Champion Power Equipment 14560M User manual

OWNER’S MANUAL & OPERATING INSTRUCTIONS
ATV/UTV Wireless Winch Kit
4500 lb. Winch
10006 Santa Fe Springs Road
Santa Fe Springs CA 90670
USA / 1-877-338-0999
www.championpowerequipment.com
SAVE THESE INSTRUCTIONS
Important Safety Instructions
are included in this manual.
MADE IN CHINA
REV 14560M-20130619
14560M
MODEL NUMBER

*We are always working to improve our products. Therefore, the enclosed product may differ slightly from the image on the cover.
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:
• Product Info & Updates
•Frequently Asked Questions
• Tech Bulletins
• Product Registration
– or –
Call our Customer Care Team Toll-Free at:
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FCC Statement
1. This device complies with Part 15 of the FCC
Rules. Operation is subject to the following
two conditions: (1) This device may not cause
harmful interference.(2) This device must
accept any interference received, including
interference that may cause undesired
operation.
2. Changes or modifications not expressly
approved by the party responsible for
compliance could void the user’s authority to
operate the equipment.
NOTE: This equipment has been tested and found
to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable
protection against harmful interference in a
residential installation. This equipment generates
uses and can radiate radio frequency energy and,
if not installed and used in accordance with the
instructions, may cause harmful interference
to radio communications. However, there is no
guarantee that interference will not occur in a
particular installation. If this equipment does
cause harmful interference to radio or television
reception, which can be determined by turning
the equipment off and on, the user is encouraged
to try to correct the interference by one or more
of the following measures:
– Reorient or relocate the receiving antenna.
– Increase the separation between the
equipment and receiver.
– Connect the equipment into an outlet on
a circuit different from that to which the
receiver is connected.
Consult the dealer or an experienced radio/TV
technician for help.

14560M
4500 lb. Winch
ATV/UTV Wirelss Winch Kit
TABLE OF CONTENTS
Introduction.................... 1
Introduction..................1
This Booklet .................1
Accessories ..................1
Manual Conventions ...............2
Safety Rules ...................3
Controls and Features ..............5
Winch .....................5
Assembly .....................6
Assembling the Winch ............6
Solenoid/Contactor Location ........6
Install the Rocker Switch ..........6
Install the Antenna ..............6
Wiring the Winch ...............7
Testing Winch Operation ...........8
Wiring Diagram ................9
Switch Wiring Diagram ............9
Antenna Wiring Diagram .......... 10
Operation .................... 11
General Tips for Safe Operation...... 11
Self Recovery ................ 11
Winching Techniques A-Z ......... 12
Maintenance .................. 13
Lubrication ................. 13
Cable Assembly Replacement ....... 13
Specifications.................. 14
Performance Specifications ........ 14
Remote Battery ............... 14
Parts Diagram ............... 15
Parts List .................. 16
Troubleshooting................. 17
Warranty..................... 18
Warranty Qualifications .......... 18
Repair/Replacement Warranty....... 18
Do Not Return The Unit
To The Place Of Purchase......... 18
Warranty Exclusions ............ 18
Limits of Implied Warranty
And Consequential Damage ........ 18
Contact Information ............ 18
Address ................. 18
Customer Service ........... 18
Technical Service ........... 18

1 REV 14560M-20130619
ENGLISH 14560M
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
Model Number
Serial Number
Date of Purchase
Purchase Location
1-877-338-0999
14560M

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14560M ENGLISH
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 indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, may result in
property damage.
CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
DANGER
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
WARNING
If you have questions regarding your winch,
we can help. Please call our help line at
1-877-338-0999
NOTE
MANUAL CONVENTIONS

3 REV 14560M-20130619
ENGLISH 14560M
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.
DANGER
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.
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
Do not move the vehicle to pull a load
(towing) on the winch cable. This could result
in cable breakage.
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
Pull only on areas of the vehicle as specified
by the vehicle manufacturer.
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.
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
SAFETY RULES

REV 14560M-20130619 4
14560M ENGLISH
Do not use as a hoist. Do not use for overhead
lifting.
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
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.
WARNING
Use gloves to protect hands when handling
the cable. Never let the cable slide through
your hands.
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.
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
SAFETY RULES
DO NOT Mix Old and New batteries
DO NOT Mix Alkaline, Standard, or
Rechargeable Batteries
CAUTION

