Come.up Winch DV-6000S User manual

Self-Recovery Winch
Thank you for purchasing a Winch. This manual
covers operation and maintenance of the winch. All
information in this publication is based on the latest
production information available at the time of printing
General Safety Precautions
A Winch is designed to give safe and dependable service if operated
according to the instructions. Read and understand this manual before installation and
operation of winch.
Follow these general safety precautions:
Don't use unsuitable pulleys or accessories.
Don't use unsuitable rope in construction, strength or having any defects.
Check the winch for smooth operation without load before winching operation.
Make sure the wire rope is wound evenly on the first layer on the drum, rewind it if not
evenly wound.
1. The winch is rated for intermittent-periodic duty.
2. The winch is not to be used to lift, support or otherwise transport personnel.
3. A minimum of five (5) wraps of rope around the drum are necessary to support the
rated load.
4. When choosing the right winch, you need to consider the vehicle size and weight.
As a general guide, you need a winch with a maximum load rating of at least one and
a half times greater than the gross vehicle weight.
5. The rated line pull of the winch must be powerful enough to overcome the added
resistance caused by whatever the vehicle is stuck in.
6.Operate the winch cable in and cable out at no load if a winch has had any ingress of
water.
WARNING

Fleet angle
15°
Centre line of anchor point
I. Safety Precautions
Please read and understand this Instruction Manual before installing your winch.
Don’t use unsuitable wire rope in construction, strength or having any defects.
Don’t use an unsuitable hook or snatch block for wire rope.
The operator of a winch in some cases, is required to have qualifications according to
applicable laws and ordinances.
Do not use the winch as a lifting device or a hoist for
vertical lifting (Fig1).
Do not use winch to move people.
Do not exceed maximum line pull ratings shown in
tables. Shock load must not exceed these ratings.
Keep hands clear of wire rope and fairlead opening.
Pull from an angle below 15。to straighten up
the vehicle or load. (Fig2)
Use leather gloves or a heavy rag when handling the
wire rope.
When winching a heavy load lay a heavy blanket or
jacket over the wire rope near the hook end.
Do not operate the winch under the water.
(Fig1)
(Fig2)

II. Performance Data


Performance
Model DV-6000S DV-6000L / DV-6000SL
Line pull ( kg / lb) 2,722 / 6,000 2,722 / 6,000
Line speed (mpm / fpm) 2.0 / 6.5 2.0 / 6.5
1st layer
Rope cap ( m / ft) 3.6 / 11.8 6.7 / 22
Line pull ( kg / lb) 2,264 / 4,991 2,264 / 4,991
Line speed (mpm / fpm) 2.4 / 7.8 2.4 / 7.8
2nd layer
Rope cap ( m / ft) 7.8 / 25.6 14.7 / 48.2
Line pull ( kg / lb) 1,938 / 4,273 1,938 / 4,273
Line speed (mpm / fpm) 3.1 / 10.1 3.1 / 10.1
3rd layer
Rope cap ( m / ft) 12.8 / 42 24 / 78.7
Line pull ( kg / lb) 1,694 / 3,735 1,694 / 3,735
Line speed (mpm / fpm) 3.7 / 12.1 3.7 / 12.1
4th layer
Rope cap ( m / ft) 18.5 / 60.7 30 / 100
Line pull ( kg / lb) 1,505 / 3,318
Line speed (mpm / fpm) 4.2 / 13.7
5th layer
Rope cap ( m / ft) 24.4 / 80
Line speed and Amp. Draw Main Components
At the first layer of wire rope on the drum
Ⅲ
ⅢⅢ
Ⅲ. Installation
Before using the winch, make sure all electrical components have no corrosion or damaged; the
environment should be clean and dry. The voltage drop from the battery connections to the winch
must not exceed 10% of the nominal voltage under normal operating condition.


