Comeup CWL-80 User manual

Compact Winch
1
Limited One (1) Year Warranty Statement
Comeup Industries Inc. ( ) warrants to the original purchaser that the mechanical compnents
and electrical components of the Compact Winch 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 report or his authorized 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 email, or Tel & Fax, address and registration number. Any
product determines to be defective will be repaired or replaced at sole discretion
without charge to Buyer upon Buyer’s compliance with these procedures. Seller or its Authorized
Distributors may make reasonable charges for parts and labour for repairs not covered by this Limited
Warranty.
takes the responsibility for all parts and components to be free from defects in materials and
workmanship, but the following are hereby excluded and disclaimed:
(1). All warranties of wire 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 or
the Purchaser’s modification in design. 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.

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
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 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.
If a wire rope is found an uneven winding or accumulated at one side of the drum, align it adequately.
1. The winch is not to be used to lift, 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. The owner and/or the operator shall have an understanding of these operating instructions and the
warning before operating the electrical winch. Failure to follow these warnings may result in loss of
load, damage to the winch, property damage, personal, or fatal injury.
4. The owner shall retain this manual for further reference to important warnings, installation, operating
and maintenance instructions.
2
WARNING
！

I.Installation Precaution
3
General Safety Precaution
● Low temperature below -10℃ ,high
temperature above 40℃ or humidity
above 90% conditions
※Cause malfunction of spare parts ※Cause explosion
● In heavy acid or salty conditions
● In rain or snow conditions
● In a heavy general powder conditions
※Cause malfunction of performances
● In an organic chemistry or explosive
powder conditions
※Cause malfunction of spare parts
※Cause rust or short circuit
！DANGER
The following environmental conditions may result in the possible causes of hoist trouble.

I I .Handing Precautions
4
＊To prevent the risk of electric shock, the power plug must be plugged into a matching outlet and
grounded in good condition.
＊Never try to lift a load higher than the rated cap.
＊Never hitch a ride on the hook, sling or load being moving.
＊Winches are not to be used for lifting or lowering people.
＊Don’t work, walk or stand under an operating winch.
＊Always remain in control. Never neglect the winch while actually lifting a load.
＊While working, never stand under a lifting load or within the conveying area.
＊Always look up when working around winch, there is potential danger overhead.
＊Never gravitate a load free.
＊Be sure to lift a load vertically. Slack may allow wires to be caught in the drum.
＊A minimum of five (5) wraps of rope around the drum is necessary to support the load rated.
＊Prior to starting of use, carry out the daily checking without fail, and after confirming the safety of
function.
＊If having a counter rotation incurred, make sure to correct its rotation direction.
＊Prior to lift. Make sure to have a precise performance of brake. If any malfunction of brake happened,
stop the operation immediately.
＊When load suspended in air, it will not allow to be welding.
＊Wire rope with one or more of the following defects shall be removed or replaced immediately.
1) kink, 2) distortion, 3) corrosion.
4) showing sings of excessive wear or of having broken wires not less than 10 pcs.
＊Stop the operation if there is any queer noise or vibration in the gear box to be happened.
＊Do not connect the wire rope with the grounding of welding machine.
＊While welding, do not have any contact with the welding objects because of having spark.
＊Do not pull the switch.
＊Never plugging (instant reverse-wind) or inching.
＊Do not over continuous ratings.
＊In order to prevent the layer down due to over loosening of rope irregular winding, etc., operate
according to the suitable operating method.
＊Use a winch by fixing so securely that the rope around the drum is uneven.
＊Be sure to fix a rope in the center of swivel hook.
＊Be sure to stop operation immediately when the wire rope becomes fully slackened.
＊Avoid catching the hook or lifting a load on a fixed obstruction.
＊Always leave the pendant switch positioned immediately after use.
＊Make sure that the load being lifting is well balanced and secured before starting.
＊Avoid water splashes on the pendant switch.
＊Never wrap the load with the wire rope.

