Champion Power Equipment C80195 User manual

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C80195 8,000lb Winch
Owners Manual
INTRODUCTION
Congratulations on your purchase of a Champion Power Equipment winch. CPE
designs and builds winches to strict specifications and with proper use and
maintenance should bring you years of satisfying service.
READ, STUDY AND FOLLOW ALL INSTRUCTIONS BEFORE
OPERATING THIS DEVICE.
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.
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury. This notation is also used to alert
against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided could
result in death or serious injury.
CAUTION
WARNING
WARNING

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CONTENTS
This carton contains the following items, please unpack carefully.
Read Instructions before beginning.
DESCRIPTION QUANTITY
Winch Assembly with wire rope 1
CapBoltM10x35 6
LockWashers 6
Flat Washers 6
M10Nuts 6
Mounting Channel 1
RollerFairlead 1
SnatchBlock/Pulley 1
ClevisHookw/Pin 1
Power Cord/Switch Assembly 1
FIG A

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GETTING TO KNOW YOUR WINCH
Your 8,000lb Champion Power Equipment 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 uses. Practice using your winch
before you are in a situation to need to use it.
1. Motor: Your 3.6HP motor require a 650CCA 12 volt battery for operation and
provides power to the gear mechanism which turns the drum and winds the
wire rope;
2. 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.
3. Wire Rope: Your winch has a 5/16” x 95’ galvanized aircraft cable designed
specifically for load capacity of 8,000lbs. 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.
4. 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. 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.
6. 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. The
braking action is applied by a separate mechanical brake.
7. 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.
8. Solenoid: Power from the vehicle battery flows through the weather sealed
solenoid switch before being directed to the winch motor.

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9. Remote Switch: Power switch with 12’ cord has a dual switch for powering
the rope in or out your winch drum. The 12’ cord allows you to stand clear of
the wire rope when the winch is under load.
10.Universal Flat Bed Mounting Channel: Your winch has been 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.
11.Clevis Hook: Connect the wire rope to the pulled staff, also add to the
adaptability of your winch.
12.Snatch Block: Your winch has been supplied with a snatch block that, used
properly, can double the pulling power of winch, or change your pulling
direction without damaging the wire rope. We recommend you to use a snatch
block and double your line for pulling over 5,000 lbs / 2272 kgs.
FIG B

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MOUNTING YOUR WINCH
1. Your CPE 8,000 lb winch is designed with a 10” x 4.5” 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 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. Insert 2xM10 Nuts with Lock Washers (Part# 810021 & Part # 810022) to the
mounting channel hole and attach the Roller Fairlead to the mounting channel
with the bolts provided, and guide the wire rope through the rollers. (See
Fig.2)
Mounting bolts must be SAE grade 5 or better and torque to 34 ft. lbs.
3. Turn the winch up-side-down; insert 4 Cap Bolts with Flat Washers
(Part#810023 & Part# 810024) into the holes of the winch as showed in Fig. 3.
4. Place the Mounting Channel on the winch as shown in Fig. 4. Making sure the
winch is centered in the middle of the mounting channel. Disengage the
clutch by moving the Cam Ring to the “Out” position. Release the wire rope
and pull through the slot in the front of the channel.
5. Attach using the 4 x M10 Nuts with Lock Washers (Part# 810021 & Part#
810022) into the hole. (See Fig. 5)

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6. Attach the clevis hook and hand strap. (See Fig. 6, Fig. 7)
7. Connect the battery leads. NOTICE: BATTERY SHOULD BE A MINIMUM OF
650CCA FOR WINCH TO FUNCTION PROPERLY. Connect the red (positive)
lead from the solenoid to the positive (+) terminal of the vehicles 12 volt
battery. Connect the black (negative) lead from the motor to the Negative (-)
terminal of the battery.
Caution Battery cables should not be drawn taut. Leave some slack
for cable movement.
8. Attach the hand held remote lead to the winch and test for proper operation.
(See Fig. 9)
9. 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 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.
Fig. 1 Fig. 2

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Fig. 3 Fig. 4
Fig. 5 Fig. 6
Fig. 7 Fig. 8
Fig. 9

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SAFETY PRECAUTIONS
WARNING
READ, STUDY AND FOLLOW ALL INSTRUCTIONS BEFORE
OPERATING THIS DEVICE.
WARNING – DO NOT EXCEED RATED CAPACITY.
WARNING - Do not use winch for lifting or moving people or animals.
WARNING - A minimum of 5 wraps of cable around the drum barrel is
necessary for pulling and holding the rated load. The cable clamp is not
designed to hold the load without 5 wraps of cable around the barrel.
WARNING - Keep yourself and others a safe distance to the side of the cable
when 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 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 - 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
WARNING

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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 - Use gloves to protect hands when handling the cable. Never let
the cable slide through your hands.
Don’t wrap cable around any object and hook back onto itself.
Apply blocks to the wheels of the vehicle when on an incline.
No modifications, alterations, or deviation to the winch are authorized by the
manufacturer and should not be made.
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 release the free-spool clutch when there is a load on the
winch.
CAUTION - Use hook strap when handling the hook for spooling or un-
spooling the wire rope.
WARNING - Failure to heed these warnings may result in personal injury
and/or property damage.