Mounting
1. It is very important that the winch shall be
mounted on a flat and hard surface in
order to make sure the motor, drum and
gearbox housing are aligned correctly.
2. It is recommended that you use a
mounting channel to prevent from
damaging winch or vehicle.
3. Four (4) M10 x 1.50 pitch 8.8 Grade High Tensile Steel
Bolts must be used
in order to sustain the loads imposed on the winch mounting.
4. Two(2) M12x1.75 pitch 8.8 Grade High Tensile Steel Bolts must be used for
fastening the roller fairlead into the mounting channel.
Line Pull Line Speed Amp
Kg lb mpm fpm 12v 24v
0 0 8.0 26.2 60 35
907 2,000 5.2 17 150 90
1,814 4,000 3.1 10.2 240 140
2,722 6,000 2.0 6.5 300 200



Battery cables connection
1. Attach the black battery lead(grounding) firmly to the negative (–) battery terminal.
2. Attach the red battery lead to the circuit breaker(optional accessories), connect the other end
to the positive (+) battery terminal.
3. The circuit breaker must be fitted.


Switch Connection
1. A remote switch withψ1.25 mm X 3C X 5 m(16AWG X 3C X 17ft) cord supplied.
2. Open the dust-proof cover of the winch, then insert the switch plug into the socket.
Ⅳ
ⅣⅣ
Ⅳ. Operation
Precautions
Check all safety and environmental conditions prior and during use.
A wire rope should be replaced if it shows signs of excessive wear, broken wires, corrosion or
any other defects.
The operator must remain with the winch when it is being operated.
The winches duty rating is S3 (intermittent – periodic)
If the winch fails to pull a load under normal conditions, stop the operation within 30 seconds
otherwise motor damage may be occurred.
Ensure that the winch is connected to the correct voltage. 12V DC or 24V DC only
Check that the freespool knob is in the “Engaged” position during and after use.
Remove the switch from the winch when not in use.
Do not wrap the wire rope around the load and back onto itself. Always use a strap to ensure
that the wire rope does not fray or kink.
Keep hands and clothes away from the winch, wire rope, and roller fairlead.
Never unplug the remote control when winching a load.
Before use, ensure that you are familiar with all winching operations (winch speeds &
direction).
To avoid insufficient power when winching a load, the vehicle should be running and in
neutral.
Keep the remote control clear of the wire rope at all times.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.

Cable-in/ Cable-out Operation
1). To determine “Cable - Out”, trigger →out (fig.4)
2). To determine “Cable - In”, trigger ←in (fig.5)
To stop winching, release the trigger
(Fig4) (Fig5)


Freespool Function
The freespool allows rapid pay-out of the wire rope for hooking onto a load or anchor points and is
operated by a freespool knob.
The freespool knob must be in the “Engaged” position before winching.
1). To disengage the freespool lift the freespool knob up and turn it at 90。clockwise rotation to
the “Disengaged” position, wire rope can now be freespooled off the drum.
2). To engage the freespool lift the freespool knob up and turn it at 90。counter-clockwise rotation
to the “Engaged” position.
3). If a freespool knob can’t be properly locked in the “Engaged” position, rotate the drum to make
the freespool device coupled to the gear train.
4). Wear leather gloves and use a strap when guiding the wire rope off the drum.
(Engaged) (Disengaged)
Cable-Out Cable-In

Ⅴ
ⅤⅤ
Ⅴ. Maintenance
Wire Rope Replacement
Never use a wire rope of a different size or material and only use genuine
replacement parts.
If the winch is subjected to a high duty or excess load, the rope may require
frequent replacement.
1). Disengage the freespool. (Fig6)
2). Spool the entire wire rope, and then remove it from the drum.
3). Place the replacement wire rope through the fairlead opening, pass below the
drum, and insert it into the hole on the drum core. (Fig7)
4). Tighten the screw downwards to secure the wire rope. (Fig7).
(Engaged) (Disengaged)
(Fig 6) (Fig 7)


Brake adjustment
Over time, the load-holding brake in your winch will wear. Should you find the load
beginning to slip, adjustments can be made to the brake mechanism as follows:
1). Loosen the 3 retaining bolts and remove the brake cover.
2). Remove the two retaining rings.
3). lnsert washers to maintain a spacing of 2.54 +/- 0.25mm ( .1〃+/- .01〃 )
between the ring grooves and the brake actuating cam.
4). Re-install the two rings and brake cover.



Lubrication
All moving parts in the winch are permanently lubricated at the time of assembly. Under
normal conditions factory lubrication will suffice. If re-lubrication of gear box is
necessary after repair or disassembly use Shell EP2 or equivalent grease with 0.15 litre.
Freespool knob lubricates regularly with light oil. It is not allowed to have brake ass’y
lubricated.


