Champion 100440 Operating Manual Download

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100440 - 3000 LB. WINCH KIT

TABLE OF CONTENTS

Introduction

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Safety Definitions

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Important Safety Instructions

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Controls and Features

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Winch

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Parts Included

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Assembly

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Assembling the Winch

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Mounting the Remote Control

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Wiring the Winch

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Wiring Diagram

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Operation

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General Tips for Safe Operation

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Self Recovery

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Winching Techniques A-Z

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Maintenance

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Lubrication

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Wire Rope Replacement

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Synthetic Rope Replacement

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Synthetic Rope

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Specifications

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Performance Specifications

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Parts Diagram

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Parts List

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Troubleshooting

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Summary of Contents for 100440

Page 1: ...ntains important safety precautions which should be read and understood before operating the product Failure to do so could result in serious injury This manual should remain with the product Specific...

Page 2: ...y 8 Assembling the Winch 8 Mounting the Remote Control 9 Wiring the Winch 9 Wiring Diagram 10 Operation 11 General Tips for Safe Operation 11 Self Recovery 11 Winching Techniques A Z 12 Maintenance 13...

Page 3: ...you to take the time to review this product manual and other product materials thoroughly and be fully aware and knowledgeable of the assembly operation dangers and maintenance of the product before...

Page 4: ...dous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE is used to address practices not related to physical injury IMPORTANT SAFETY INSTRUCTIONS WARNING Cancer and...

Page 5: ...ind position with the rope entering the drum from the bottom not the top To re spool correctly and while wearing gloves keep a slight load on the rope while pushing the remote button to draw in the ro...

Page 6: ...igned 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 handl...

Page 7: ...e rope 5 Winch Drum The winch drum is the cylinder on which the rope is stored It can feed or wind the rope depending on the remote winch switch 6 Free Spooling Clutch The clutch allows the operator t...

Page 8: ...llow for even distribution of the full rated load NOTICE 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 Mou...

Page 9: ...O FULLY FUNCTION CONNECT ALL LEADS CORRECTLY 3 Connect the battery leads 3a Connect the red lead to the positive terminal of the vehicle s 12 volt battery 3b Connect the black lead to the negative ter...

Page 10: ...100440 3000 LB WINCH KIT ASSEMBLY 10 Wiring Diagram...

Page 11: ...placement 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 t...

Page 12: ...rs stand clear and that no one is directly in front or behind the vehicle or anchor point o Begin winching Be sure that the rope is winding evenly and tightly around the drum The vehicle that is being...

Page 13: ...ut position 2 Extend wire rope to its full length Note how the existing rope is connected to the inside of the drum 3 Remove old wire rope and attach new one 4 Retract wire rope onto drum being carefu...

Page 14: ...00 2000 3000 KG 0 454 907 1361 Line Speed FPM 11 2 8 8 7 2 3 9 MPM 3 4 2 7 2 2 1 2 Max Current 12V DC A 15 80 120 150 Run Time Minutes 1 1 1 1 Cooling Time Minutes 5 5 5 5 If the motor becomes uncomfo...

Page 15: ...100440 3000 LB WINCH KIT SPECIFICATIONS 15 Parts Diagram 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 16 17 19 18 20 21 22 25 29 30 35 34 33 32 31 36 24 26 27 28 37 23...

Page 16: ...Black Flat 1 17 300500 C T Series F W Knob Assembly 1 18 300016 Hexagon Socket Countersunk Head Screw M6 16 2 Part Number Description Qty 19 300018 Hexagon Head Bolt M8 35 2 20 300019 Flat Washer 8 2...

Page 17: ...d until completely dry Motor runs but rope drum does not turn Clutch cam ring not engaged Move cam ring to the In position If problem persists a qualified technician needs to check and repair Motor ru...

Page 18: ...as a whole Installation Use and Maintenance This warranty will not apply to parts and or labor if the product is deemed to have been misused neglected involved in an accident abused loaded beyond the...

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