5 REV 14560M-20130619
ENGLISH 14560M
Winch
9
14
11
15
6
713
8
12
345
2
1
10
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.
(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 train, free
spool. Engaging the clutch “In” locks the
winch into the gear system.
(6) Wire Rope – 15/64” x 38’ galvanized
aircraft cable designed specifically for load
capacity of 4500 lb. (2041 kg)
(7) Clevis Hook – Provides a means for
connecting the looped ends of cables to an
anchor.
(8) Strap – Used to assist cable feed.
(9) Winch Connection Cables – Used to
connect the contactor to the winch motor.
(10) Battery Connection Cables – Used to
connect the battery to the contactor.
(11) Rocker Switch – Rocker switch with
handlebar mount for powering the rope in
or out of your winch drum.
(12) Antenna – Receives wireless signal from
wireless remote control from within a
50 ft. radius.
(13) Solenoid/Contactor – Power from the
vehicle battery flows through the weather
sealed solenoid/contactor switch before
being directed to the winch motor.
(14) Wireless Remote Control – Activate the
wireless system by pressing and holding
the POWER button on the wireless remote
for 3 seconds.
(15) Mount Assembly – Flatbed mounting
channel.
CONTROLS AND FEATURES

REV 14560M-20130619 6
14560M ENGLISH
ASSEMBLY
Assembling the Winch
This CPE 4500 lb. (2041 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
trucks, UTVs and ATVs. If you cannot find a kit
locally, contact CPE and we will provide you with
the name of a dealer.
1. Insert M10x20 bolts through the mounting
channel holes and attach the roller fairlead
to the mounting channel with the M10 lock
washers and M10 nuts provided.
Mounting bolts must be SAE grade 5 or better
and torque to 34 ft. lbs.
CAUTION
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 lockers 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 wire rope and pull
through the roller fairlead.
5. Attach the clevis hook to the cable, and then
hand strap to the clevis hook. Installing the Antenna (Wireless Use Only)
1. Determine the mounting location.
2. If mounting on a flat surface, mark and drill a
minimum of two (2) mounting holes, one (1)
on each side of the antenna. Loosely attach
the antenna using the supplied bolts and lock
nuts. Do NOT tighten fasteners at this time.
3. If mounting on a frame tube, loosely attach
using the supplied cable ties.
Solenoid/Contactor Location
Find a location for the solenoid/contactor. It is
recommended that the solenoid/contactor be
mounted close to the battery in a clean, dry
location. Make sure the location chosen allows for
sufficient clearance from all metal components.
Drill mounting holes if required. Once a location
is found, DO NOT install the unit until all wiring
is completed (see wiring section).
Installing the Rocker Switch
1. Decide which handlebar the rocker switch will
be mounted on. (The rocker switch is usually
installed on the left handlebar).
2. Use a piece of electrical tape (not provided)
around the handlebar to help prevent rotation
of the mount.
3. Tighten the rocker switch in place. DO NOT
over tighten or tighten/clamp over any hoses
or cables.
4. Once the rocker switch is mounted, the wires
can be routed back to where the solenoid/
contactor is located.
5. Make sure the handlebars have full range of
motion and then secure the rocker switch’s
cable with the supplied cable ties.
Terminals coming in contact with metal will cause
a direct short, possibly causing solenoid/contactor
and/or battery damage.
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).
NOTE
If utilizing a mounting plate, ensure that the three
major sections (motor, drum and gear housing) are
properly aligned. Proper alignment of the winch will
allow for even distribution of the full rated load.
CAUTION

