Comeup CHAMPIONSHIP WINCH User manual

Automotive Winch
WARRANTY
1
Limited One(1) Warranty for Mechanical Components
Limited One (1) Year Warranty for Electrical Components
Industries Inc. ( ) warrants to the original purchaser that the mechanical components and
electrical components of the Blazer will be free of defects in material and workmanship for one (1) year. All
mounting kits and other accessories carry one (1) year limited warranty against defects in material
workmanship.
This warranty applies only to the original purchaser of the winch. 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 winch 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 winch 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 winch.
takes the responsibility for winch 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 and synthetic rope assemblies 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 winch. This warranty is void when
serial number plate is removed or defaced.
’s liability to the purchaser under the winch purchases for any loss or damage howsoever and whatsoever
arising shall not exceed the price of the initial winch 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.

Championship 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. We reserve the right to make changes without notice because of continued product
improvement.
The winch has been designed to give safe and dependable service if operated according to the
instructions. Please read and understand this manual before installation and operation of winch.
Careless winch operation can result in serious injury or property damage.
When requesting information or ordering replacement parts, always give the following information:
1. Winch Model and Voltage
2. Serial Number
3. Item. No. and Part Number
4. Part Description
1. This winch is a very powerful high-speed machine designed for application of competition or special
demand and it is necessary to be required professional operators or competitors to operate properly.
Treat with extreme care and observe all caution and warnings.
2. The winch is rated at the first layer of synthetic rope on the drum for intermittent-periodic duty.
3. The winch is not to be used to lift, support or otherwise transport personnel.
4. A minimum of ten (10) wraps of rope around the drum is necessary to support the rated load.
5. Keep clear of winch, rope, hook, and fairlead while operating.
6. Synthetic rope can break without warning. Always keep a safe distance from the winch and rope while
under a load.
7.
Remain a certain of tension on synthetic rope before winching. Surprise winching will result in the
broken synthetic as well as crush deformation.
8. Failure to adequately align, support, or attach winch to a suitable mounting base could result in a loss
of efficiency of performance or damage the winch, rope and mounting channel.
2
WARNING
！

I.Safety Requirement
In some cases, the operator of a winch may be required to have qualifications according to
applicable laws and ordinances.
Check safety and environmental conditions prior to and during use.
Only use correctly rated synthetic rope in construction, strength.
Inspect for damage and/or defects before use.
Don’t use an unsuitable hook and snatch block for rope.
The operator must remain with the winch during operation.
The winch duty rating is S3 (intermittent-periodic).
Do not use the winch as a lifting device or a hoist for vertical lifting
and moving people
Ensure that the winch is connected to the correct power source such as hydraulic or 12V DC.
Do not exceed maximum line pull ratings. Shock load must not exceed these ratings.
Keep hands clear of synthetic rope and roller fairlead opening.
Pull from an angle below 10° in the horizontal plane to straighten
up the vehicle or load.
Always use leather gloves when handling the synthetic rope.
When winching, always use a recovery damper. Place over the
synthetic rope in the middle third of its length.
A synthetic rope should be replaced if it shows signs of excessive
wear, broken strands, corrosion or any other defects.
If the winch fails to pull a load under normal conditions, stop the
operation within 30 seconds, or motor damage may occur.
Remove the remote control from the winch when not in use.
Do not wrap the synthetic rope around the load and back onto itself. Always use a tree truck strap.
Keep hands and clothes away from the winch, synthetic rope, and roller fairlead.
Never unplug the remote control when winching a load.
To avoid insufficient power when winching a load, the vehicle should be running and in neutral.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.
The rope shall be wound in according to drum rotation sticker or refer to owner’s manual.
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General Rules
3