5
● It is forbidden to lift loads above
the rated capacity of the winch
● Do connect the power lead on the
main power source directly and
fasten them
● Ban on transporting persons ● Don’t ignore fault accessories
● Don’t stand under winching
operation
● Don’t operate winch in rain.
● Do perform maintenance on
schedule
● Do anchor crane with ballasted
container and wire rope

III. Winching Principles
6
Percentage Duty Cycle
Load Rated
The life of the winch is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its continuous ratings.
Continuous ratings means the percentage duty cycle (%ED) is subject to the rated voltage,
rated frequency and a 63% of rated load.
Percentage duty cycle (%ED)＝ X 100 (%)
Tb: total sum of overall loadings operating hours.
Ts: total sum of stopping hours.
Tb + Ts = approximately 1 to 10 minutes.
For this reason, all compact winches are rated at a 25% percentage duty cycle (%ED).
Load and speed vary according to how
much wire rope is on the drum. The first layer
of rope on the drum delivers the slowest speed
and the maximum load. A full drum delivers the
maximum speed and the minimum load. For this
reason, all compact winches are rated at their
top layer of wire rope on the drum.
Calculating Head Loads
Use a tackle block for double fall operation to increase the rated load by approximately
85% but its speed will be deducted by half accordingly.
P: Rope tension
η: Sheave efficient
θ: Angle
W: Load
μ: Friction factor
！WARNING
Never hoist over the rated percentage duty cycle.
First layer (Min.speed Max.load)
Half layer (Med.speed Med.load)
Top layer (Max.speed Min.load)
Flange of drum
P
W
P= W
η
P
W
P= W
2η
P
P= W
4η
W
P
WP= W
μ.
μ
P
μ
W
θ
P= Wμ.. sinθ +W.cosθ
Tb
Tb + Ts

7
Calculating Fleet Angle
● The winch should be mounted as close to centre
and as perpendicular as possible to the direction
of the line pull. This will keep the wire rope fleet
angle centre 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.
Experience has shown that the best wire rope service is obtained if the maximum fleet angle
is not more than 1.5° for smooth drum.
For example, the correct distance varies according to drum length.
D/d Ratio
It means ratio of pitch circle diameter of drum to the rope diameter.
In principle, a 12:1 D/d ratio is suggested for most pulling application and a 15:1 D/d ratio for
lifting and lowering applications. For example, a CWL-200 comes with a 95 mm dia. drum and
a 5 mm x 46 m wire rope, therefore its D/d ratio is calculated as follow.
D/d ratio = (95 + 5 mm ) /5 mm = 20 times
Rope Safety Factor
The working coefficient of the wire rope shall be determined from the ratio of the minimum
breaking force of the rope and the maximum possible lifting capacity.
In principle, a 3.5 times of rope safety factor is suitable for most pulling applications and a
5 times for lifting and lowering applications. For example, a CWL-200 comes with a 5 mm
x 46 m wire rope with 1,270 kg minimum breaking force, therefore its rope safety factor is
calculated as follow.
Rope safety factor =1,270 kg / 200 kg = 6.35 times
θ
θ
Correct Distance
Drum Length
Fleet Angle
Model CWL-80 CWL-200 CWL-301 CWL-200L CWL-301L
Drum Length 46 mm 97 mm 147 mm
Correct
Distance
87.4 cm at least 1.84 m at least 2.79 m at least

IV. Compliance with EU Directives
8
Electric Winches shall comply with the following regulations
1. European Standards of EN 14492-1 for Power Driven Winches came to effect from 29th.
December 2009
2. European Machinery Directive 2006/42/EC.
3. European Directive on Electromagnetic Compatibility ( EMC ) 2004/108/EC
4. European Low Voltage Directive ( LVD ) 2006/95/EC
To comply with EN 14492-1, the following optional accessories must be fitted
to all winches
•Low voltage control •Rope drum cover
•Remote control w/ an emergency stop button •Up and down limits protection devices
When using and installing a winch, the owner or end user shall ensure that all legal requirements
are completely complied with.
Extracts from the Directives
1. EN 14492-1 Section 5.15.6 Wire Rope
Wire rope minimum break to be twice winch rating
2. EN 14492-1 Section 5.7.2 Rope Drum
Rope drum mean diameter to be 10 times the diameter of the wire rope and 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.
3. EN 14492-1 Section 5.7.6 Rope Fastening onto the rope drum
Rope attachment to withstand 2.5 times the winch rating
Rope must have at least two wraps winding before fixing point
4. EN 14492-1 Section 5.15.5 Brake
Winch to hold full rated load
5. EN 14492-1 Section 5.15.2 Rated Capacity Limiters
Winch for lifting and lowering purpose with a rated capacity of 1,000 kg or more shall be
fitted with a rated capacity limiter to prevent overloading of the winch
d
10:1 D/d ratio
at least 5 wraps
fixing point
freeboard >1.5d

