch Cam Ring not engaged Move Cam Ring to the In position If problem drum does not turn persists a qualified ear needs to check and repair Motor runs slowly or Insufficient current or voltage The battery is weak recharge Run winch with vehicle without normal power motor running Battery should have a strong charge Loose or corr
11. g oil A WARNING Cable Assembly Replacement It is recommended that any modifications be Never operate a damaged or defective winch Improper maintenance will void your warranty performed by a manufacturer s authorized repair Complete all scheduled maintenance in a timely facility and that only manufacturer supplied parts manner Correct any issue before operating the be used Move the clutch to the Out position 2 Extend cable assembly to its full length Note winch NOTE how the existing cable is connected to the inside of the drum For service or parts assistance contact our 3 Remove old cable assembly and attach new help line at 1 877 338 0999 4 Retract cable assembly onto drum being careful not to allow kinking 11 REV 100129 20140821 100129 ENGLISH Performance Specifications Rated Pull Gear Reduction Ratio Motor Drum Size Cable Gross Weight Net Weight Height Width Length Bolt Pattern SPECIFICATIONS 4700 Ib 2132 kg 166 1 Permanent Magnet 1 6 HP 1 2 kW 12V DC 2 in D x 3 2 in L 50 8 mm D 81 mm L 15 64 in D x 38 ft L 6 mm D 11 6 m L 35 3 Ib 16 kg 32 2 Ib 14 6 kg 5 in 12 7 cm 4 6 in 11 6 cm 14 6 in 37 1 cm 4 9 in X 3 in 12 4 cm X 7 6 cm Te 5 454 907 01 aise Line Speed 12V DC Trew 8 ss es 69 39 Titer 0000 a 28 s0 120 160 200 If the motor becomes uncomfo
12. he vehicle s 12 volt battery see wiring diagram 4 Connect the winch leads Connect red lead of the winch connection cables to the positive terminal of the winch motor Connect the black lead of the winch connection cables to the negative terminal of the winch motor see wiring diagram 5 Check for proper drum rotation Pull and turn the clutch knob to the out position Free spooling Pull out some cable from the drum and then turn the clutch knob to the In position to engage the gears Press the cable out button on the handlebar switch If the drum is turning and releasing more cable then your connections are accurate If the drum is turning and collecting more cable then reverse the leads on the motor Repeat and check rotation CAUTION Battery cables should not be drawn taut Leave some slack for cable movement 100129 ENGLISH ASSEMBLY Wiring Diagram x CO co Red Positive Positive Negative OS Les EE Les 3 201408 REV 100129 OPERATION General Tips for Safe Operation Your 100129 winch is rated at a 4700 Ib 2132 kg capacity in first layer max when spooling the first cable layer on the drum Overloads can damage the winch motor and or cable For loads over 2350 Ib 1066 kg we recommend the use of the pulley block snatch block to double the cable line This will aid in two Ways
13. ied by the manufacturer are to be used 9 REV 100129 20140821 ENGLISH 100129 Self Recovery Locate a suitable anchor such as a strong tree trunk or boulder Always use a sling as an anchor point A roller fairlead included will help guide the cable and to reduce binding on short side pulls Do not winch from an acute angle as the cable will pile up on one side of the drum causing damage to cable and the winch Short pulls from an angle can be used to straighten the vehicle Long pulls should be done with the cable at a 90 angle to the winch vehicle When pulling a heavy load place a blanket or jacket over the cable 5 ft or 6 ft 1 5 m to 1 8 m 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 For pulls over 2350 Ib 1066 kg we recommend the use of the snatch block pulley block to double line the cable not included SINGLE LINE DOUBLE LINE This reduces the load on the winch and the strain on the cable by approximately 50 100129 ENGLISH Winching Techniques A Z a Take time to assess your situation and plan your pull b Put on gloves to protect your hands c Disengage the clutch to allow free spooling and also save battery power d Attach the hook strap to the clevis hook e Pull out the cable to your desired anchor point using the hook strap f Secure the clevis
14. nty Qualifications Repair Replacement Warranty Do Not Return The Unit To The Place Of Purchase Warranty Exclusions Limits of Implied Warranty And Consequential Damage Contact Information Address Customer Service Technical Service 12 i2 13 14 15 16 16 16 16 16 16 16 16 16 16 INTRODUCTION Introduction Congratulations on your purchase of a Champion Power Equipment winch CPE designs and builds winches to strict specifications With proper use and maintenance this winch will bring years of satisfying service This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual We reserve the right to change alter and or improve the product and this document at any time without prior notice ENGLISH Accessories Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase To find out more about our covers tree savers hooks fairleads etc please visit our web site at www championpowerequipment com Record the model and serial numbers as well as date and place of purchase for future reference Have this information available when ordering parts and when making technical or warranty inquiries Champion Power Equipment Support 1 877 338 0999 Model Number Serial Number Date of Purchase Purchase Location 100129 ENGLISH MANUAL CONVENTIONS This manual uses the following symbol