7 REV 14560M-20130619
ENGLISH 14560M
ASSEMBLY
6. Splice the end of the red wire on the rocker
switch, to an ignition (keyed) controlled power
source using the supplied wire tap.
7. Once all wiring is connected to the solenoid/
contactor it can then be mounted using the
supplied M6 hardware.
8. Tighten the solenoid/contactor terminal nuts.
DO NOT over tighten.
9. Connect the black lead to the negative (–)
terminal of the vehicle’s 12 volt battery.
10. Place all terminal boots over terminals and
secure all cables with cable ties or electrical
tape (not included).
11. 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 rocker 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.
Battery cables should NOT be drawn taut.
Leave some slack for cable movement.
CAUTION
Wireless Use Only
Non-Wireless Use Only
1. Connect the yellow and blue cables to the
motor terminals on the winch. (Yellow to the
positive (+) terminal of the motor. Blue to the
negative (-) terminal of the motor). Tighten
the terminal nuts on the motor. DO NOT over
tighten. Route the other ends to the solenoid/
contactor location.
2. Connect the yellow and blue cables to the
solenoid/contactor (yellow to yellow and
blue to blue). DO NOT tighten nuts.
3. Connect the red and black cables to the
solenoid/contactor (red to red and
black to black). DO NOT tighten nuts. Route
the other ends to the vehicle’s battery.
4. Connect the red lead to the positive (+)
terminal of the vehicle’s 12 volt battery.
5. Connect the rocker switch to the solenoid/
contactor (black to black and green to green).
1. Connect the yellow and blue cables to the
motor terminals on the winch. (Yellow to the
positive (+) terminal of the motor. Blue to the
negative (-) terminal of the motor). Tighten
the terminal nuts on the motor. DO NOT over
tighten. Route the other ends to the solenoid/
contactor location.
2. Connect the yellow and blue cables to the
solenoid/contactor (yellow to yellow and
blue to blue). DO NOT tighten nuts.
3. Connect the red and black cables to the
solenoid/contactor (red to red and
black to black). DO NOT tighten nuts. Route
the other ends to the vehicle’s battery.
4. Connect the red lead to the positive (+)
terminal of the vehicle’s 12 volt battery.
5. Connect the rocker switch to the solenoid/
contactor (black to black and green to green).
Depending on the location of the solenoid/
contactor, you may need to use the black and
red cables in place of the yellow and blue, and
the yellow and blue in place of the red and
black. Just remember that this also changes
the diagram.
NOTE
You may need to use a test light to locate a
suitable wire. The wire should only have power
when the key is in the ON position.
NOTE
Wiring the Winch (Non-Wireless Use) Cont’d.
Wiring the Winch
NEVER route electrical cables across any
sharp edges, through and/or near moving
parts, or near parts that may become hot.
CAUTION

REV 14560M-20130619 8
14560M ENGLISH
Wiring the Winch (Wireless Use) Cont’d. Wiring the Winch (Wireless Use) Cont’d.
This kit is designed for use on front mounted
self-recovery winches only. The remote is
not designed for and should not be used on
winches or hoists in industrial applications
(car haulers/carriers, wrecker, cranes, etc.) or
for any other remote controlled applications.
WARNING
Test Winch Operation
When testing the winch for correct connections
and operation (Non-wireless and Wireless).
1. Make sure there are no exposed terminals or
wiring.
2. Wiring to all components is correct.
3. All loose wires are secured.
4. Turn the vehicle ignition switch to the ON
position, but DO NOT start the vehicle.
5. Check the winch for proper operation using
the rocker switch (or remote). The wire rope
should spool in and out in the direction
indicated on the switch (or remote).
LED Indicator Light
– Steady Red: System active and ready to use.
– Flashing Red: Winch powering in or out.
NOTE
6. Locate the black and green wires running
from the solenoid/contactor to the rocker
switch. Find the bullet connectors on these
wires located near the solenoid/contactor.
7. Plan a route for the wire harness between the
antenna and these bullet connectors.
8. Pull apart the bullet connectors on the black
and green wires identified in step 6 above.
9. Connect the rocker switch and solenoid/
contactor to the antenna (black to black and
green to green).
10. Connect the black ground wire with the ring
to the black, negative (-) terminal on the
solenoid/contactor.
11. Splice the end of the red wire on the rocker
switch, to an ignition (keyed) controlled power
source using the supplied wire tap.
12. Splice the end of the red wire on the antenna,
to an ignition (keyed) controlled power source
using the supplied wire tap
13. Once all wiring is connected to the solenoid/
contactor, it can then be mounted using the
supplied M6 hardware.
14. Tighten the solenoid/contactor terminal nuts.
DO NOT over tighten.
15. Connect the black lead to the negative (-)
terminal of the vehicle’s 12 volt battery.
16. Place all terminal boots over terminals and
secure all cables with cable ties or electrical
tape (not included).
17. Activate the wireless system by pressing and
holding the POWER button on the wireless
remote for 3 seconds. This enables the
wireless control system. A red indicator light
on the wireless remote turns on when the
system is active and ready to use.
18. 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 remote. 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.
19. Deactivate the system by pressing the POWER
button on the wireless remote and holding for
3 seconds, until red light turns off or after
2 mins of idle time, the wireless system de-
activates.

