Comeup GTD-650 User manual

Heavy Duty Hoist
1
Limited One (1) Year Warranty
Comeup Industries Inc. ( ) warrants to the original purchaser that heavy duty hoist will
be free of defects in material and workmanship for a period of one (1) year from the original date of purchase.
All mounting kits and other accessories carry a one (1) year limited warranty against defects in material workman-
ship.
This warranty applies only to the original purchaser of the hoist. To obtain any warranty service, the purchaser
under this Limited Warranty is requested to advise or its authorized distributors on any claim. The
purchaser must provide a copy of the purchase receipt bearing the hoist serial number, date of purchase, owners
name, email or Tel & Fax, address and purchaser vehicle details. Any products that determines to be
accountable for defective will be repaired or replaced or refund at sole discretion without charge to
buyer upon buyer’s compliance with these procedures. In the event of repair or replace, purchaser must send the
defective hoist or part, with freight prepaid, to or its authorized distributor. And will send
the serviced product back to purchaser on ’s cost. This warranty does not cover the removal or reinstallation
of the hoist.
takes the responsibility for hoist parts and components to be free from defects in
materials and workmanship, but the following portions are hereby excluded and disclaimed. or its
authorized distributors may make reasonable charges for parts and labour for repairs or resumption in the following
portions not covered by this limited warranty.
(1). All warranties of wire rope assembly after initial use
(2). All warranties of fitness for a particular purpose
(3). All warranties of the product’s finish
(4). All warranties of merchantability
The limited warranty does not cover any failure that results from improper installation/operation, third party part
substitution, purchaser’s alteration or modification on hoist. This warranty is void when
serial number plate is removed or defaced.
’s liability to the purchaser under the hoist purchases for any loss or damage howsoever and whatsoever
arising shall not exceed the price of the initial hoist purchase receipt. shall not in any event be liable to
the purchaser for any consequential and/or indirect loss or damage whether for loss or for profit or otherwise, costs,
expenses or other claims for consequential compensation whatsoever and whether caused by negligence of employees,
distributors and their employees or otherwise. reserves the right to change product design without notice.
In situations in which has changed a product design, shall have no obligation to
upgrade or otherwise modify previously manufactured products.
WARRANTY

Heavy Duty Hoist
2
Thank you for purchasing a Hoist. This manual covers operation and maintenance of
the hoist. All information in this publication is based on the latest production information available at
the time of printing. We reserve the right to make changes without notice because of continued product
improvement.
It has been designed to give safe and dependable service if operated according to the instructions.
Read and understand this manual before installation and operation of hoist. Careless hoist operation
can result in serious injury or property damage.
When requesting information or ordering replacement parts, always give the following information:
1.Hoist model and voltage
2.Serial Number
3.Item. No. and Part Number
4.Part Description
1. The hoist is rated at its top layer of wire rope on the drum for S3 Intermittent duty.
2. A minimum of five (5) wraps of rope around the drum is necessary to support the rated load.
3. Keep clear of hoist, rope, and hook while operating.
4. Wire rope can break without warning. Always keep a safe distance from the hoist and rope while under
a load.
5. Failure to adequately align, support, or attach hoist to a suitable mounting base could result in a loss
of efficiency of performance or damage the hoist, rope and mounting channel.
6. The hoist is a very powerful machine. Treat with extreme care and observe all caution and warnings.
WARNING
！

I.Safety Requirement
The operator of a hoist in some cases is required to have qualifications according to applicable
laws and ordinances.
Check all safety and environmental conditions prior to and during use.
Don’t use unsuitable rope in construction, strength or having any defects.
Don’t use an unsuitable hook and snatch block for rope.
The operator must remain with the hoist when it is being operated.
The hoist is rated at S3 25% Intermittent duty only.
Do not use the hoist as moving people.
Ensure that the hoist is connected to the correct voltage. 12V DC or 24V DC only.
Do not exceed maximum lifting load shown in tables. Shock load must not exceed these ratings.
A rope should be replaced if it shows signs of excessive wear, broken strands, corrosion or any
other defects.
If the hoist fails to lift a load under normal conditions, stop the operation within 30 seconds
otherwise motor damage may occur.
Remove the switch from the hoist when not in use.
Keep hands and clothes away from the hoist and rope.
Never unplug the remote control when hoisting a load.
To avoid insufficient power when hoisting a load, the vehicle should be running and in neutral.
If noise or vibration occurs when running, stop the hoist immediately and return it for repair.
The rope shall be wound in according to drum rotation sticker or refer to owners manual,
otherwise, the brake will not function.
Ensure to use the insulating boots on the exposed connections to offer better insulations and
to prevent electrical shorting.
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General Rules
！WARNING
1. The owner and/or the operator shall have an understanding of these
operating instructions and the warning before operating the electrical
hoist. Failure to follow these warnings may result in loss of load, damage
to the hoist, property damage, personal, or fatal injury.
2. The owner shall retain this manual for further reference to important
warnings, installation, operating and maintenance instructions.

