40252
Rev 40252-20090223
10006 Santa Fe Springs Road
Santa Fe Springs, CA 90670 USA
Made in China
Owner’s Manual and Operating Instructions
SAVE THESE INSTRUCTIONS
Important Safety
Instructions are included in
this manual
4500 lb.
WINCH
Table of Contents
Introduction ..................................... 1 Accessories................................................ 1 This Booklet .............................................. 1 Manual Conventions ......................... 2 Safety Rules ...................................... 3 Controls and Features ....................... 5 Winch ........................................................ 5 Mounting .......................................... 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 ............................. 13 Warranty ........................................ 14 Warranty Qualifications ......................... 14 Repair/Replacement Warranty .............. 14 Do not return the unit to the place of
purchase .................................................. 14 Warranty Exclusions............................... 14 Normal Wear ....................................... 14 Installation, Use and Maintenance ..... 14 Other Exclusions ................................. 14 Limits of Implied Warranty and
Consequential Damage ........................... 14 Contact Information ............................... 15 Address ................................................ 15 Customer Service ................................ 15 Technical Service................................. 15 Notes .............................................. 16 Introduction
Introduction
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.
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 Owner’s Manual contains important
safety instructions and information. SAVE
THESE INSTRUCTIONS FOR FUTURE
REFERENCE.
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
40252
Serial Number
Date of Purchase
Purchase Location
Rev 40252-20090223
1
Manual Conventions
Manual Conventions
CAUTION
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.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Follow all safety messages to avoid or reduce
the risk of serious injury or death.
CAUTION
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
NOTE
WARNING
If you have questions regarding your winch, we
can help. Please call our help line at 1-877-3380999.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
2
Rev 40252-20090223
Safety Rules
Safety Rules
WARNING
WARNING
Do not move the vehicle to pull a load (towing)
on the winch cable. This could result in cable
breakage.
Read this manual thoroughly before operating
your winch. Failure to follow instructions could
result in serious injury or death.
WARNING
WARNING
Pull only on areas of the vehicle as specified by
the vehicle manufacturer
Do not exceed the rated capacity.
WARNING
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 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.
Do not accelerate your vehicle while winching.
Loss of traction can cause a shock load on the
cable.
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 40252-20090223
3
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
Do not use as a hoist. Do not use for overhead
lifting.
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.
Electric winches are designed and made for
intermittent use and should not be used in
constant duty applications.
CAUTION
CAUTION
Use gloves to protect hands when handling the
cable. Never let the cable slide through your
hands.
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.
4
Rev 40252-20090223
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
(1) Motor: 1.6 HP 12V DC motor provides
power to the planetary gear mechanism.
(2) 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.
(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) 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.
(5) Free spooling Clutch: The clutch
allows the operator to manually disengage
(“Out”) the spooling drum from the gear
Rev 40252-20090223
train, free spool. Engaging the clutch (“In”)
locks the winch into the gear system.
(6) Remote Switch: Rocker switch with
handlebar mount for powering the rope in or
out of your winch drum.
(7) Hand Saver bar
(8) Clevis Hook
(9) Wire Rope: 7/32” x 52’ galvanized
aircraft cable designed specifically for load
capacity of 4,500lbs.
(10) 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.
5
Mounting
Mounting
This CPE 4,500 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.
CAUTION
Mounting bolts must be SAE grade 5 or better
and torque to 34 ft. lbs.
1.
Insert 2 M10 bolts to the mounting
channel hole and attach the Roller
Fairlead to the mounting channel with
the Nut M10 provided. (see page 11 for
diagram)
2. Insert M8 bolt through M8 lock washer,
M8 flat washer, and mounting channel
to attach each winch leg. Repeat for all
four legs.
3. Disengage the clutch by rotating the
clutch knob to the “Out” position.
Release the wire rope and pull through
the slot in the front of the channel.
6
4. Attach the clevis hook and hand strap.
5. Connect the battery leads. FOR WINCH
TO FUNCTION PROPERLY: Connect
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.
6. Attach the remote lead to the winch and
test for proper operation.
7. 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.
CAUTION
Battery cables should not be drawn taut. Leave
some slack for cable movement.
Rev 40252-20090223
Operation
Operation
General Tips for Safe
Operation
Your 40252 winch is rated at 4,500 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 2,000 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.
Rev 40252-20090223
Self Recovery
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 2,000lbs., 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%
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 freespooling 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.
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.
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.
8
Rev 40252-20090223
Maintenance
Maintenance
The owner/operator is responsible for all
periodic maintenance.
WARNING
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 periodically using
a light penetrating oil.