I I .Performance Data
4
Rated line pull: 3,630 kg ( 8,000 lb ) single line
Line speed (1st layer): 50 mpm / 164 fpm 96 A at 12V at no load
Motor: 5,250 w / 7.0 hp 12V series wound x 2 pcs
Gear ratio: 3-stage spur gear train 33.5:1
Clutch (freespooling): Air free-spooling
Brake (outside the drum): Ratchet brake hold full load without slippage
Winch construction: Aluminum die cast housings with steel drum
Drum size: 63.5 x 197 x 290 mm ( 2.5” x 7.8” x 11.4” )
Control: Waterproof remote with thermometric indicator LED w/ 5 m cord
Recommended rope: Synthetic rope
Recommended rope size: 11 mm x 46 m ( 7/16” x 151’ )
Mounting bolts pattern: 330 mm x 114.3 mm ( 13” x 4.5” )
III. Winching Principles
Mount the Winch
● It is very important that the winch will be mounted on a flat and hard surface of mounting
channel in order to make sure the motor, drum and gearbox housing are aligned correctly.
● Hawse fairlead does not mount to the winch directly
● The synthetic rope shall be wound in an under-wound orientation only
● Four (8) M12 x 1.75 pitch 12.9 grade with 76 N-m torque settings (maximum) high tensile
steel bolts must be used in order to sustain the loads imposed on the winch mounting.
● Two (2) M10 x 1.5 pitch 8.8 grade with 44 N-m torque settings (maximum) high tensile steel
bolts must be used for fastening the hawse fairlead into the mounting channel.

5
Wiring Diagram
The winch is supplied with twin 7.0 hp series wound motors and twin contactor kits each,
please be compliance with the following wiring tips.
1. Use 2/0 AWG (America Wire Gauge for 60-70 mm2 in area) lead (red) from the contactors
kits to the positive (+) battery terminal.
2. Use 2/0 AWG (America Wire Gauge for 60-70 mm2 in area) lead (black) from the grounding
terminal of the motor to the negative (-) battery terminal.
3. Use thick copper buss bar of F-1, F-2 and A of the motors to the contactors
4. Link red wire of twin contactor in parallel for “Cable In” operation
5. Link black wire of twin contactor in parallel for “Cable Out” operation
6. Link green wire of twin contactor in parallel for earth grounding.
7. Link red, green and black wires to the remote socket
8. The recommended battery shall be 650 CCA minimum
9. Recommend the use of a 100 amp 12V plus alternator
Red
Green
Black
White
White
Yellow
Yellow
Green
Battery
Black
Red
Remote control

IV.Winching Principles
6
Calculating Fleet Angle
To obtain the best synthetic rope service, the direction of pull will be on a horizontal within ±10
degrees and perpendicular to be centerline of the winch drum within ±10 degrees. If the fleet
angle is bigger than the recommended angles, a good spooling cannot be obtained as the rope
will spoon on to one side of the rope drum.
Duty Cycle Ratings
The winch is rated at S3 10%ED & 1 min/10 min rating intermittent periodic duty.
Securing Anchor Point
When choosing an anchor point, select a safe and firm point such as a tree, stump or rocks.
If using a winch to retrieve another vehicle, the rescue vehicle is considered the anchor point and
should be made secure.
The anchor point must be strong enough to hold the gross weight of the vehicle and be positioned
to keep the fleet angle between the centre of the anchor point and the synthetic rope maintained less
than 10°. Always use a tree trunk protector strap to prevent ring barking the tree and damaged to
the synthetic rope.
Required Pulling Force
You need a winch powerful enough to overcome the weight of your vehicle with the added
resistance caused by the obstacle, moving water, mud, snow, sand or on a steep hill.
As a general guide, you need a winch with a maximum line pull of at least 1.5 times greater
than the gross vehicle weight.
There are three factors listed that influence the line pull effect required to recover the vehicle.
The values and calculations in this section are approximate and are for reference only.
Load Rating
Load and speed varies according to how
much synthetic rope is on the drum. The first
layer of rope on the drum delivers the slowest
speed and the maximum load.
The top layer delivers the maximum speed and
the minimum load.
For this reason, Blazer winch is rated at their
first layer capacities.
According to EN 14492-1 Section 5.7.2,
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.

Surface Type
Surface Drag (S)
Gradient
Angle ( )
Gradient (G)
Metal
0.15
5%
3°
0.06
Sand
0.18
10%
6°
0.11
Gravel
0.20
20%
11°
0.2
Soft Sand
0.22
30%
17°
0.3
Mud
0.32
50%
26°
0.44
Marsh
0.52
70%
35°
0.58
Clay
0.52
100%
45°
0.71
For example, if a vehicle weighing 3,000 kg is winched up an incline by 100% on the marsh
road, the above formula would be used as follows:
Where Wt: 2,000 kg, S: 0.52 G: 0.71
RPF = (Wt X S) + (Wt X G)
= (2,000 kg X 0.52) + (2,000 kg X 0.71)
= 1,040 kg + 1,420 kg
= 2,460 kg ≒5,412 lb of effect required to
recover the vehicle
A gradient of 10% is a rise of one
meter in ten meters (High / Distance)
a). Gross vehicle weight
b). Type of the surface to be traversed
c). Gradient to overcome
In recovery and loading the winch is used to pull something, the required pulling force (RPF)
can be calculated according to the formula:
RPF = (Wt X S) + (Wt X G) Where: Wt = The gross vehicle weight
S = The type of the surface to be traversed
G = The gradient to overcome
7
θ
Gradient
Distance
High
Winching V.S. Hoisting
A pulling winch should not be used for lifting. Please refer to Comeup’s website to view our
full range of lifting winches.

