Champion Power Equipment 10013 Operator's Manual for All Serial Numbers in

10013
Rev 10013-20070327
Owner’s Manual and Operating Instructions
2500 lb.
WINCH
WITH SPEED MOUNT
HITCH ADAPTER
Table of Contents
Introduction ..................................... 1
Accessories................................................ 1
This Booklet.............................................. 1
Manual Conventions.........................2
Safety Rules......................................3
Controls and Features.......................5
Winch........................................................ 5
Mounting..........................................6
Mounting the Winch.................................6
Operation .........................................7
General Tips for Safe Operation............... 7
Self Recovery ............................................ 7
Winching Techniques A-Z........................8
Maintenance.....................................9
Lubrication ...............................................9
Cable Assembly Replacement ..................9
Specifications .................................10
Performance Specifications.................... 10
Winch Diagram........................................11
Winch Parts List ..................................... 12
Troubleshooting ............................. 14
Warranty ........................................ 15
Warranty Qualifications .........................15
Repair/Replacement Warranty.............. 15
Do not return the unit to the place of
purchase..................................................15
Warranty Exclusions...............................15
Normal Wear.......................................15
Installation, Use and Maintenance..... 15
Other Exclusions................................. 15
Limits of Implied Warranty and
Consequential Damage........................... 15
Contact Information...............................16
Address................................................16
Customer Service ................................16
Technical Service.................................16
Notes .............................................. 17
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.
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
10013
Serial Number
Date of Purchase
Purchase Location
Rev 10013-20070327 1
Manual Conventions
Manual Conventions
This manual uses the following symbols 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.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, minor or moderate injury.
may
result in
CAUTION
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, or serious injury.
will
result in death
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, death or serious injury.
could
result in
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided,
may
result in property damage.
NOTE
If you have questions regarding your winch, we can help. Please call our help line at 1-877-338-
0999.
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Safety Rules
Safety Rules
WARNING
Read this manual thoroughly before operating your winch. Failure to follow instructions could result in serious injury or death.
WARNING
Do not exceed the rated capacity.
DANGER
Do not use this winch for lifting or moving people or animals.
DANGER
Keep yourself and others a safe distance to the side of the cable when under tension.
DANGER
Never step over a cable or near a cable under load.
WARNING
Do not move the vehicle to pull a load (towing) on the winch cable. This could result in cable breakage.
WARNING
Pull only on areas of the vehicle as specified by the vehicle manufacturer
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.
WARNING
Disconnect the remote control and battery leads when not in use.
WARNING
Avoid “shock loads” by using the control switch intermittently to take up the slack in the wire rope. “Shock loads” can far exceed the rate capacity for the wire rope and drum.
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.
Rev 10013-20070327 3
Do not accelerate your vehicle while winching. Loss of traction can cause a shock load on the
cable.
Safety Rules
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.
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 let your hands get within 12” of the winch while re-spooling. Turn off the winch and repeat the procedure until a few feet of cable is 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.
WARNING
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.
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.
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.
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 wire rope.
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Controls and Features
Controls and Features
Read this owner’s manual before operating your winch. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference.
Winch
Motor (1): 1.2 HP 12V DC motor provides power to the planetary gear mechanism. Winch Drum (2): The winch drum is the cylinder on which the wire rope is stored. It can feed or wind the rope depending on the remote winch switch. Wire Rope (3): 3/16” x 45.9’ galvanized aircraft cable designed specifically for load capacity of 2,500lbs. (44 useable feet with five wraps on the drum). The wire rope feeds onto the drum in the “under wind” position through the roller fairlead (4) and is looped at the end to accept the clevis hook pin (11). Roller Fairlead (4): When using the winch at an angle the roller fairlead acts to guide the wire rope onto the drum and minimizes damage to the wire rope from abrasion on the winch mount or bumper. Free spooling Clutch (5): 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. Braking System (6): Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the wire rope.