I I .Handing Precautions
4
Operation Precaution
＊ To prevent the risk of electric shock, the power plug must be plugged into a matching outlet
and grounded in good condition.
＊ Never try to lift a load higher than the rated cap.
＊ Never hitch a ride on the hook, sling or load being moving.
＊ Hoists are not to be used for lifting or lowering people.
＊ Don’t work, walk or stand under an operating hoist.
＊ Always remain in control. Never neglect the hoist while actually hosting a load.
＊ While working, never stand under a lifting load or within the conveying area.
＊ Always look up when working around hoist, there is potential danger overhead.
＊ Never gravitate a load free.
＊ Be sure to lift a load vertically. Slack may allow wires to be caught in the drum.
＊ Prior to starting of use, carry out the daily checking without fail, and after confirming the safety
of function.
＊ If having a counter rotation incurred, make sure to correct its rotation direction.
＊ Prior to lift, make sure to have a precise performance of brake. If any malfunction of brake
happened, stop the operation immediately.
＊ When load suspended in air, it will not allow to be welding.
＊ Wire rope with one or more of the following defects shall be removed or replaced immediately.
1) kink, 2) distortion, 3) corrosion.
4) showing sings of excessive wear or of having broken wires not less than 10 pcs.
＊Stop the operation if there is any queer noise or vibration in the gear box to be happened.
＊ Do not connect the wire rope with the grounding of welding machine.
＊ While welding, do not have any contact with the welding objects because of having spark.
＊ Do not pull the switch.
＊ Never plugging (instant reverse-wind) or inching.
＊ Do not over duty cycle ratings.
＊ In order to prevent the layer down due to over loosening of rope irregular winding, etc.,
operate according to the suitable operating method.
＊ Use a hoist by fixing so securely that the rope around the drum is even.
＊ Be sure to fix a rope in the centre of swivel hook.
＊ Be sure to stop operation immediately when the wire rope becomes fully slackened.
＊ Avoid catching the hook or lifting a load on a fixed obstruction.
＊ Always leave the remote switch positioned immediately after use.
＊ Make sure that the load being lifting are well balanced and secured before starting.
＊ Avoid water splashes on the remote switch.
＊ Never wrap the load with the wire rope.

5
● It is forbidden to lift loads above
the rated capacity of the hoist
● Do connect the power lead on the
main power source directly and
fasten them
● Ban on transporting persons ● Don’t ignore fault accessories
● Don’t stand under hoisting operation ● Never submerge winch in water
as winch rated at IP44.

III.Environment Precautions
6
！DANGER
The following environmental conditions may result in the possible causes of hoist trouble.
● Low temperature below -10°C, high
temperature above 40°C or humidity
above 90% conditions.
※ Cause malfunction of spare parts ※ Cause explosion
● In the rain or snow conditions. ● In a heavy general powder.
※ Cause malfunction of performances.
● In an organic chemistry or explosive
powder condition.
※ Cause malfunction of spare parts.