V. Accessories
Hawse Fairlead
The basic hawse fairlead is designed to guide the synthetic rope to and from the winch drum.
Do not use cast steel hawse fairleads as they have sharp edges and they do not have enough
radius for the rope to bend over.
Snatch Block
Recovery Damper
An important aid to successful winching is the use of
snatch block, which can be used to increase the pulling
power of a winch or change the direction of a pull.
A winch double lined with a snatch block creates a
mechanical leverage cutting the effort required by half.
The double line pull shows self recovery using a snatch
block attached to an anchor point; the pull applied to the
vehicle is almost twice as much as the line pull of the winch.
The use of one snatch block shows an indirect pull
where the vehicle is limited due to unsuitableground or
obstruction.
A recovery damper is a safety device designed to help eliminated the possibility of injury or
property damage in the event of a synthetic rope failure. Place in the middle third of a live rope.
The damper can help absorb the energy in the rope and reduce the likelihood of injury or damage.
8

VI. Operation
9
Control with Thermal Sensor – Warning LEDs
Cable-in / Cable-out Operation
1).To determine “Cable - Out”, trigger → out
2).To determine “Cable - In”, trigger ← in
3).To stop winching, release the trigger
Clutch Function
The air clutch must be in the “Engaged” position before winching.
1). Apply air pressure to the PF-1/4”-19 fitting for with 60 - 120 psi (4.1 ~ 8.3 bar).
2). To disengage the drum by operating the air control valve to pull out the synthetic rope by
hand. Pull out the synthetic rope but leave at least 10 wraps on the drum.
3). To engage the drum by moving the control valve lever to the appropriate position. Do not
attempt to pull a load until the air clutch in the “Engaged” position.
4). Wear leather gloves and use a strap when guiding the synthetic rope on and off the drum.
5). It cannot be clutched when the load is under load.
The warning LEDs are shown on the remote control. You shall stop operation and allow
winch to cool (Green LED) when the Red LED was illuminated.
Functions
LEDs
Plug in the Winch
Green
Normal Winching
Conditions
Green
Abnormal winching
Conditions
Red
Stop the Winch
Green
(Normal winching) (Abnormal winching)

10
Synthetic Rope Replacement
Tip for prolonging the life of Synthetic rope
1. Regular maintenance and periodically check the rope for damage or wear
2. Since too much abrasion can damage or weaken your synthetic rope, protect your rope from
rubbing against sharp objects or edge
3. An aluminum hawse fairlead is highly recommended since it has no sharp edges and resists
damage more easily than a roller fairlead
4. Keeping your synthetic rope clean and dry. To clean it after a muddy ride, spool out the rope,
rinse it with a hose, and let it dry completely before re-spooling
1). Disengage the winch, remove existing rope and replace hawse if necessary.
2). Guide the new rope through the collar and make a firm self-knob (Fig 1 & 2).
3). Leave about 20 – 25 cm / 8” – 10” rope on the drum (Fig. 3) and Cut the lateral side of the
end by 45° and apply 3 wraps of electrical tape to hold cut strands in place (Fig. 4).
4). Tighten and wrap the synthetic rope around the drum (Fig 5).
5). A minimum of ten (10) wraps of synthetic rope around the drum is necessary to support
the rated load (Fig. 6 )
1 2 3
4 5 6

