Champion Power Equipment SUP2500 Kurzanleitung

ELECTRICAL WINCH

SUP2500

SUP3500

Assembly & Operating Instructions

CONTENTS

INTRODUCTION.................................................................................................. 1

GETTING TO KNOW YOUR WINCH...............................................................1

SAFETY PRECAUTIONS.................................................................................. 3

GENERAL TIPS FOR SAFE OPERATION.................................................... 4

WINCHING TECHNIQUES A-Z.........................................................................5

WINCH ASSEMBLY AND MOUNTING...........................................................7

MOUNTING DRAWING...................................................................................... 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 SUP2500/SUP3500................................1 2

WINCH PARTS LIST SUP2500/EWSUP3500............................................. 1 3

SPECIFICATION（SUP2500）...................................................................... 1 4

SPECIFICATION（SUP3500）...................................................................... 1 5

INTRODUCTION

Congratulations on your purchase of a high quality winch. We design and build

winches to strict specifications and with proper use and maintenance should bring

you years of satisfying service.

WARNING -Read, study and follow all instructions before operating this

device. Failure to heed these instructions may result in personal injury

and/or property damage.

Your winch can develop tremendous pulling forces and if used unsafely or

improperly could result in property damage, serious injury or death. Throughout

this manual you will find the following symbols for caution, warning and danger.

Pay particular attention to the notes preceded by these symbols as they are

written 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 WINCH

Your winch is a powerful piece of machinery. It is important that you

understand the basics of its operation and specifications so that when you

need to use it, you can use it with confidence and safety. Below is a list of

the components of your winch and their use. You should practice using

your winch before you are in a situation where you need to use it.

1. Your winch is part of our new product line which has been engineered with

several patented technologies.

CAUTION

WARNING

2. Motor: Your motor is powered by a volt battery and provides power to the gear

mechanism which turns the drum and winds the wire rope;

3. Winch Drum: 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.

4. Wire Rope (cable):Your winch has a galvanized aircraft cable designed

specifically for load capacity of rated line pull. The wire rope feeds onto the

drum in the “under wind” position through the roller fairlead and is looped at the

end to accept the clevis hook pin.

5. Roller Fairlead: 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.

6. Mechanic Gear System: The reduction gears convert the winch motor power

into extreme pulling forces.

7. Braking System: Braking action is automatically applied to the winch drum

when the winch motor is stopped and there 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 gear train, free spool. Engaging

the clutch (“CLUTCH IN”) locks the winch into the gear system.

10.Solenoid: Power from the vehicle battery flows through the weather-sealed

switch before being directed to the winch motor.

11.Remote Switch: The Power switch leads have a dual switch for powering in or

powering out your winch drum. The remote switch allows you to stand clear of

the wire rope when the winch is under load.

12.Wireless Remote Control: allow you to control winch far from 50 Ft away.

13.Universal Flat Bed Mounting Channel: Your winch could have been optionally

supplied with a flat bed mounting channel that can be mounted to most flat

surfaces such as trailers, step bumpers, truck beds, etc. The mounting channel

also has holes to accept your roller fairlead.

14.Snatch Block: If your winch is supplied with a snatch block that can double the

pulling power of the winch, or change the pulling direction without damaging the

wire rope. We recommend you to use double line and snatch block for pulling

over 70% of the rated line pull.

SAFETY PRECAUTIONS

WARNING

WARNING – Do not exceed rated capacity shown in this table.

WARNING – Intermittent use only. Allow winch to cool between uses.

WARNING – Do not use winch to lift (vertically).

WARNING – Do not use winch to pull or move people in any way.

WARNING – NEVER cut, weld, or modify any part of the winch or cable.

WARNING – A minimum of five wraps of cable around the drum barrel is

necessary for pulling and holding the rated load.

WARNING – Keep yourself and others a safe 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.

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 – Do not exceeds maximum line pull ratings shown on the tables.

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 spool correctly you should 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 hand by rotating the drum by hand with the clutch disengaged.

Keep hands clear of the fairlead and drum while the winch is under power.

Do not use as a hoist. Do not use for overhead lifting.

Failure to heed these warnings may result in personal injury and/or property

damage.

WARNING – Use gloves to protect hands when handling the cable. Never let

the cable slide through your hands.

WARNING – Never connect the cable back to itself. Apply blocks to the wheels

of the vehicle when on an incline. 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 disengage the clutch when there is a load on the winch..

CAUTION – Use the hand saver hook when handling the hook for spooling or

un-spooling the wire rope.

GENERAL TIPS FOR SAFE OPERATION

The winch and its all-derivative types are rated at rated capacity when spooling

the first rope layer on the drum. Overloading can damage the winch/motor/ or

wire rope. For loads over 70% of rated line pull, we recommend the use of the

pulley block/snatch block to double the wire rope line. This 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 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 amount of 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 must be replaced immediately. Use only the manufacturer’s replacement

rope with the exact specifications.

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 way, is found to be worn, or

operates abnormally shall be removed from service.

Pull only on parts of the vehicle as specified by the vehicle manufacturer.

Only attachments and/or adapters supplied by the manufacturer shall be used.

Whenever before your winch start to working, please slightly test-run your

winch in two direction, even if the winch drum only round a few degree of angle,

ensure the winch is well-balanced, especially after you operated the clutch,

test-running winch can make winch in gear.

WINCHING TECHNIQUES A-Z

a. Take time to asses your situation and plan your pull.

b. Put on gloves to protect your hands.

c. Disengage the clutch to allow free-spooling and to save energy.

d. Attach the hand saver hook to the clevis hook.

e. Pull out the wire rope to your desired anchor point using the hand saver hook.

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.

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 well clear. Never step over the wire rope.

k. Disengage the clutch to allow free-spooling and to save energy.

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 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 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.

WINCH ASSEMBLY AND MOUNTING

1. Your 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 popular vehicles and mounting channels. If you will utilize the mounting

channel you must ensure that it is mounted on a flat surface so 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.

2. Start by connecting the roller fairlead to the mounting channel 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 and feed the wire loop through the opening in the front of the mounting

channel and roller fairlead. Now, using the remaining cap screws assembly

secure the winch to the mounting channel.

4. Connect the battery and motor leads as the drawing above. Keep in mind that

every type of winch is different each other.

CAUTION – Batteries contain gases which are flammable and explosive.

Wear eye protection during installation and remove all jewelry. Do not lean over

battery while making connections.

5. Assemble the clevis hook to the cable. Take off the pin from the clevis hook,

connect the clevis hook to the cable and mount the pin back to the clevis Hook.

6. Always use the hand saver when free-spooling and re-spooling the wire rope.

Using the hand saver keeps your hands and fingers away from the rotating

drum.

7. Check for proper drum rotation. Pull and turn the clutch knob to the “CLUTCH

OUT” position. Pull out some cable from the drum, and then turn the clutch

knob to the “CLUTCH IN” position to engage the gears. Press the cable out

button on the power 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.

MOUNTING DRAWING

The mounting drawing

D type A type

Black Motor -

Red Motor +

Black Battery -

Red Battery +

Fixing Panel

Switch

OUT

WINCH ACCESSORIES YOU WILL NEED

NOT INCLUDED WITH YOUR WINCH

Gloves – For handling the wire rope and hook strap.

Anchor Strap/Chain – Tree saver anchor straps are made of high quality nylon with

high tensile strengths from 5,000lbs to 10,000lbs.

Heavy Blanket – place on the cable to absorb energy should the wire rope break.

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