Planetary Gear System (7): The reduction gears convert the winch motor power into extreme pulling forces. This system allows high torque while maintaining compact size and light weight. Remote Switch (8): Rocker switch with handlebar mount for powering the rope in or out of your winch drum. Speed Mount™ Hitch Adapter (9): Adapter for front or rear end hitch receiver mounting and off-vehicle storage. Solenoid (10): Power from the vehicle battery flows through the weather sealed solenoid switch before being directed to the winch motor. Clevis Hook (11): Provides a means for connecting the looped ends of cables to an anchor. 18” Quick Connect Lead (12): Used to connect the winch to the solenoid or to the 48” extension. 48” Quick Connect Lead (13): Used to lengthen the winch connection cable. Snatch Block (14): Used to double the pulling power of the winch or to change the direction of the pull without damaging the wire rope. Thermal Switch (15): 50 Amp over­current protection.
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Mounting
Mounting
This CPE 2,500 lb 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 trucks, SUV’s and ATV’s. If you cannot find a kit locally, contact CPE and we will provide you with the name of a dealer near you.
If you will utilize the CPE Speed Mount™ Hitch Adapter, you must ensure that the three major sections (motor, drum and gear housing) are properly aligned. Proper alignment of the winch will allow even distribution of the full rated load.
Mounting the Winch
1. Insert 2 x M10 Nuts with Lock Washers
to the mounting channel hole and attach the Roller Fairlead to the mounting channel with the 2 Lock Washers and Nut M10 provided.
CAUTION
the red (positive) lead of the solenoid to the positive (+) terminal of the vehicle’s 12 volt battery. Connect the black (negative) lead of the solenoid to the negative (-) terminal of the vehicle’s 12 volt battery.
8. OPTIONAL: Install the 50 Amp thermal
switch (provided in the winch kit) between the red battery lead from the solenoid and the battery.
CAUTION
The thermal switch will shut down current to the winch when it becomes overheated.
Allow the winch to cool down for several minutes then begin winching again.
9. Connect the 48” quick connect lead to
the solenoid quick connect lead.
10. Connect the red (positive) lead of the 18”
quick connect to the positive (+) terminal of the motor. Connect the black (negative) lead of the 18” quick connect to the negative (-) terminal of the motor.
11. Connect the 48” quick connect lead to
the 18” quick connect lead.
Mounting bolts must be SAE grade 5 or better and torque to 34 ft. lbs.
2. Place the winch up-side-down on a
stable working surface. Position the Speed Mount™ Hitch Adapter on the winch, making sure the winch is centered in the middle of the mounting channel.
3. Attach using the 4 M8 x 12 tapered head
screws through the channel into the winch.
4. Disengage the clutch by rotating the
clutch cap to the “Out” position. Release the wire rope and pull through the slot in the front of the channel.
5. Attach the clevis hook and hand strap.
6. Insert the Speed Mount™ Hitch Adapter
into your hitch receiver and secure with the pin.
7. Connect the battery leads. FOR WINCH
TO FUNCTION PROPERLY: Connect
CAUTION
Battery cables should not be drawn taut. Leave some slack for cable movement.
12. Attach the rocker switch lead to the
solenoid and test for proper operation.
13. 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 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.
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Operation
Self Recovery
Operation
General Tips for Safe Operation
Your 10013 winch is rated at 2,500 lbs. capacity in first layer (max) when spooling the first rope layer on the drum. Overloads can damage the winch, motor and/or wire rope. For loads over 1,800 lbs. we recommend the use of the pulley block/snatch block to double the wire rope line. The will aid in two ways: a) reduce the number or rope layers on the
drum, as well as,
b) reduce the load on the wire rope 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 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 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 supplied by the manufacturer are to be used.
Locate a suitable anchor such as a strong tree trunk or boulder. Always use a sling as an anchor point.
Your winch is equipped with a roller fairlead to help guide the wire rope and to reduce binding on short side pulls. Do not winch from an acute angle as the wire rope will pile up on one side of the drum causing damage to wire rope and the winch.
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. For pulls over 1,800lbs., we recommend the use of the snatch block/pulley block to double line the wire rope.
This reduces the load on the winch and the strain on the rope by approximately 50%
Rev 10013-20070327 7
Operation
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 wire rope to your desired
anchor point using the hook strap.
f. Secure the clevis hook to the anchor
point: Sling, chain or snatch block. Do
not attach the hook back onto the wire
rope.