Maintenance Schedule
Ensure that a responsible person carries out all inspections as per schedule.
Inspections are dived into Daily, Monthly and 3 Monthly.
Classification of check
Periodical
Daily
One
month
Three
month
Item Checking method Checking reference
Installation
Mounting bolts & alignment. Bolt tension & wear. Existence of abnormalities
Working Manual Reasonable actuation

Remote
control
Wearing in contact points Visual. Free of wear or damage.
Broken strands Visual, measuring Less than 10%
Decrease in rope diameter
Visual, measuring 7% of nominal diameter
max
Deforming or corrosion Visual Existence of abnormalities

Wire rope
Fastening condition of end Visual Existence of abnormalities
Freespool Wear in spring Visual evidence of wear Free of wear or damage.
Motor Staining, damage Visual evidence of wear Existence of abnormalities
Wearing of brake disc Visual evidence of wear Free of wear or damage.

Brake
Performance Visual Reasonable actuation
Gear Train Damage, wearing Visual evidence of wear Free of wear or damage.

Ⅶ
ⅦⅦ
Ⅶ. Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault while
Symptom Possible Cause Remedy
Cut circuit Check battery lead.
Weak battery Recharge or replace battery (at least 650CCA)
Damaged over-load protector(option) Replace over-load protector(option)
Bad connection of wirings Reconnect tightly
Damaged solenoid Replace solenoid
Cut circuit on switch Replace switch
Damaged motor or worn carbon brush. Replace motor or carbon brush
Winch will not
operate
Dropt or lost motor wirings. Replace wirings or tight it.
Broken wirings or bad connections Reconnect or replace wirings
Damaged or stuck solenoid Replace solenoid
Switch inoperative Replace switch
Motor runs in one
direction.
Dropt or lost wirings. Replace wirings and tighten.
Freespool not disengaged Engaged freespool
Damaged 1st shaft Replace 1st shaft
Damaged brake cam and disc Replace brake cam and disc
Drum will not
freely spool.
Damaged output shaft Replace output shaft
Damaged brake cam and disc Replace brake cam and disc
Damaged gear box Replace gear box
Dropt retaining ring Replace retaining ring
Oil leakage at brake Clean oil leakage
No brake
Damaged or inoperative spiral spring Replace and position spiral spring
Worn or damaged brake Replace or adjust brakeBrake distance is
too long Oil leakage at brake. Clean oil leakage
Too much brake powder Clean brake ass’y
Over pre-pressed spiral spring Adjust pre-pressed spiral spring
Brake will be
locked
Stuck between brake lining and gear box Replace a new winch
Hit by certain exterior force. Replace the damaged components
Damaged gear train. Replace the damaged components
Damaged gear box
Over load operation. Replace a new winch
Long period of operation Allow to cool
Damaged motor Replace or repair motor
Motor runs
extremely hot
Damaged or inoperative brake Replace or repair brake

Ⅶ
ⅦⅦ
Ⅶ. Replacement parts List
DV-6000S、
、、
、DV-6000L
No. Description Q’ty No. Description Q’ty No. Description Q’ty
1 Motor 1 24 Freespool lever 1 37 Mounting hardware 1
2 Motor support rack 1 25 Gasket 2 38 Spring pin 1
3 Gearbox support rack 1 26 Tie bar 2 39 Bearing 1
4 Drum bushing 1 27 Gear box 1 40 Bearing 1
5 Drum 1 28 Brake cover 1 41 Retaining ring 1
6 Drum bushing A 1 29 Remote control 1 42 Retaining ring 2
7 Cable tensioner 1 30 Solenoid pack 1 43 Retaining ring 1
8 Hex bolt 2 -1 Upper solenoid box 1 44 Hex nut 1
9 Motor coupling 1 -2 Remote switch socket 1 45 Hex nut 2
10 1st shaft 1 -3 Socket gland 1 46 Hex bolt 1
11 1st pinion 1 -4 Cross screw 2 47 Hex bolt 4
12 1st stage carrier 1 -5 Nut 2 48 Hex bolt 2
13 2nd stage carrier 1 -6 Solenoid ass'y 1 49 Hex bolt 1
14 1st & 2nd ring gear 1 -7 Cross screw 4 50 Hex bolt 9
15 3rd ring gear 1 -8 Lower solenoid plate 1 51 Hex bolt 3
16 Brake cam B 1 -9 Hex bolt 3 52 Spring washer 1
17 Cone brake disc 1 -10 Socket packing 1 53 Spring washer 4
18 Brake cam A 1 -11 Battery lead 1 54 Spring washer 2
19 Brake freespool base 1 31 Handsaver strap 1 55 Spring washer 3
20 Spiral spring 1 32 Handle 1 56 Foot print 1
21 Freespool knob 1 33 Handle plate 1 57 Roller fairlead 1
22 Freespool sleeve 1 34 Wire rope w/hook 1
23 Pressed spring 1 36 Snatch block 1