IV. Hoisting Principles
7
Load Rated
Load and speed varies according to
how much wire rope is on the drum. The first
layer of rope on the drum delivers the slowest
speed and the maximum load. The top layer
of rope on the drum delivers the maximum
speed and the minimum load. For this reason,
all hoists are rated at their top layer capacities.
The flanged drum end plates shall protrude beyond the rope wound on the drum at the
top layer by at least 1.5 x the nominal rope diameter.
Calculating Head Loads
P: Rope tension
η: Sheave efficient
θ: Angle
W: Load
μ: Friction factor
First layer (Min.speed Max.load)
Half layer (Med.speed Med.load)
Top layer (Max.speed Min.load)
Flange of drum
P
W
P= W
η
P
W
P= W
2η
P
P= W
4η
W
P
WP= W
μ.
μ
P
μ
W
θ
P= Wμ.. sinθ +W.cosθ
Calculating Fleet Angle
● The hoist should be mounted as close to centre
and as perpendicular as possible to the direction
of the line pull. This will keep the wire rope fleet
angle centred on the drum as small as possible.
● If the proper fleet angle is not maintained, the
wire rope could wind onto one side of the drum.
This could cause failure of the hoist or wire rope, resulting in damage, injury or death.
● Experience has shown that the best wire rope service is obtained when the maximum fleet
angle is not more than 1.5° for smooth drums.
● Therefore the correct distance between centre of drum and of should be derived as a fleet angle
of 1.5° is the equivalents of approximately 19 cm of lead for each centimetre of overall drum
length.
θ
θ
Correct Distance
Drum Length
Fleet Angle
No. of sheaves 1 2
Roller bearing 0.98 0.96
Sleeve bearing 0.96 0.92
Model GTD-650 GTD-800 GTD-1200 GTD-2200 GTD-2800
Drum
Length
61.2 mm 68 mm 89 mm 108 mm 135 mm
Correct
Distance
1.29 m
at least
1.16 m
at least
1.69 m
at least
2.05 m
at least
2.57 m
at least

8
Percentage Duty Cycle
The life of the hoist is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its %ED ratings.
Continuous ratings means the percentage duty cycle (%ED) is subject to the rated voltage
and a 63% of rated load.
Percentage duty cycle (%ED)＝ X 100 (%)
Tb: total sum of overall loadings operating hours.
Ts: total sum of stopping hours.
Tb + Ts = approximately 1 to 10 minutes.
Rated lifting
kg / lb
GTD-650
min / 10 min
12V 24V
GTD-800
min / 10 min
12V 24V
GTD-1200
min / 10 min
12V 24V
GTD-2200
min / 10 min
12V 24V
Cont.
－ －
！WARNING
Never hoist over the rated percentage duty cycle.
Tb
Tb + Ts
The duty cycle of heavy duty hoist varies according to the rated lifting.
D/d Ratio
The drum diameter to wire rope diameter ratio (D/d) determines the wire rope size required.
Minimum hoist drum root diameter = wire rope diameter x ANSI B30.5* ratio minus rope diameter.
The greater the ratio the longer the wire rope life.
* In compliance with standard of ANSI B 30.5, the rope safety factory shall maintain at least 18:1
Cont.
－
－
8.0
－
－
6.0
4.5
3.0
－
8.0
－
－
6.0
－
－
4.0
3.0
2.0
－
GTD-2800
min / 10 min
－
9.0
－
－
－
7.0
－
5.0
3.5
2.5
－
7.0
－
－
－
4.5
－
3.0
2.5
2.0
No load
147 / 320
181 / 400
227 / 500
272 / 600
362 / 800
408 / 900
454 /1000
544 / 1,200
771 / 1,700
998 / 2,200
1,270 / 2,800
3.0
2.0
－
－
1.5
－
－
－
－
－
－
3.0
－
2.0
－
－
1.5
－
－
－
－
－
2.5
2.3
－
－
2.0
－
1.8
－
1.5
－
－
Cont.
12V 24V
－ －

9
Rope Safety Factor
The working coefficient shall be determined from the ratio of the minimum breaking force
of the rope and the maximum possible lifting force.
* In compliance with standard of ANSI B 30.5, the rope safety factory shall maintain at least 3.5:1
When using and installing a hoist, the owner or end user shall ensure that all legal requirements
are completely complied with.
Standard compliance of EC Directives
The EC directive includes the following individual directives
• Machinery Directive 2006/42/EC
It applies to independently functional machinery or the interlinking machines to form entire
systems. The complete machine and plant must always fulfill the directive.
• Electromagnetic Compatibility Directive (EMC) 2004/108/EC
It applies to most electrical and electronic apparatus, that is, finished products and systems
that include electrical and electronic equipment to ensure that the electromagnetic disturbance
generated by apparatus does not exceed a level allowing radio and telecommunications
equipment and other apparatus to operate as intended, and that apparatus has an adequate
level of intrinsic immunity to electromagnetic disturbance to enable it to operate as intended.
Extracts from the EC Directive & Comeup compliance:
1. EN 14492-1 Section 5.15.6 Wire Rope
Wire rope minimum break to be twice hoist rating
2. EN 14492-1 Section 5.7.2 Rope Drum
Rope drum mean diameter to be 10 times the diameter of the wire rope
3. EN 14492-1 Section 5.7.6 Rope Fastening onto the rope drum
Rope attachment to withstand 2.5 times the hoist rating
Rope must have at least two wraps winding before fixing point
4. EN 14492-1 Section 5.15.5 Brake
Hoist to hold full rated load
5. EN 14492-1 Section 5.15.2 Rated Capacity Limiters
The thermal overload cutout limit the driving power of the motor prevents hoist overloading
To comply with EN 14492-1, the following optional accessories must be fitted
to all hoists
• Overload protection device • Rope drum cover
• Emergency stop kit • Battery isolator switch
• Up and Down limits protection device

