Comeup CWL-80 User manual

Compact 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.
General Safety Precautions
A Winch is designed to give safe and dependable service if operated
according to the instructions. Read and understand this manual before installation and
operation of the winch.
Follow these general safety precautions:
˙Confirm that the winch complies with the using conditions.
˙Keep the winch secure strongly and the rope is not wound to be deviated to the drum.
˙Don't use unsuitable pulleys or accessories concerned.
˙Don't use unsuitable rope in construction , strength or having any defects.
˙Pay attention to the grounding , it provides a path of least resistance for electric current to
reduce the risk of shock.
˙Check the winch for smooth operation without load before loading operation.
˙Make sure the wire rope to be wound evenly in the first layer on the drum, rewind it if a
mixed windings in existence.
1.The winch is not to be used to life, support or otherwise transport personnel.
2.A minimum of five(5) wraps of rope around the drum is necessary to support the load
rated.
3.Come-Up takes no responsibility for the subsequent performance of mechanical
components if oil possessing properties other than what Come-Up recommends is
used
WARNING

I. Performance Data
Specification
MODEL CWL-80 CWL-200L CWL-301 CWL-301L CWL-200
Lifting load (kg) 80 200 300 300 200
Speed (M / min.) top layer 25 16 25 25 16
Power source 50/60 Hz single phase 110V or 220 / 240V
type series wound
110V 0.3 x 6 x 1.2 x 12
Motor
Output
220/240V 0.3 x 6 2.3 x 11 1.2 x 6
Braking for motor electromagnetic brake
methods for gear mechanical brake
Duty cycle percentage 25% ED
diameter(mm) 4 5 6 6 5
length(M) 24 71 30 55 46
Wire rope
construction 6 x 19 6 x 19 6 x 19 6 x 19 6 x 19
General Safety Precaution
Danger
The following environmental conditions may result in the possible causes of which trouble.
Low temperature below
-10℃, high temperature
above 40℃or humidity
above 90% conditions.
In heavy acid or salty conditions
*Cause malfunction of
spare pares
In the rain or snow
*Cause rust or short circut
Dan ger
DangerDanger
Danger
In a organic chemistry
or explosive power
conditions.
*Cause explosion
In a heavy general
powder conditions
* Cause malfunction of
performances

II. Methods of Operation
Plug Insertion
Insert the plug of switch cable
into the receptacle of the winch.
Tighten it by turning the locking
ring clockwisely.
Be sure to fix the switch cable
by snap hook. Do not allow the
cable to be caughted by wire rope and drum.
Up And Down Control
To lift a load, press the up button, the drum will rotate in the lifting direction.
To lower a load, press the down button, the drum will rotate in the lowering
direction.
Wire Rope Replacement
Insert the wire rope into the hole of drum and fix it with a P. T. screw, then press
the "UP" button of switch for rotate the drum in the lifting direction.
Wind the wire rope accurately around the drum, and a irregular winding will cause
the load to be swing, thus damaging the wire and reducing the lift of winch.
When replacing, according to the following procedures.
*Pull out a R-dowel "D" from the round head pin "C".
*Pull out a round head pin "Cc from hook body "A".
*Put a wire rope "B" into the hole of hook body "A", and insert a round head pin
"C" through wire rope and fixture hole of hook body "A".
*Insert a R-dower "D" into the hole of round head pin "C".

Carbon Brush Replacement
The carbon brush can be used for about 100 working hours.
It shall be replaced immediately if its length left to 7.5mm.
Any negligence of replacement of it may do cause damage to motor.
Remove the brush cap and replace it accordingly.
Oil Replacement
Gear lubrication is an important component in insuring the long life of your winch.
The type of lubricant will have a great influence. The gear oil your winch was
shipped with is Castrol Alpha Series, SP-220, a viscosity ( cSt ) is 226.14/19.5 at
40℃/100℃. Consult your local lubricant distributor on the selection that best fits your
climate and application.
The initial lubricant should be changed after the first 10 hours of operation. Subsequent
changes of 100 cc for CWL-80 and 300 cc for others should be scheduled every 250
hours of operation or annually.
Cables Recommendations
WINCH MODEL POWER CABLE SWITCH CABLE
CWL-80 1.5 mm2x 3C x 3M 1.25 mm2x 6C x 3M
CWL-200/200L 2.0mm2x 3C x 5M 1.25 mm2x 6C x 10M
CWL-301/301L 2.0mm2x 3C x 5M 2.0 mm2x 6C x 10M
For any other cases, the cable should use a bigger section of cable or a
magnetic control box should be suggested.