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GENERAL TIPS FOR SAFE OPERATION
•The C80195 is rated at 8,000 lbs. capacity in first layer (Max) when
spooling the first rope layer on the drum. Overloads can damage the
winch/motor/ or wire rope. For loads over 5,000 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 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.

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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 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.
WARNING

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RIGGING TECHNIQUES
Self Recovery
Locate a suitable anchor such as a strong tree trunk or boulder.
Always use a sling as an anchor point. CAUTION- Do not attaches
the clevis hook back onto the cable as this could cause damage to the
cable.
As shown in Fig 3.1
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. Fig 3.2
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 as shown in Fig 3.3.
For pulls over 5,000lbs., we recommend the use of the snatch
block/pulley block to double line the wire rope. Fig 3.4.
This reduces the load on the winch and the strain on the rope by
approximately 50%.
WARNING - Never use your winch for overhead hoisting or for
lifting people or moving people.
Fig 3.1
Fig 3.2
Fig 3.3
Fig 3.4
Fig35

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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 well clear. Never step
over the wire rope.
k. Double check your anchors and make sure all connections are secure.

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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 all well 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.

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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
Lubrication
1. All moving parts within the Electric Winch having been Lubricated using
high temperature lithium grease at the factory. No internal lubrication is
required.
2. Lubricate Cable Assembly (4) periodically using a light penetrating oil.
Cable Assembly Replacement
It is recommended that any such modifications be performed by a
manufacturer’s authorized repair facility, and that only manufacturer-supplied
parts be used.
1. Move Cam Ring 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.

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TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION
Motor does not
turn on
-Switch Assembly not
connected properly
-Loose battery cable
connections
-Solenoid malfunctioning
-Defective Switch
Assembly
-Defective motor
-Water has entered motor
-Insert Switch Assembly all the way into
the connector.
-Tighten nuts on all cable connections.
-Battery should minimum 650CCA.
-Tap solenoid to loosen contacts. Apply
12 volts to coil terminals directly. A
clicking indicates proper activation.
-Replace Switch Assembly.
-Check for voltage at armature port with
Switch pressed. If voltage is present,
replace motor.
-Allow to drain and dry. Run in short
bursts without load until completely dry.
Motor runs but
Cable drum does
not turn
-Cam Ring (clutch) not
engaged
-Move Cam Ring to the “In” position. If
problem persists, a qualified technician
needs to check and repair.
Motor runs slowly
or without normal
power
-Insufficient current or
voltage
-Battery weak, recharge. Run winch with
vehicle motor running.
-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
solenoid
-Defective Switch
Assembly
-Tap solenoid to loosen contacts.
-Repair or replace solenoid.
-Replace Switch Assembly.

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WINCH ASSEMBLY DRAWING
35
28
29
2
39
40
37
31
30
33
32
38
1
24
4
3
13
23
22
20
21
26
27
30
25
33
31
32
6
17
8
7
13
16
15
14
18
19
17
12
11
10
9
34
5
36
35
36

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WINCH PARTS LIST
Item # Part # Qty Description
1 810100 1 Gear Carrier Assembly.-Input
2 810200 1 Gear Carrier Assembly.-Intermediate
3 810300 1 Gear Carrier Assembly.-Output
4 810400 1 Cable Assembly
5 810500 1 Motor/End Bearing Assembly
6 810600 1 Break/Shaft Assembly
7 810700 1 Up-setting Solenoid Assembly
8 810800 1 Switch Assembly
9 810900 1 Drum Assembly
10 810001 6 Screw M4 x 12
11 810002 1 Cover – Gear Housing
12 810003 1 Gasket
13 810004 2 Thrust Washer
14 810005 1 Thrust Disc
15 810006 1 Gear – Input, Sun
16 810007 1 Thrust Washer
17 810008 1 Bushing – Drum
18 810009 1 Gear – Intermediate, Sun
19 810010 1 Bushing-Shaft
20 810011 1 Gear – Output, Sun
21 810012 1 Cap Screw M6 x 10
22 810013 1 Hexagonal Shaft
23 810014 6 Cap Screw M6 x 20
24 810015 1 Retainer – Ring
25 810016 1 Gear – Ring
26 810017 1 Cam Ring
27 810018 1 Locking Ring
28 810019 6 Spring
29 810020 1 End Bearing
30 810021 6 Cap Screw M10 x 35
31 810022 6 Lock Washer Ф10
32 810023 6 Washer – Flat Ф10
33 810024 6 Nut M10
34 810025 1 Terminal Protector
35 810026 4 Nut M6
36 810027 4 Cap Screw M6 x 25
37 810028 1 Mounting Channel
38 811000 1 Roller Fairlead
39 811100 1 Snatch Block
40 810029 1 Strap