Comeup ATV-3000 User manual

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ATV/UTV WINCH
Thank you for purchasing a . 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
WARNING: FAILURE TO READ AND FOLLOW THE SAFETY INSTRUCTIONS IN
THIS OWNER’S MANUAL BEFORE INSTALLING OR USING YOUR ELECTRIC
WINCH COULD RESULT IN DAMAGE TO YOUR WINCH AND SERIOUS OR FATAL
INJURY!!
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 of 12VDC only.
Check that the freespool 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 freespool can’t be properly locked in the “Engaged” position, rotate the drum to have the
freespool 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.The rated line pull of the winch must be powerful enough to overcome the added
resistance caused by whatever the vehicle is stuck in.
5.Never operate the winch under water.
6.Operate the winch cable in and cable out at no load after a winch was ingressed by
water.
WARNING

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II. Performance Data
Specifications Line Pull and Rope Capacity
Model ATV-3000 UTV-4000 Model ATV-3000 UTV-4000
Line Pull
(first layer) 1,360 kg / 3,000 lb
1,814 kg / 4,000 lb Line pull ( kg / lb) 1,363 / 3,000 1,814 / 4,000
Line speed (mpm / fpm) 2.6 / 8.5 2.6 / 8.5
Line Speed
(first layer, no load)
7.6 mpm / 24.9 fpm 6.0 mpm / 19.7 fpm
1st layer
Rope cap. ( m / ft ) 2.6 / 8.5 3.3 / 10.8
Amp.
Draw
12V 230A 230A Line pull ( kg / lb ) 1,170 / 2,590 1,694 / 3,735
Line speed (mpm / fpm) 2.9 / 9.5 3.0 / 9.8
Type Permanent magnet
2nd layer
Rope cap. ( m / ft ) 5.7 / 18.7 7.2 / 23.6
Line pull ( kg / lb ) 1,030 / 2,270 1,446 / 3,188
Motor
Input 12V 800 w / 1.0 hp 800 w / 1.0 hp
Line speed (mpm / fpm) 3.3/10.8 3.5 / 11.5
Type 3 stage planetary
3rd layer
Rope cap. ( m / ft ) 9.2 / 30.2 11.9 / 39.0
Gear
Train
Ratio 145:1 184:1 Line pull ( kg / lb ) 920 / 2,030 1,261 / 2,780
Freespool Sliding shaft gear Line speed (mpm / fpm) 3.8 4.0 / 13.1
Brake Dynamic and mechanical
4th layer
Rope cap. ( m / ft ) 13.1/ 43 15.2 / 50
Line pull ( kg / lb ) 830 / 1,830 ＊
Control Remote switch &
trigger switch Remote switch
Line speed (mpm / fpm)
4.2 ＊
Type A7 x 19 aircraft galvanized
5th layer
Rope cap. ( m / ft ) 15.2 /50 ＊
Length 15.2 m / 50 ft 15.2 m / 50 ft
Wire
Rope
Size 4.8 mm / 3/16 in 5.5 mm / 7/32 in
Drum size 55mm×75mm 55mm×119mm
Line Speed and Amp. Draw
(First layer of wire rope on the drum)
Model ATV-3000 UTV-4000
Line Pull Line Speed Amp. Line Speed Amp.
kg lb mpm fpm 12V mpm fpm 12V
0 0 7.6 24.9 15 6.0 19.7 20
230 500 6.3 20.7 40 3.9 12.8 45
450 1,000 4.9 16.1 70 3.4 11.2 70
680 1,500 4.3 14.1 100 3.1 10.2 90
900 2,000 3.7 12.1 140 2.9 9.5 120
1,140 2,500 3.1 10.2 180 2.7 8.9 150
1,363 3,000 2.5 8.2 230 2.4 7.9 180
1,588 3,500 ＊＊＊2.2 7.2 210
1,814 4,000 ＊＊＊2.0 6.6 230
Your winch will pull your ATV/UTV up or down in a ramp, it also help another ATV/UTV
or a load if it is anchored in a stationary position.