V. Operation
10
Electrical Wiring Diagram
Before using the hoist, 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 hoist must not exceed 10% of the nominal voltage under normal operating
condition.
Switch Connection
1. A remote switch with 1.25 mm (diameter) X 3C X 5 m
(16AWG X 3C X 17ft) cord supplied.
2. Open the dust-proof cover of the hoist and then insert
the switch plug into the socket.
Battery Recommendations
A fully charged battery and good connections are essential for the proper operation of
your hoist. The minimum requirement for battery is 650 cold cranking amp.
Lubrication
All moving parts in the hoist are permanently lubricated at the time of assembly. Under
normal conditions factory lubrication will suffice. If re-lubrication is necessary after repair or
disassembly use marine type grease.
Cable-in / Cable-out Operation
1. To determine “Cable - Out”, trigger → out
2. To determine “Cable - In”, trigger ← in
3. To stop hoist, release the trigger

VI. Maintenance
11
Tip for prolonging the life of wire rope
1). Do not wind out past the red paint section of the rope to secure the anchorage of the rope
on the drum.
2). Make sure the first layer of wire rope is tight and maintain a freeboard at least 1.5 x rope
diameter on the drum
3). To compensate for uneven spooling and the decrease in line pull capacity as the drum fills
up, use as short a wire rope as practical.
4). A minimum of five wraps of rope around the drum load is necessary to support the rated
load.
Wire Rope Replacement
For GTD-650/800/1200
Before installing a new wire/synthetic rope, wrap the end
of the wire rope with tape to prevent fraying. Wind the wire rope
on the drum by pulling a force to keep the tension constant. Never
use a wire/synthetic rope of a different size or material.
1). Spool the old wire rope, and then remove it from the drum.
2). Pass it below the drum. Insert rope into pocket opening and
through wedge pocket.
3). Loop rope end around wedge and feed rope back through
wedge pocket.
4). Once slack is taken up, the wire rope is properly installed.
5). Tighten the horizontal roller of the roller fairlead and bolts of the roller/hawse fairlead
6). Wear leather gloves and use a strap when guiding the wire/synthetic rope off the drum.
7). Rewind wire/synthetic rope on the drum correctly, it is necessary to keep a slight load on
the wire/ rope while cable in.
For GTD-2200/2800
1). Feed the end of the wire rope into No. 1 anchor hole in the
drum and wind about 1/4 wrap of rope on the drum. Insert the
wire rope into No. 2 hole and tighten the set screw securely.
2). Make sure the first layer of wire rope is tight and maintain a
freeboard at least 1.5 x rope diameter.
3). Wire rope shall be wound in an under-wound orientation only.
4). To compensate for uneven spooling and the decrease in line
pull capacity as the drum fills up, use as short a wire rope as
practical.
Set Screw
Set Screw
No.1
No.2