15. oded battery cable Clean Tighten or replace connections Motor overheating winch running time too long Allow winch to cool down periodically Motor runs in one Defective or stuck Contactor Tap Contactor to loosen contacts direction only Repair or Replace contactor Defective Switch Assembly Replace Switch Assembly For further technical support Technical Service Mon Fri 8 30 AM 5 00 PM PST PDT Toll Free 1 877 338 0999 tech championpowerequipment com 15 REV 100129 20140821 100129 ENGLISH WARRANTY CHAMPION POWER EQUIPMENT 2 YEAR LIMITED WARRANTY Effective September 1 2006 Replaces all undated warranties and all warranties dated before September 1 2006 Warranty Qualifications Champion Power Equipment CPE will register this warranty upon receipt of your Warranty Registration Card and a copy of your sales receipt from one of CPE s retail locations as proof of purchase Please submit your warranty registration and your proof of purchase within ten 10 days of the date of purchase Repair Replacement Warranty CPE warrants to the original purchaser that the mechanical and electrical components will be free of defects in material and workmanship for a period of one year parts and labor and two years parts from the original date of purchase 90 days parts and labor and 180 days parts for commercial amp industrial use Transportation charges on product submitted for repair or replacement un
16. rself with the location and function of the controls and features Save this manual for future reference Winch 1 2 3 4 5 6 Remote Control Powers the cable in or out of your winch drum Motor 1 6 HP 1 2 kW 12V DC motor provides power to the planetary gear mechanism Braking System Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the cable Winch Drum The winch drum is the cylinder on which the cable is stored It can feed or wind the cable depending on the remote winch switch 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 Free Spooling Clutch The clutch allows the operator to manually disengage Out the spooling drum from the gear train free spool Engaging the clutch In locks the winch into the gear system d REV 100129 20140821 7 8 9 10 11 12 Roller Fairlead When using the winch at an angle the roller fairlead acts to guide the cable onto the drum and minimizes damage to the cable from abrasion on the winch mount or bumper Wire Cable 15 64 in x 38 ft 6 mm x 11 6 m galvanized aircraft cable designed specifically for load capacity of 4700 Ib 2132 kg Clevis Hook Provides a means for connecting the looped ends of
17. rtably 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 are designed and made for intermittent use and should not be used in constant duty applications REV 100129 20140821 12 ENGLISH 100129 SPECIFICATIONS Parts Diagram 13 REV 100129 20140821 100129 ENGLISH Part Number Description a Coo lem Joel 7 faa 5002 Spring covping Fos 150002 aal 7 fas 100200 8F EIER Gear Housing End Bearing D 2 OUAEE Black Flat Eed H 450005 A Gear 450006 Gear Carrier Assembly 1 Output 450007 Gear Carrier Assembly 1 Intermediate 450008 Gear Carrier Assembly 1 Input REESEN ER fra asooo Gear Fred sack rat ER elen owen sing o Pra 250002 wasrer rat 6 Ps soon ear wexes efeso 2 EERSTEN Ps fesos mge 2 Pao fasor o ring sear 1 lest orm aussing aa soca J eseagg EE aa 00008 te sarod ER ea 50800 leo wm crews Hook 2 emo vetowsvap ida lt lt oor maszs fas s0cer wasrer ER Part Number Description Cross Recess Pan Head 450031 Screw M6 x 8 ales sme ER GB2760BB06002 SS Radial Ball Bearing 6002 1 Sealed aa 250019 len 6 7 fas 250012 ass 7 as 450032 8F outer corer Beor a 37 8 Radial Ball Bearing 16002 1 Sealed e faos foune fon foras oo ESCHER ER ole Jaan
18. s to help differentiate between different kinds of information The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment Follow all safety messages to avoid or reduce the risk of serious Injury or death A DANGER CAUTION DANGER indicates an imminently hazardous CAUTION used without the safety alert situation which if not avoided will result in symbol indicates a potentially hazardous death or serious injury situation which if not avoided may result in property damage Z WARNING Se WARNING indicates a potentially hazardous situation which if not avoided could result in If you have questions regarding your winch death or serious injury we can help Please call our help line at 1 877 338 0999 CAUTION CAUTION indicates a potentially hazardous Situation which not avoided may result in minor or moderate injury SAFETY RULES Z WARNING Read this manual thoroughly before operating your winch Failure to follow instructions could result in serious injury or death Z WARNING Do not exceed the rated capacity A DANGER Do not use this winch for lifting or moving people or animals A DANGER Keep yourself and others a safe distance to the side of the cable when under tension A DANGER Never step over a cable or near a cable under load Z WARNING The cable may break before the motor stalls For heavy loads at or near rate
19. t your hands get within 12 in 30 5 cm of the winch while re spooling Turn off the winch and repeat the procedure until a few feet of cable are left Disconnect the remote control and finish spooling by rotating the drum by hand with the clutch disengaged Keep hands clear of the fairlead and drum while the winch is under power Z WARNING Do not use as a hoist Do not use for overhead lifting CAUTION Use gloves to protect hands when handling the cable Never let the cable slide through your hands CAUTION Do not wrap the cable around any object and hook it back onto itself CAUTION Apply blocks to the wheels of the vehicle when on an incline SAFETY RULES CAUTION 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 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 cable CONTROLS AND FEATURES ENGLISH 100129 Read this owner s manual before operating your winch Familiarize you
Download Pdf Manuals
Related Search