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. Power in the wire rope 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 wire
rope.
k. Double check your anchors and make
sure all connections are secure.
l. Inspect the wire rope. Make sure there
are at least 5 wraps of wire rope around
the winch drum.
m. Drape a blanket or jacket over the wire
rope approximately 5 to 6 feet from the
hook. Open the hood for added
protection.
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 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 neutral and the emergency brake released. Only release the brake pedal when under full tension. Avoid shock loads to the winch. This can damage the winch, rope and vehicle.
q. 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.
r. The winching operation is complete
once the vehicle is on stable ground and is able to drive under its own power.
s. Secure the vehicle. Be sure to set the
brakes and place the vehicle in park.
t. Release the tension on the wire rope.
The winch is not meant to hold the vehicle for long periods of time.
u. Disconnect the wire rope from the
anchor.
v. Rewind the wire rope. 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 rope is tight.
w. Keep your hands clear of the winch
drum and fairlead as the wire rope is being drawn in.
x. Secure the hook and hook strap.
y. Disconnect the remote control and store
in a clean, dry place.
z. Clean and inspect connections and
mounting hardware for next winching operation.
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Maintenance
Maintenance
The owner/operator is responsible for all periodic maintenance.
WARNING
Never operate a damaged or defective winch.
WARNING
Improper maintenance will void your warranty.
Complete all scheduled maintenance in a timely manner. Correct any issue before operating the winch.
NOTE
For service or parts assistance, contact our help line at 1-877-338-0999.
Lubrication
All moving parts within the Electric Winch having been Lubricated using high temperature lithium grease at the factory. No internal lubrication is required. Lubricate Cable Assembly (4) periodically using a light penetrating oil.
Cable Assembly Replacement
It is recommended that any modifications be performed by a manufacturer’s authorized repair facility, and that only manufacturer­supplied parts be used
1. Rotate the clutch cap to the “Out” position.
2. Extend Cable Assembly to its full length. Note how the existing cable is connected to the inside of the drum.
3. Remove old Cable Assembly and attach new one.
4. Retract Cable Assembly onto drum being careful not to allow kinking.
Rev 10013-20070327 9
Specifications
Specifications
Performance Specifications
Rated Pull 2,500 lbs (1134 kg) Gear Reduction Ratio 171:1 Motor Permanent Magnet
1.2 HP/0.89 KW (DC 12V) Drum Size 1.5” (D) x 3.15” (L) 38 mm (D) x 80 mm (L) Cable 3/16” (D) x 45.9’ (L)
4.8 mm (D) x 14 m (L)
(44 useable feet with five wraps on the winch drum)
Weight 29.21 lbs. (13.25 kg) Height 4.5 inches (114 mm) Width 4.4 inches (112 mm) Length 13.2 inches (336 mm) Bolt Pattern 4.9” x 3” (124mm x 76 mm)
Line speed and Motor Current (First layer)
Line pull Max
(12VDC)
Max Current amps 15 50 80 120 170 Cooling Time minutes 5 5 5 5 5
Layers of cable on drum 1 2 3 4 5
layer
per layer
* Use double line and snatch block for pulling loads over 1,800lbs / 816.48kgs.