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Main Components
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.
1: Winch Ass'y with Wire Rope
2: Remote Control
3: Trigger Switch Ass'y (ATV-3000 only)
4: Remote Socket
5: Solenoid CES-2012
6: 6 Gauge Battery Lead
7: 4 Way Roller Fairlead
8-1 Mounting Plate (for ATV-3000)
8:
8-2 Mounting Plate (for UTV-4000)
9-1 Snatch Block (for ATV-3000)
9:
9-2 Snatch Block (for UTV-4000)
10: Handlebar Hardware (ATV-3000 only)
11: Mounting Hardware

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

Winch & Roller Fairlead Mounting
1. It is very important that the winch shall be
mounted on a flat hard surface in order to make
sure the motor, drum and gearbox housing are
aligned correctly.
2. If a different mounting plate is used, the thickness
shall be 5 mm (3/16”). If different hardware
is used, it must be SAE grade 8 minimum.
3. Four (4) included M8x 25L Grade 8.8 High
Tensile Steel Bolts must be used for securing the
winch on the mounting plate in order to sustain the loads imposed on the winch mounting.
4. Two (2) included M8 x 20L Grade 8.8 High Tensile Steel Bolts must be
used for securing the roller fairlead on the mounting plate.


Solenoid 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.


Remote Socket Mounting
1.Determine the mounting location for the remote socket.
2.Drill three holes on a plate and install.
ATV-3000 UTV-4000

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

Trigger Switch Mounting (ATV-3000 only)
Handlebar mounted trigger switch can be operated without removing your hand from the grip.


wiring Diagram
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 trigger level

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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 shifter located on the end of the winch.
1). To engage the freespool, turn the freespool shifter counter-clockwise to the “Engaged” position.
The winch is now ready for pulling.
2). To disengage the freespool, turn the freespool shifter clockwise to the “Disengaged” position.
Wire rope can now be free spooled off the drum.
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 aircraft grade wire ropes.
1). Disengage the freespool.
2). Spool the old wire rope, and then remove it from the drum.
3). Have horizontal roller and bolts apart from the roller fairlead, then place the replacement wire rope
through the roller fairlead throat, 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 roller and bolt of roller fairlead
6). Wear leather gloves and use a strap when guiding the wire rope off the drum.
7). It is very important that the winch shall be mounted on a flat surface , with the wire rope feeding
form the bottom of the drum.
8). To rewind wire rope on the drum correctly , it is necessary to keep a slight load on the wire rope
while cable in.
(Disengaged)
(Engaged) (Disengaged)

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

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.


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

Remote
control
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
Freespool 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.

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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
Damaged over load protector Replace over load protector
Loose connection of wirings Checking all wirings
Damaged or stuck solenoid Replace solenoid
Defective remote control Check winch operation with an
auxiliary switch
Winch will not operate
Damaged motor or worn carbon brush Replace motor or carbon brush
Broken wiring or bad connection Reconnect or replace wiring
Damaged or stuck solenoid Replace solenoid
Switch inoperative Replace switch
Motor runs in one
direction.
Dropt or lost wiring Replace wiring and tighten.
Freespool not disengaged Engaged freespool
Damaged brake or freespool ass’y Replace brake or freespool 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 freespool Engaged
Damaged output shaft Replace output shaft
No brake
Damaged 1st shaft Replace 1st shaft
Brake distance is too
long Worn or damaged brake Replace or adjust brake
Motor leads crossed Reverse electrical connections to
motor
Solenoid control crossed Reverse black and red wires on the
solenoid
Winch runs opposite
direction
Remote control or 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

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Ⅶ
ⅦⅦ
Ⅶ. Replacement Parts List


ATV-3000
No. Description No. Description No. Description
1 Motor 1
16
Freespool block 1
31
Wire rope 1
2 Motor support rack 1
17
Friction block 1
32
Roller fairlead 1
3 Gearbox support rack 1
18
Tie bar 2
33
Snatch block 1
4 Drum bushing 2
19
Plain washer 1
34
Remote control 1
5 Drum 1
20
Anti-leakage packing 2
35
Solenoid 1
6 Connector A 1
21
Bearing 1
36
Remote socket 1
7 Connector B 1
22
Dented retaining ring 1
37
Battery lead 1
8 Brake spring 1
23
Dented retaining ring 1
38
Battery lead 1
9 1st shaft 1
24
Hex bolt 4
39
Battery lead 1
10
Pressed spring 1
25
Hex bolt 3
40
Battery lead 1
11
2nd stage carrier 1
26
Spring washer 4
41
Mounting hardware 1
12
1st stage carrier 1
27
Screw 1
42
Cable tie 10
13
Ring gear 1
28
Foot print 1
43
Handlebar hardware 1
14
Freespool base 1
29
Base plate 1
44
Trigger switch 1
15
Freespool shifter 1
30
1st pinion 1
45
Spring Packing 3