9 REV 14560M-20130619
ENGLISH 14560M
ASSEMBLY
Wiring Diagram
Switch Wiring Diagram
Green
Red
Ignition Wire
Black
Negative (–)
Positive (+)
Negative (–)
Blue
Positive (+)
Yellow
Red
Black
To Switch And
Remote Wiring
(See Below)

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14560M ENGLISH
ASSEMBLY
Ignition Wire
Green
Green
To Black (-) terminal on
the Solenoid/Contactor
Black or White
Red
BlackBlack
Red
7.5
Amp
Black Green
Antenna Wiring Diagram

11 REV 14560M-20130619
ENGLISH 14560M
OPERATION
General Tips for Safe Operation
Your 14560M winch is rated at a 4500 lb.
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
2,250 lbs. (1021 kg.) 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 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.
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 (not included) will 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 2,250 lbs.
(1021 kg.), 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%.
RIGHT WRONG
SINGLE LINE DOUBLE LINE

REV 14560M-20130619 12
14560M ENGLISH
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.
Winching Techniques A-Z Cont’d.
(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.

13 REV 14560M-20130619
ENGLISH 14560M
MAINTENANCE
The owner/operator is responsible for all periodic
maintenance.
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.
Cable Assembly Replacement
It is recommended that any modifications be
performed by a manufacturer’s authorized repair
facility, and that only manufacturer-supplied parts
be used.
1. Move the clutch 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.
Complete all scheduled maintenance in a timely
manner. Correct any issue before operating the
winch.
Never operate a damaged or defective winch.
WARNING
Improper maintenance will void your warranty.
WARNING
For service or parts assistance, contact our
help line at 1-877-338-0999
NOTE

REV 14560M-20130619 14
14560M ENGLISH
SPECIFICATIONS
Performance Specifications
– Rated Pull ......................................4500 lb. (2041 kg)
– Gear Reduction Ratio .......................................180:1
– Motor ...........................Permanent Magnet 1.6 HP/1.2 kW (12V DC)
– Drum Size....................1.73 in. (D) x 3.15 in. (L) [44 mm (D) x 80 mm (L)]
– Cable ...................... 15/64 in. (D) x 38 ft. (L) [6.0 mm (D) x 11.6 m (L)]
– Gross Weight ......................................29.8 lb. (13.5 kg)
– Net Weight .......................................26.9 lb. (12.2 kg)
– Height........................................4.9 inches (12.4 cm)
– Width ........................................4.5 inches (11.5 cm)
– Length ......................................13.5 inches (34.4 cm)
– Bolt Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 in. x 3 in. (12.4 cm x 7.6 cm)
Line Speed and Motor Current (First Layer)
Line Pull LB 01000 2000 3000 4500
KG 0454 907 1361 2041
Line Speed (12V DC) FPM 12.8 9.8 8.5 6.9 4.6
MPM 3.9 3.5 2.7 2.0 1.4
Motor Current (12V DC) A28 80 140 180 280
Running Time* Minutes 11111
Cooling Time** Minutes 55555
Line Pull and Cable Capacity Per Layer
Line of Cable 1234
Rated Line Pull LB 4500 3629 3041 2616
KG 2041 1648 1380 1188
Cable Capacity FT 6.7 15.0 24.9 38.0
M2.0 4.8 7. 6 11.6
Remote Battery
OEM battery: 23A (12V DC)
Replacement Batteries: 3LR50, A23BP, AG23, KE23A, MN21 or equivalent.
*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.