DV
DVDV
DV-
--
-6000S
6000S6000S
6000SL
LL
L
No.
No.No.
No. Description
DescriptionDescription
Description Q'ty
Q'tyQ'ty
Q'ty No.
No.No.
No. Description
DescriptionDescription
Description Q'ty
Q'tyQ'ty
Q'ty No.
No.No.
No. Description
DescriptionDescription
Description Q'ty
Q'tyQ'ty
Q'ty
1 Motor 1 25 Gasket 2 36 Snatch block 1
2 Motor support rack 1 26 Tie bar 2 37 Mounting hardware 1
3 Gearbox support rack 1 27 Gear box 1 38 Spring pin 1
4 Drum bushing 1 28 Brake cover 1 39 Bearing 1
5 Drum 1 29 Remote control 1 40 Bearing 1
6 Drum bushing A 1 30 Solenoid pack 1 41 Retaining ring 1
7 Cable tensioner 1 -1 Solenoid upper plate 1 42 Retaining ring 2
8 Hex bolt 2 -2 Solenoid lower plate 1 43 Retaining ring 1
9 Motor coupling 1 -3 Remote switch socket 1 44 Hex nut 1
10 1st shaft 1 -4 Socket gland 1 45 Hex nut 2
11 1st pinion 1 -5 Screw 2 46 Hex bolt 1
12 1st stage carrier 1 -6 Nut 2 47 Hex bolt 4
13 2nd stage carrier 1 -7 Solenoid 1 48 Hex bolt 2
14 1st & 2nd ring gear 1 -8 Hex bolt 5 49 Hex bolt 1
15 3rd ring gear 1 -9 Toothed washer 5 50 Hex bolt 9
16 Brake cam B 1 -10 Hex bolt 2 51 Hex bolt 3
17 Cone brake disc 1 -11 Nut 4 52 Spring washer 1
18 Brake cam A 1 -12
Spring 2 53
Spring washer 4
19 Brake freespool base
1 -13 Lead gland 3 54
Spring washer 2
20 Spiral spring 1 -14
Socket plate 1 55
Spring washer 3
21 Freespool knob 1 31 Handsaver strap 1 56 Foot print 1
22 Freespool sleeve 1 32 Handle 1 57 Roller fairlead 1
23 Pressed spring 1 33 Handle plate 1
24 Freespool lever 1 34 Wire rope w/hook 1

Limited Warranty
This Limited Warranty is given by the COMEUP INDUSTRIES INC (the
“Seller”) to the original purchaser (the “Purchaser”) of a
Winch specified in this manual. This Limited Warranty is not transferable
to any other party.
The Seller takes the responsibility for all parts and components, with the
exception of the wire rope, to be free from defects in materials and
workmanship appearing under normal use for as long as the said
Purchaser owns the vehicle that the winch was originally mounted on.
Electrical components are warranted for 1 Year from date of purchase
under the same conditions. Any Winch, which is defective,
will be repaired or replaced without charge to the Purchaser.
Upon discovering any defect, the Purchaser under this Limited Warranty
is requested to return the complete winch and inform the seller or their
authorised distributors of any claims. The Purchaser must provide a copy
of the proof of purchase bearing the winch serial number, date of
purchase, owners name and address, vehicle details and registration
number.
The Limited Warranty does not cover any failure that results from
improper installation, operation or the Purchaser’s modification in design.
The winch is designed for vehicle self-recovery use only and should not
be used in industrial applications or for moving people. The Seller does
not warrant them to be suitable for such use.
DV 2007-07-1000