Comeup Cub3 User manual

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ATV/UTV Winch
Thank you for purchasing a COMEUP 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.
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 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
2. Serial Number
3. Item. No. and Part Number
4. Part Description
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.Aminimum of five (5) wraps of rope around the drum is 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 penetrated
b
y
water.
WARNING
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I. Safety Requirement
WARNING: FAILURE TO READ AND FOLLOW THE SAFETY INSTRUCTIONS IN
THIS OWNER’S MANUALBEFORE INSTALLING ORUSING YOUR ATV/UTV WINCH
COULD RESULT IN DAMAGE TO YOUR WINCHAND SERIOUS OR FATAL INJURY!!
XGeneral Rules
Check all safety and environmental conditions prior to and during use.
Before use, ensure that you are familiar with all winching performance and
operation such as speed & direction.
A wire rope/synthetic rope should be replaced if it shows signs of excessive wear,
broken strands, 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 motordamage may occur.
Ensure that the winch is connected to the correct voltage of 12VDC only.
Check that the clutch shifter is in the “Engaged” position during and afteruse.
Remove the remote control from the winch when not in use.
Do not wrap the wire rope/synthetic rope around the load and back onto itself.
Always use a strap to ensure that the wire rope/synthetic rope does not fray or
kink.
Keep hands and clothes away from the winch, wire rope/synthetic rope, and roller
fairlead/hawse fairlead during operation.
Never unplug the remote control and battery leads when winching a load.
To avoid insufficient powerwhen 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/synthetic 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.

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II. Main Components
III. Installation
XComplete Kit Installation
To install the complete kit, you need to mount the winch, roller fairlead/hawse
fairlead, contactor, rocker switch, remote socket (option) and remote control (option).
Read and understand the following instruction to choose the proper mounting
locations.
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XWinch & Roller Fairlead/Hawse 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 at
least 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/hawse fairlead on the mounting plate.
XContactor Mounting
1. It disconnects your winch from the power source when the vehicle is not in use.
2. It should be mounted close to the battery and keep the location from all metal
structures.

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XRemote Socket Mounting (Option)
1. Determine the mounting location for the
remote socket.
2. Drill three holes on a plate and install.
XRocker Switch Mounting
Handlebar mounted rocker switch can be operated without removing your hand from
the grip.
XWiring Diagram
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IV. Operation
XCable In and Out
1). To determine “Cable Out“, Press to the “Out” position
2). To determine “Cable In“, Press to the “In” position
3). To stop winching, release the rocker level
XClutch Function
The clutch allows rapid pay-out of the wire rope/synthetic rope for hooking onto
a load or anchor points and is operated by a clutch shifter located on the end of
the winch.
1). To engage the clutch, turn the clutch shifter counter-clockwise to the positioned
point of “Engaged”. The winch is now ready for pulling.
2). To disengage the clutch, turn the clutch shifter clockwise to the positioned point
of “Disengaged”. Wire rope/synthetic rope can now be free spooled off the
drum.

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V. Maintenance
XWire Rope/Synthetic Rope Replacement
Before installing a new wire rope/synthetic rope, wrap the end of the wire
rope/synthetic rope with tape to prevent fraying. Wind the wire rope/synthetic rope on
the drum by pulling a force to keep the tension constant. Never use a wire
rope/synthetic rope of a different size or material and only use aircraft grade wire
rope/synthetic rope.
1). Disengage the clutch.
2). Spool the old wire rope/synthetic 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/synthetic rope through the roller fairlead/hawse 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/synthetic rope.
5). Tighten the horizontal roller and bolt of roller fairlead.
6). Wear leather gloves and use a strap when guiding the wire rope/synthetic rope on
and off the drum.
7). It is very important that the winch shall be mounted on a flat surface, with the wire
rope/synthetic rope feeding form the bottom of the drum.
8). To rewind wire rope/synthetic rope on the drum correctly, it is necessary to keep a
slight load on the wire rope/synthetic rope while cable in.
XLubrication
All moving parts in the winch are permanently lubricated at the time of kit. Under
normal conditions factory lubrication will suffice. If re-lubrication is necessary after
repair, please use marine type grease.
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XMaintenance Schedule
Carry out all inspections below on schedule. All inspections are performed by Daily,
Monthly and Quarterly basis. Clean all connections because corrosion on electrical
connections will reduce performance or may cause a short.
Classification of check
Periodical
Daily Monthly
Quarterly
Item Checking method Checking
reference
cComplete winch Operate the winch in
and out
Minimum
corrosion of the
internal motor
components
cInstallation
Mounting bolts &
alignment Bolts tension & wear Tightened and
aligned
cWorking Manual Reasonable
actuation
c
Control /
Switch Wearing in
contact points Visual Free of wear or damage
cBroken strands Visual, measuring Less than 10%
ccDecrease in rope
diameter Visual, measuring 7% of nominal diameter max
c
Wire rope /
Synthetic
rope Deforming or
corrosion and
fastening
condition of end
Visual No existence of
abnormalities
cClutch kit Damaged clutch
kit Visual evidence of
wear Free of wear or damage
cMotor Staining, damage
Visual evidence of
wear No existence of abnormalities
cWearing of lining Visual evidence of
wear Free of wear or damage
c
Brake Performance Visual Reasonable
actuation
cGear train Damage, wearing Visual evidence of
wear
Free of wear or
damage and
distortion

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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 lead
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 orstuck contactor Replace contactor
Defective remote control Check winch operation with an auxiliary
switch
Winch will not
operate
Damaged motor Replace motor
Broken wiring or bad connection Reconnect or replace wiring
Damaged orstuck contactor Replace contactor
Switch inoperative Replace switch
Motor runs in one
direction
Dropt or lost wiring Replace wiring and tighten
Clutch does not disengage Engaged clutch
Damaged brake or clutch kit Replace brake or clutch kit
Damaged drum bushing Replace drum bushing
Drum will not
clutch
Damaged gear box Replace gear box
Damaged orinoperative pressed spring Replace pressed spring
Disengaged clutch Engaged
Damaged 3rd stage carrier Replace 3rd stage carrier
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
Contactor control crossed Reverse black and red wires on the
contactor
Winch runs in
opposite direction
Remote control or rocker switch crossed Reverse electrical connections
Long period ofoperation Stop operation to have it cooled
Over-load Reduceload
Motor runs
extremely hot Damaged or inoperative brake Replace or repair brake