12
Brake Kit Replace
Under normal operation, there is no need to adjust the brake mechanism. When the
brake fails to hold a load within the distance 1.5% of line speed, please follow steps below to
replace the brake kit:
For GTD-650/800
1). Loosen the 3pcs M6 screws on motor support rack, and depart the motor support rack
from the drum.
2). Take off C-type retaining ring(R25) with a C clip, and take out coupler A, coupler B, and
brake spring.
3). Insert new coupler A, brake spring, coupler B, and C-type retaining ring(R25) in order.
4). Make sure the brake spring is inserted in correct direction, the upper feet of brake spring
need to fit in the notch of coupler A.
5). Make sure the notch of coupler B is toward down, and the lower feet of brake spring can
fit in the notch while rotating the coupler B.
6). Insert the C-type retaining ring (R25) with a C clip.
7). Assemble motor support rack and drum with 3pcs of M6 screws.
For GTD-1200/2200/2800
1). Loosen and take off the bolts on the brake cover to remove the brake cover.
2). After the brake clutch base is removed, take off 2 C-type retaining rings with a C clip, then
replace the brake kit and wave washer.
3). Insert new brake kit, have the foot of volute spring inserted into the pin hole of the brake kit.
4). Check the brake gap and insert spacers to maintain the brake gap to be:
2.0~1.5 for GTD-1200.
2.2 ± 0.25 mm for GTD-2200/2800.
5). Insert the block A, rotate it counter-clockwise by around 140 degree tor GTD-1200 and 150
degree for GTD-2200/2800; install spacer and 2 C-type retaining rings.
6). Install the brake clutch base and brake cover in order.
7). To avoid impacting the brake function, please remember to install the enclosed wave washers
while replacing the brake clutch base.

13
For GTD-650/800 For GTD-1200 For GTD-2200/2800

14
Maintenance Schedule
1. Ensure that a responsible person carries out all inspections as per schedule.
2. Inspections are dived into Daily, Monthly and Quarterly.
3. Always keep the hoist and accessories free of dirt, oil, grease, water and other substances.
Classification of check
Item Checking
method Checking reference
Daily
Periodical
Monthly
Quarterly
Installation Mounting bolts &
alignment
Bolt tension
& wear
Existence of
abnormalities
Remote
control /
contactor
Working Manual Reasonable actuation
Wearing in contact
points Visual Free of wear or damage
Wire rope
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
Fastening condition
of end Visual Existence of abnormalities
Wirings Fastening condition
of terminals Visual Free of corrosion and tightening terminals
Motor Staining, damage
Visual
evidence of
wear
Existence of
abnormalities
Brake
Wearing of lining
Visual
evidence of
wear
Free of wear or damage
Performance Visual Reasonable actuation
Gear train Damage, wearing Damage,
wearing Free of wear or damage
Housing
Tie bar Visual Mounting surface is flat
to within ± 0.5 mm
Support racks Visual Free of bent or crack

VII. Trouble Shooting
15
When the hoist fails to operate after several attempts, or if there is any fault while
Symptom
Possible Cause
Remedy
Hoist will not
operate
Cut circuit
Check battery lead
Weak battery
Recharge or replace battery (at least
650CCA)
Damaged circuit breaker
Replace circuit breaker
Bad connection of wirings
Reconnect tightly
Damaged contactor
Replace contactor
Cut circuit on switch
Replace switch
Damaged motor or worn carbon brush
Replace motor or carbon brush
Dropt or lost motor wiring
Tighten wirings
Motor runs in one
direction
Broken wiring or bad connection
Reconnect or replace wiring
Damaged or stuck contactor
Replace contactor
Switch inoperative
Replace switch
Dropt or lost wiring
Replace wiring and tighten, wirings
Hoist won’t lift
rated load
Considerable voltage drop exceeds by
10% of the rated voltage of 12V DC or 24V
DC.
Correct leads size
Replace battery as bad condition
Clean and tighten the wirings
No brake
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Dropt snatch ring
Replace snatch ring
Oil leakage at brake
Clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Damaged or stuck solenoid
Replace solenoid
Brake distance is
too long
Worn or damaged brake
Replace or adjust brake
Oil leakage at brake
Clean oil leakage
Damaged or stuck solenoid
Replace solenoid
Damaged gear
train
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Replace a new hoist
Motor runs
extremely hot
Long period of operation
Allow to cool
Damaged motor
Replace or repair motor
Damaged or inoperative brake
Replace or repair brake
Hoist vibrates
badly or is noisy
Damaged brake
Replace or repair brake
Mounting surface is not flat
Make sure mounting surface is flat
Tie bar is bent
Replace tie bar
Crack on the motor and gearbox support
racks
Replace racks

NOTES

COMEUP INDUSTRIES INC.
No.139, Jieyukeng Rd., Ruifang Dist., New Taipei City 22453, Taiwan
TEL:[phone] FAX:[phone]
Email: [email protected]
http://www.comeupwinch.com
882480 Ver:03
Specifications subject to change without notice