Never operate a damaged or defective winch.
Cable Assembly
Replacement
WARNING
Improper maintenance will void your warranty.
Complete all scheduled maintenance in a
timely manner. Correct any issue before
operating the winch.
NOTE
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 knob 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.
For service or parts assistance, contact our help
line at 1-877-338-0999.
Rev 40252-20090223
9
Specifications
Specifications
Performance Specifications
Rated Pull
Gear Reduction Ratio
Motor
4,500 lb (2041 kg)
166:1
Permanent Magnet
1.6 HP/(DC 12V)
Duty Cycle
Intermittent
Drum Size
2” (D) x 4.92” (L)
50.8 mm (D) x 125 mm (L)
Cable
7/32” (D) x 52’ (L)
5.4 mm (D) x 16 m (L)
Weight
34.9 lb. (15.8 kg)
Height
5.0 inches (127 mm)
Width
4.55 inches (115.5 mm)
Length
16.3 inches (415 mm)
Bolt Pattern 6.6” x 3” inches (168 mm x 76
mm)
Line pull Max
Line speed
(12VDC)
Max Current
Running Time*
Cooling Time**
Line speed and Motor Current (First layer)
lb
0
1000
2000
kg
0
454
907
FPM
12.8
9.8
8.5
MPM
3.9
3.0
2.6
amps
28
80
130
Minutes
1
1
1
Minutes
5
5
5
3000
1361
6.9
2.1
180
1
5
4500
2041
3.9
1.2
280
1
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 are designed and made for intermittent use and should not be used in constant duty applications.
Line pull and cable capacity
Layers of cable on drum
1
2
3
4
Max pulling capacity
per layer
lb
4500
3841
3310
2907
kg
2041
1742
1501
1319
Cable capacity
ft
13.4
28.8
45.8
52
per layer
m
4.1
8.8
14
* Use double line and snatch block for pulling loads over 2,000lb / 907 kg
10
16
Rev 40252-20090223
Specifications
Winch Diagram
Rev 40252-20090223
11
Specifications
Winch Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
12
Part Number
450100
450001
450002
450003
450200
450004
450005
450006
450007
450008
450009
450010
450300
250002
450011
450012
450013
450014
450015
450016
450017
450018
450019
450400
450020
300900
450021
300020
300019
450022
450023
250036
450024
450500
300022
450025
450026
450027
Description
Motor Assembly
Coupling, I
Spring, Coupling
Coupling, II
Drum Assembly
Gear Housing / End Bearing
Gear Ring
Gear Carrier Assembly, Output
Gear Carrier Assembly, Intermediate
Gear Carrier Assembly, Input
Gear - Input, Sun
Gear, Fixed
Clutch Assembly
Washer ø6, Flat
Bolt M6x25
Bolt M6x100
Seal
Friction Washer
Retaining Ring
O-Ring Seal
Drum Bushing
Hexagonal Shaft
Tie Bar ø10
Cable Assembly
1/4" Clevis Hook
Strap
Bolt M8x25
Washer ø8, Locking
Washer ø8, Flat
Mounting Channel
Bolt M10x20, Square Neck
Locking Nut M10
Roller Fairlead
Switch Assembly
Hand Saver Bar
Tie Bar ø8
Bolt M4x25
Washer ø4, Flat
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
6
4
2
2
2
1
1
2
1
2
1
1
1
4
4
4
1
2
2
1
1
1
1 2 2 Rev 40252-20090223
Troubleshooting
Troubleshooting
Problem
Motor does not turn on
Cause
Switch Assembly not connected properly
Loose battery cable connections
Solenoid malfunctioning
Solution
Insert Switch Assembly all the way into
the connector.
Tighten nuts on all cable connections.
Tap solenoid to loosen contacts. Apply 12
volts to coil terminals directly. A clicking
indicates proper activation.
Defective Switch Assembly
Defective motor
Replace Switch Assembly.
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.
Rotate clutch knob to the "In" position. If
problem persists, a qualified technician
needs to check and repair.
Motor runs but Cable drum
does not turn
Clutch not engaged
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 cable
connections.
winch running time too long
Defective or stuck Solenoid
Clean, Tighten, or replace.
Motor overheating
Motor runs in one direction
only
Defective Switch Assembly
Rev 40252-20090223
Allow winch to cool down periodically.
Tap Solenoid to loosen contacts.
Repair or Replace solenoid.
Replace Switch Assembly.
13
Warranty
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.
14
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.
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 40252-20090223
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
Rev 40252-20090223
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
15
Notes
Notes
16
Rev 40252-20090223
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