Comeup ATV-1500 User manual

1

2
ATV 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.
I. General Safety Precautions
To prevent serious injury and property damage, please read and understand this Instruction
Manual before installing your winch.
Check all safety and environmental conditions prior and during use.
Before use, ensure that you are familiar with all winching performance and operation such as
speed & direction.
A wire rope should be replaced if it shows signs of excessive wear, broken wires, corrosion or
any other defects.
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 occur.
Ensure that the winch is connected to the correct voltage. 12VDC only and any voltage drop
shall be less than 10% during operation.
Check that the clutch shifter is in the “Engaged” position during and after use.
Remove the remote control from the winch when not in use.
Do not wrap the wire rope around the load and back onto it self. 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 fairlead during operation..
Never unplug the remote control and battery leads when winching a load.
To avoid insufficient power when winching a load, the vehicle should be running and in neutral.
When winching a heavy load, lay a heavy blanket or jacket over the wire rope near to the hook
end
If excessive noise or vibration occurs when running, stop the winch immediately and return it for
repair.
If a clutch can’t be properly locked in the “Engaged” position, rotate the drum to have the clutch
coupled to the gear train.
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.
WARNING

3
II. Performance Data
Specifications Line Pull and Rope Capacity
Model ATV-1500 Model ATV-1500
Line Pull (first layer) 680 kg / 1,500 lb Line pull ( kg / lb) 680 / 1,500
Line speed (mpm / fpm) 1.13 / 3.7
Line Speed
(first layer, no load) 4.6 mpm / 15 fpm 1st layer
Rope cap. ( m / ft ) 2.4 / 7.9
Amp. Draw 12V 65A Line pull ( kg / lb ) 571 / 1,256
Line speed (mpm / fpm) 1.34 / 4.4
Type Permanent magnet 2nd layer
Rope cap. ( m / ft ) 5.2 / 17.1
Line pull ( kg / lb ) 492 / 1,082
Motor
Input 12V 300 w / 0.4 hp Line speed (mpm / fpm) 1.55 / 5.1
Type 3 stage planetary
3rd layer
Rope cap. ( m / ft ) 8.5 / 27.9
Gear Train
Ratio 103:1 Line pull ( kg / lb ) 433 / 953
Clutch Sliding shaft gear Line speed (mpm / fpm) 1.77 / 5.8
Brake Dynamic and mechanical
4th layer
Rope cap. ( m / ft ) 12.2 / 40.0
Line pull ( kg / lb ) 386 / 849
Control Remote switch Line speed (mpm / fpm) 1.98 / 6.5
Type A7 x 19Aircraft galvanized
5th layer
Rope cap. ( m / ft ) 15.2 / 50
Length 15.2 m / 50 ft
Wire Rope
Size 4 mm / 5/32”
Line Speed and Amp. Draw (First layer of wire rope on the drum)
Model ATV-1500
Line Pull Line Speed Amp.
kg lb mpm fpm 12V
0 0 4.6 15 6A
230 500 3.3 11 27A
450 1,000 2.1 7 44A
680 1,500 1.5 5 65A
Your winch will pull your ATV up or down in a ramp, it also help another ATV or a load if
it is anchored in a stationary position.
Main Components

4
Ⅲ
ⅢⅢ
Ⅲ. Installation


Complete kit installation
To install the complete kit, you need to amount the winch, roller fairlead, solenoid, remote
socket and trigger switch. Read and understand the following instruction to choose the
proper mounting locations.


Winch & Roller Fairlead Mounting
1. It is very important that the winch shall be mounted on a
flat hard base plate in order to make sure the motor,
drum and gearbox housing are aligned correctly.
2. If a different base plate is used, the thickness
shall be 5 mm (3/16”).
3. Four (4) M8x 20L 8.8 Grade High Tensile
Steel Bolts must be used for securing the
winch on the base plate in order to sustain the loads imposed on the winch mounting.
4. Two (2) M10 x 20L Grade High Tensile Steel Bolts must be used for securing the roller
fairlead on the base plate.
ATV-1500

5


Solenoid Kit Mounting
1. It disconnects your winch from the
power source when the vehicles is
not in use.
2. It should be mounted close to the
battery and keep the location from
all metal structures.


Handlebar Trigger Switch Mounting
Handlebar mounted trigger switch can be operated without removing your
hand from the grip.


Wiring Diagram

6
I
N
O
U
T
I
N
O
U
T
Ⅳ
ⅣⅣ
Ⅳ. Operation


Cable In and Out
1). To determine “ Cable Out “, trigger to the “Out” position
2). To determine “ Cable In “, trigger to the “In” position
3). To stop winching, release the freespoling shitter
Freespooling Function
The freespooling allows rapid payout of the wire rope for hooking onto a load or anchor
points and is operated by a freespooling shifter located on the end of the winch.
1).To engage the freespooling, turn the freespooling shifter counter-clockwise to the
“Engaged” position. The winch is now ready for pulling.
2).To disengage the freespooling, turn the freespooling shifter clockwise to the
“Disengaged” position. Wire rope can now be free spooled off the drum.