lbs 0 1000 1500 2000 2500
kgs 0 454 680 907 1134
FPM 8.86 7.55 6.23 5.25 4.27 Line speed
MPM 2.7 2.3 1.9 1.6 1.3
Line pull and cable capacity
lbs 2500 2033 1713 1480 1303 Max pulling capacity per kgs 1134 922 777 671 591
ft 7.15 15.45 24.7 34.5 45.9 Cable capacity
m 2.18 4.71 7.52 10.52 14
10 Rev 10013-20070327
Specifications
Winch Diagram
Rev 10013-20070327 11
Specifications
Winch Parts List
No Part # Description Qty
1 250100 Motor Assembly 1 2 250001 Screw M6 x 20 4 3 250002 Washer - Flat Φ6 6 4 250003 Tie Bar 2 5 250004 Bushing Shaft 1 6 250005 Coupling Shaft 1 7 250006 Screw M5 x 6 1 8 250007 Drum 1
9 250200 Cable Assembly 1 10 250008 Rear Bush Drum 1 11 250009 Front Thrust Washer 1 12 250010 Gear Ring Output 1 13 250300 Gear Carrier Assembly 1 14 250011 Circlip for holes 1 15 250012 Spring 1 16 250013 Cover Clutch Housing 1 17 250014 Cap Screw M6 x 70 2 18 GB276-BB-16002-SS Radial Ball Bearing 16002 Sealed 1 19 250016 Clutch Cap 1 20 250017 Locking Washer Φ6 1 21 250018 Cap Screw M6 x 16 1 22 250019 Axis Support Bushing 1 23 GB276-BB-6002-SS Radial Ball Bearing 6002 Sealed 1 24 250021 Clutch Bushing 1 25 250022 Above Clutch Axis Washer 1 26 250023 Cam Clutch Gear 1 27 250024 Gear Housing / End Bearing 1 28 250025 Gear Ring 1 29 250026 Hand Saver Bar 1 30 250039 48" Battery Power Lead 1 31 250028 32 250029 Roller Fairlead 1 33 250030 Strap 1 34 250040 Solenoid Assembly 1 35 250400 Switch Assembly 1 36 250032 Cap Screw M8 x 12 4 37 250033 Screw M10 x 30 2 38 250034 Washer - Flat Φ10 2 39 250035 Locking Washer Φ10 2 40 250036 Nut M10 2 41 250037 Pin 1 42 250038 Retaining Pin 1 43 250041 18" Battery Power Lead 1 44 250031 Snatch Block 1 45 240500 Thermal Switch 1 46 250042 Screw M6 x 50 4 47 250043 Washer - Flat ?6 4 48 250044 Nut M6 4 49 250045 2 50 250046 1 51 250047 52 250048 Screw M5 x25 2 53 250049 Washer - Flat Φ5 3 54 250050 Locking Washer Φ5 3 55 250051 Screw M5 x 18 1
Speed Mount Hitch Adapter
Mounting Hardware
1
1
12 Rev 10013-20070327
Specifications
No Part # Description Qty
56 250052 Nut M5 3 57 250053 Screw M3 x5 2 58 250054 Locking Washer Φ5 2
Rev 10013-20070327 13
Troubleshooting
Troubleshooting
Problem Cause Solution
Motor does not turn on
Motor runs but Cable drum does not turn
Motor runs slowly or without normal power
Motor overheating winch running time too long Allow winch to cool down periodically. Motor runs in one direction
only
Switch Assembly not connected properly Insert Switch Assembly all the way into
Loose battery cable connections Tighten nuts on all cable connections. Solenoid malfunctioning Tap solenoid to loosen contacts. Apply 12
Defective Switch Assembly Replace Switch Assembly. Defective motor Check for voltage at armature port with
Water has entered motor Allow to drain and dry. Run in short bursts
Clutch not engaged Rotate clutch cap to the "In" position. If
Insufficient current or voltage The battery is weak, recharge. Run winch
Loose or corroded battery cable connections.
Defective Switch Assembly Replace Switch Assembly.
the connector.
volts to coil terminals directly. A clicking indicates proper activation.
Switch pressed. If voltage is present, Replace motor.
without load until completely dry.
problem persists, a qualified technician needs to check and repair.
with vehicle motor running (Battery should have a strong charge)
Clean, Tighten, or replace.
Tap Solenoid to loosen contacts. Defective or stuck Solenoid Repair or Replace solenoid.
14
Warranty
Warranty Exclusions
Warranty
CHAMPION POWER EQUIPMENT ONE 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 (1) year from the original date of purchase (90 days for commercial & industrial use). Transportation charges on product submitted for repair or replacement under 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 e­mail. 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.
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.
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 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.
Rev 10013-20070327 15
Warranty
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 10006 Santa Fe Springs Rd. Santa Fe Springs, CA 90670
Customer Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT) Toll Free: 1-877-338-0999 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
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Notes
Notes
Rev 10013-20070327 17
1-877-338-0999
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
© 2007 Champion Power Equipment, Inc.
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