15 REV 14560M-20130619
ENGLISH 14560M
SPECIFICATIONS
Parts Diagram

REV 14560M-20130619 16
14560M ENGLISH
Parts List
# Part Number Description Qty
1456100-BF Motor Assembly -
Black Flat 1
2450001 Coupling, I 1
3450002 Spring,Coupling 1
4450003 Coupling, II 1
5410001 Spring 1
641020 0-BF Drum Assembly -
Black Flat 1
7410002 Tie Bar 3
8410003-BF Gear Housing Cover
-Black Flat 1
9410004 O Ring 100x1.9 1
10 410005 Gear Ring I 1
11 410006 Gear Carrier
Assembly,Output 1
12 410007 Gear Ring II 1
13 410008 Gear Carrier
Assembly,Intermediate 1
14 410009 Gear Carrier
Aseembly,Input 1
15 410010 Axis Support Bushing 1
16 410011 Cam Clutch Gear 1
17 410012-BF Gear Housing - Black
Flat 1
18 410013 Bolt M5 x 20 1
19 250002 Washer Ø6, Flat 1
20 250018 Bolt M6 x 16 1
21 250016-BF Clutch Cap - black
Flat 1
22 GB2760BB6802-
2Z
Radial Ball Bearing
6802-2Z Sealed 1
23 410014 Cultch Spring 1
24 GB2760BB0606-
2Z
Radial Ball Bearing
0606-2Z Sealed 1
25 410015 Sun Gear,Input 1
26 410016 Drum Bushing 2
27 410017 Seal Ring 2
28 410018 Bolt M5 x 16 5
29 450800 Cable Assembly -
6.0mm(D) x 11.6m(L) 1
30 C20002 1/4" Clevis Hook 1
31 250059-BF Mounting Channel -
Black Flat 1
32 400009 Bolt M10 x 20 2
33 250036 Nut M10, Locking 2
34 250029-BF Roller Fairlead - Black
Flat 1
35 250035 Washer Ø10, Locking 2
36 300020 Washer Ø8, Locking 4
# Part Number Description Qty
37 300019 Washer Ø8, Flat 4
38 450021 Bolt M8 x 25 4
39 410019 Contactor 1
40 400011 Bolt M6 x 25 4
41 250002 Washer Ø6, Flat 4
42 400028 Washer Ø6, Locking 4
43 400013 Nut M6,Locking 4
44
456001 Battery Wires - Red,
36”(L) / 6GAUGE 1
456002 Battery Wires - Black,
36”(L) / 6GAUGE 1
45 400017 Terminal Protector 8
46 250001 Bolt M6 x 20 2
47
456003 Winch Wires - Yellow,
72”(L) / 6GAUGE 1
456004 Winch Wires - Blue,
72”(L) / 6GAUGE 1
48 400020 Wire Tap 2
49 400021 Mini-Rocker Switch 1
50 400023 Washer Ø5, Flat 3
51 400025 Nut M5 3
52 400026-BF Mini-Rocker Switch
Clamp - Black Flat 2
53 400027 #6-32x9/32" 2
54 400028 Washer Ø6, Locking 2
55 400029-BF
Mini-Rocker Switch
Mounting Angle -
Black Flat
1
56 400030-BF Mini-Rocker Switch
Extender - Black 1
57 400031 Bolt M5 x 18 1
58 400022 Bolt M5 x 25 2
59 400024 Washer Ø5, Locking 3
60 18029-1 Wireless Remote 1
61 18029-2 Wireless Receiver 1
62 410022 Yellow Strap 1
63 410025 Hexagonal Shaft 1
64 410024 Screw M6 x 8 1
65 250011 Circlip Ø15 1

17 REV 14560M-20130619
ENGLISH 14560M
TROUBLESHOOTING
For further technical support:
Technical Service
Mon – Fri 8:30 AM – 5:00 PM (PST/PDT)
Toll Free: 1-877-338-0999
[e-mail]
Problem Cause Solution
Motor does not turn on Switch Assembly not connected
properly
Insert Switch Assembly all the way into the connector.
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
drum does not turn
Clutch (Cam Ring) not engaged Move Cam Ring to the "In" position. If problem
persists, call a qualified service technician to check
and repair.
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.
Clean, Tighten, or replace.
Motor overheating winch running time too long Allow winch to cool down periodically.
Motor runs in one
direction only
Defective or stuck Contactor Tap Contactor to loosen contacts.
Repair or Replace contactor.
Defective Switch Assembly Replace Switch Assembly.