7
Ⅴ
ⅤⅤ
Ⅴ. Maintenance


Wire Rope Replacement
Before installing a new wire rope, wrap the end of the wire rope with tape to prevent
fraying. Wind the wire rope on the drum by pull a force to keep the tension constant.
Never use a wire rope of a different size or material and only use genuine wire ropes.
1). Disengage the freespooling.
2). Spool the old wire rope, and then remove it from the drum.
3). Have horizontal rollers and bolts apart from the roller fairlead, then place the
replacement wire rope through the throat, of the roller fairlead pass below the
drum, and insert it into the hole on the drum core.
4). Use a hex wrench to tighten the screw downwards to secure the wire rope.
5). Tighten the horizontal rollers and bolts of the roller fairlead
6). Wear leather gloves and use a handsaver strap when guiding the wire rope off the
drum.


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 is necessary
after repair or disassembly use a marine type grease.

8


Maintenance Schedule
Carry out all inspections listed below on schedule and inspections are divided into Daily,
Monthly and 3 Monthly. Clean all connections because corrosion on electrical connections
will reduce performance or may cause a short.
Classification of check
Periodical
Daily
One
month
Three
month
Item Checking method Checking reference
Complete winch Operate the winch in and out
Minimum corrosion of the
internal motor components
Installation
Mounting bolts & alignment. Bolts tension & wear. Tightened and aligned
Working Manual Reasonable actuation

Trigger
switch
Wearing in contact points Visual. Free of wear or damage.
Broken strands Visual, measuring (monthly)
Less than 10%
Decrease in rope diameter
Visual, measuring (monthly)
7% of nominal diameter
max

Wire rope
Deforming or corrosion and
fastening condition of end
Visual No existence of
abnormalities
Freespooling Wear in spring Visual evidence of wear Free of wear or damage.
Motor Staining, damage Visual evidence of wear No existence of
abnormalities
Wearing of lining 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 and
distortion.

9
Ⅵ
ⅥⅥ
Ⅵ. Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault operation
while winching, check followings.
Symptom Possible Cause Remedy
Cut circuit or loosing Check battery cable.
Weak battery or insufficient power Recharge or replace battery
Loose connection of wirings Checking all wirings
Damaged or stuck solenoid Replace solenoid
Defective trigger switch Check winch operation with an auxiliary switch
Winch will not operate
Damaged motor or worn carbon brush Replace motor or carbon brush
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 wiring and tighten.
freespooling not disengaged Engaged freespooling
Damaged brake or freespooling ass’y Replace brake or freespooling ass’y
Damaged drum bushing Replace drum bushing
Drum will not free spool
. Damaged gear box Replace gear box
Damaged or inoperative pressed spring Replace pressed spring
Disengaged Freespooling Engaged
Damaged output shaft Replace output shaft
No brake
Damaged 1st shaft Replace 1st shaft
Worn or damaged brake Replace or adjust brake
Brake distance is too long
Motor leads crossed Reverse electrical connections to motor
Solenoid kit crossed Reverse black and red wires on the solenoid
Winch runs opposite
direction Trigger switch crossed Reverse electrical connections
Long period of operation Stop operation to have it cooled
Over-load Reduce load
Motor runs extremely hot
Damaged or inoperative brake Replace or repair brake

10
Ⅶ
ⅦⅦ
Ⅶ. Replacement Parts List


ATV-1500
No. Description Q’ty No. Description Q’ty No. Description Q’ty
1
Motor 1 14 1st stage carrier 1 27 Hex. bolt 2
2
Motor support rack 1 15 2nd stage carrier 1 28 Hex bolt 2
3
Gearbox support rack 1 16 3 stage carrier 1 29 Solenoid 1
4
Cooper bushing 2 17 Ring gear 1 30 Sleeve 4
5
Drum 1 18 Freespoling shifter 7 31 Handsaver strap 1
6
Fix lever 2 19 Pressed spring 1 32 Handlebar hardware 1
7
Gear box 1 20 Freespoling knob 1 33 Trigger switch ass’y 1
8
Bearing 1 21 Retaining ring 1 34 Connector 2
9
Connection A 1 22 Foot print 1 35 Hex bolt 1
10
Connection B 1 23 Base plate 1 36 Mounting hardware 1
11
Brake spring 1 24 Wire rope 1 37 Spring washer 1
12
1st shaft 1 25 Roller fairlead 1
13
1st pinion 1 26 Hex bolt 2

MEMO

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.