11
Brake Adjustment
Lubrication
The lubrication for gear box and brake assembly with proper oil or equivalent quality in insuring
the long life of your winch will have a great influence.
Quality: Shell Omala 460; BP Energol GR-XP 460 ; Castrol Alpha SP-460; Mobil XMP460
Esso Spartan EP460
Viscosity(cSt): 457.81 mm2/s at 40°C and 29.83 mm2/s at 100°C
Quantity: 1.2 litre
Intervals: The lubrication frequency is based on the working hours. in general, it is essential
to replace oil every three months or 20 working hours at lease
●Braking device is composed of a mechanic ratchet brake and, in general, it is not essential
to have the brake adjusted, unless the brake distance from the time of braking until stopping
is be beyond 1.5% of rope length to the wound in during 1 minute.
●It is highly recommended that any adjustments are carried out by a qualified technician at
an authorized service centre.
●Brake adjustment procedures.
Step 1. Disassemble the winch.
Step 2. Remove retaining ring and spring pin.
Step 3. Tighten 2nd gear and braking shaft
clockwise until holding to the ratchet.
Step 4. Find the closed pole between spring
pins and fit plate (two pair of hole
among 8 pairs ),then put the fix plate
onto the hex hole of braking shaft.
Step 5. Insert spring pins and lock retaining ring.
Step 6. Reassemble the winch.

VII. Maintenance Schedule
12
● Ensure that a responsible person carries out all inspections as per schedule.
● Inspections are dived into Daily, Monthly and Quarterly.
Classification of check
Item Checking method Checking reference
Daily
Periodical
Monthly
Quarterly
Installation
Loosening and center
Checking of
Existence of
abnormalities
Remote
control
Working Manual
Reasonable
actuation
Wearing in contact
points
Visual
Free of wear or
Synthetic
rope
Broken strands
Visual, measuring
Two or more
adjacent strands are
cut
Decrease in rope
diameter
Visual, measuring
25% of nominal
diameter max
Fused or melted fibers Visual
Existence of
abnormalities
Fastening condition of
end Visual Existence of
abnormalities
Clutch Wearing of handle Operating
To be free from
remarkable wearing
Motor Staining, damage
Decomposition
Existence of
abnormalities
Brake
Wearing of brake disc Decomposition
checking
To be free from
remarkable
wearing
Performance Visual
Reasonable
actuation
Gear Damage, wearing Decomposition
checking
To be free from
remarkable wearing
Low oil level
Visual
Replenish oil
damage
and damage
and damage
and damage
checking
installing boltsrun-out of foundation

VII. Trouble Shooting
13
Symptom
Possible Cause
Remedy
Winch will not
operate
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 wiring
Reconnect tightly
Damaged contactor
Replace contactor
Cut circuit on switch
Replace switch
Damaged motor or worn carbon
brush
Replace motor or carbon brush
Poor or lost connections to motor
Replace wiring or tighten it
Motor runs in one
direction
Broken wiring or bad connections
Reconnect or replace wiring
Damaged or stuck contactor
Replace contactor
Switch inoperative
Replace switch
Drum will not
clutch
Clutch does not disengage
Replace clutch
Damaged 1st shaft
Replace 1st shaft
Damaged brake cam and disc
Replace brake cam and disc
Damaged output shaft
Replace output shaft
No brake
The gear train is mechanically binding
up
Check to insure the winch is mounted on a
flat, rigid surface
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Broken retaining ring
Replace retaining ring
Oil leakage into brake cavity
Repair and clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Brake distance is
too long
Worn brake disc or loose brake
spacer
Replace brake disc or adjust brake spacer
according to brake adjustment procedures
Oil leakage into brake cavity
Repair and clean oil leakage
Brake will be
locked
Too much brake disc powder in the
brake hub
Clean brake hub
Over tensioned spiral spring
Adjust tension on spiral spring
Stuck between brake disc and gear
box
Replace with new brake assembly
Damaged gear
box
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Stop the winch operation and reduce the
load
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

IX. Replacement Parts List
14

Item No.
Description
Part No.
Qty
1
Motor 12V
882698
2
2
Motor support rack kit
882699
1
3
1st gear kit
882700
1
4
2nd gear kit
882701
1
5
Stopper
882702
1
6
Ratchet stopper kit
882703
1
7
3rd gear kit
882704
1
8
Gear box kit
882705
1
9
Drum kit
882706
1
10
Transmitter shaft
882707
1
11
Clutch socket kit
882708
1
12-1
Tie bar kit
882709
1
12-2
Tie bar kit
882769
1
13
Gearbox support rack kit
882710
1
14
Air inlet cover kit
882712
1
15
Guard cover kit
882713
1
16
Control pack 12V
882714
1
17
Hawse fairlead
882697
1
18
Remote control
880126
1
19
Grounding lead
882720
1
20
Mounting hardware
882721
1
21
Handsaver strap
880026
1
22
Motor bracket kit
882757
1
15

NOTES
16

PN 882722 Ver:0
Specifications subject to change without notice
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