III. HandlingPrecautionsAndCalculations
HandlingPrecautions
The operator of winch in some cases is required for qualifications according to
applicable laws and ordinances.
Prior to starting of use, carry out the daily checking without fail, and use after
confirming the safety of function.
Don't use exceeding the lead rated.
The operator of winch must not be apart from the operating position under the
loading condition.
Carry out the operation of lifting and lowering after stopping the winch once, and
avoid the rapid speed operation as far as possible.
Even in the condition where the rope is feed out at most, the rope must remain by
five more windings on the drum.
Record the daily operating time and take into consideration so as to obtain the
suitable time for intermediate inspection and arrangement.
Calculating Head Loads
P: Rope tension
η: Sheave coefficient
θ: Angle
W: Load
μ: Friction factor
Calculating Fleet Angle
The winch should be mounted as close to center and as perpendicular as possible to
the direction of the line pull. This will keep the wire rope fleet angle centered 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 winch 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.
The distance from centre of the rope drum till the first rope sheave or roller fairlead
shall in the ideal case be 19 times the drum width

IV. Checking Reference
Checking Reference1
Classification of checks
Periodical
Daily
One
month
Three
month
One
year
Checking Item Checking Method Checking Reference
◎Marking Lable and the like Visual Existence of label
◎
Winding-in
direction of wire
rope
Visual , measuring
Fleet angle
θ=within 1.5 degree
◎
Installation
Loosing and centre
run-out foundation
Checking of
installing bolts
Existence of
abnomalities
◎Working Manual Reasonable actuation
◎Condition of
clamping of wiring
Decomposition
checking
Confirming of
accuracy of fastening
condition
◎
Wearing of
contact point
Decomposition
checking
To be free from
remarkable wearing
and damage
◎
Outer damage of
cable Visual
To be free from
exposure of
conductive wire
◎◎
Attaching
condition of earth
line
Visual
Existence of
abnormalities of
connecting wires
◎
Control/Switch
Condition of
insulation
Measure with 500v
insulation-
Resistance tester
1MΩmin
◎Condition
of insulation
Measure with
resistance tester
1MΩmin
◎
Motor
Staining damage
Decomposition
check
Existance of
abnormalities
◎Loosing of set
screws
Decomposition
check
To be free from
loosening
◎Wearing of lining
Decomposition
check
To be free from
remarkable wear and
damage
◎◎
Brake
Performance Visual
Distance to be not
more than 1.5% of
rope length to be
wound-in during 1
minute
◎Damage , wearing
Decomposition
check
To be free from
remarkable wear and
damage
◎
Gear
Condition
of grease feeding
Measuring
Existence of
suitability of amount
and deterioration
with Castrol Alpha
Series, SP-220, a
viscosity(cSt) is
226.14/19.5 at 40∘
C/100∘C

Checking Reference
Classification of Checks
Periodical
Daily
One
month
Three
month
One
year
Checking Item Checking Method
Checking
Reference
◎
Breaking of base
wire Visual Less than 10%
◎
Decreasing of
diameter Visual 7% of normal
diameter max
◎
Kink phenomena
run-
out of
foundation
Visual
To be free
from kink
phenomena
◎Deforming or
corrosion Visual To be not remarkable
◎
Fastening condition
of end Visual
To be
sufficient for
hanging up of
load
◎
Condition of rope
winding-in Visual
To be free
from irregular
winding
◎Condition of feed
oil Visual
To be not
insufficient in
feed-out
◎
Wire Rope
Confirming o
f dead
turn of rope Visual
Confirming of
normalities of
operating-out
◎◎Frame Structure Visual
To be free
cracks,
rupture
harmful
deforation
◎◎Reture of flange
Visual
To be free
cracks,
rupture,
harmful
deforation
◎
Drum
Wear of drum Visual
To be free
from
remarkable
wearing
◎Rotary direction
Visual
Winding-in
direction is
normal
◎Rotary abnormal
sound Hear out
To be free
from
oscillation
and impact
sound
◎
Operation
Over load test Working Existence of
abnormalities

V. Trouble Shooting
Before operation, open terminal box of motor to ascertain the corrective wirings.
Checking winch for smooth operation by pressing up and down button of push button
switch.
When winch fails to start after several attempts, or and defective operation to be
happened, check followings.
Observed anomaly Possible cause Solution
No power Check power source
Disconnection of the plug, power
Replace or repair
Burnt or communicated motor Replace
Burnt diode ass’y Replace, clean motor
No reaction
Considerable voltage down Ascertain the corrective input
Overload Reduce load
Check voltage
Lifting speed to be slow Considerable voltage down
Check the section of power cable
Burnt motor resulting from Replace motor
Carbon brush worn down Replace it and clean powder left
Dry
Electricity leakage or shock Water invaded in motor or push
button switch Replace
Brake lining worn down Replace
Burnt D type resistor Replace
Breaking distance more the 1.5%
Voltage too high Check power source
Replace oil sealInsufficient oil resulting from oil
leakage Fill with sufficient oil Large noise in gear box
Distortion of gear box Repair