V. Working Method
9
Power Core Insertion
Cords Sections
Insert the power plug into the power
receptacle of the winch, and tighten it by
turning the locking ring, clockwise. Be sure
to lock the cord by a hook. Do not allow the
cord to be caught by wire rope and drum.
The length for power lead or switch cords are subject to the distance of 20 meter, for any
other cases, the cords should use a bigger section by 3.5 mm2or a magnetic control box should
be suggested to prevent a considerable voltage drop to be happened.
Grounding
To prevent the risk of electric shock, the power plug must be plugged into a matching
outlet and grounded in good condition.
Up and Down Switching
To lift a load, press ↑ button and drum will rotate as shown below operation.
To lower a load, press ↓ button and drum will rotate as shown below.
To stop winching, release ↑or ↓ button.
To have an emergency stop function, press the emergency stop button (option). Rotate the
button clockwise for returning.
Locking ring
Plug
Hook
Winch model
Lifting capacity
Power Lead
Switch Cord
CWL-80
80 kg
1.5 mm2x 3C x 3 m
1.25 mm2x 6C x 3 m
CWL-200/200L
200 kg
1.5 mm2x 3C x 3 m
1.25 mm2x 6C x 10 m
CWL-301/301L
300 kg
3.5 mm2x 3C x 0.6 m
2.0 mm2x 6C x 10 m
Up button
Wire drum Rotation
(Lifting direction)
UP
OILOILOILOIL
Winch Model
Pendant Switch, Standard
Pendant Switch w/an emergency stop, Option
CWL-80
CPB-413, 16A 2a1b
PB-316A, 16A 2a1b
CWL-200/200L
CPB-313, 16A 2a1b
PB-417, 2a1b + Emergency Stop 1a1b
CWL-301/301L
CPB-313, 16A 2a1b
PB-417, 2a1b + Emergency Stop 1a1b

10
Wire Rope Replacement
● Insert the wire rope into the hole of drum and fix it with a P. T. screw, then press the ↑ button
of switch for rotate the drum in the lifting direction.
● Wind the wire rope accurately around the drum, and an irregular winding will cause the load
to be swing, thus damaging the wire and reducing the life of winch.
● When replacing, according to the following procedures.
* Pull out an 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 an R-dower "D" into the hole of round head pin "C".
Carbon Brush Replacement
● It is essential to check the carbon brush periodically. If its length is left less than 7.5 mm
resulting from wear, it is absolute necessary to replace carbon brush immediately.
● While replacing, smoothly insert carbon brush into carbon holder in the first place, then put
brush cap into the hole.
● Before tightening the carbon brush holder, make sure to position O-ring.
● A set of carbon brush consists 2 piece of carbon brush. Ascertain to replace 2 pieces of
carbon brush on opposite sides of winch body at the
Lifting direction Wire rope
Wire drum
！WARNING
Clean the accumulated powder of carbon brush periodically to ascertain the
insulation resistance up to 1MΩ.
Brush cap

11
Braking
● Braking device is composed of a mechanic brake and an electronic generated brake. The
brake distance from the time of braking until stopping completely should be within 1.5% of rope
length to the wound in during 1 minute.
● Owing to the rope speed on no load is 1.5 – 1.8 times faster than that on rated load, the brake
distance on no load will be longer, but still within 1.5% of rope length.
● It is highly recommended that any adjustments are carried out by a qualified technician at an
authorized service centre.
● Brake adjustment procedures
Step1. Remove retaining ring and spring pin
Step2. Tighten 1st gear/2nd shaft for CWL-80 or 3rd gear /4th shaft for CWL-200/200L/301/301L
counter-clockwise until holding to the ratchet
Step3. Find the closed pole between spring pins and fit plate (one between four selections),
then put the fix plate onto the square hole of 3rd or 4th shaft.
Step4. Insert spring pins and lock retaining ring.
Oil Replacement
Gear lubrication is an important component in insuring the long life of your winch. Winch are
pre-lubricated at the factory and do not require initial lubrication. Re-lubrication interval depends
upon service, 250 working hours of a year, or after repair or disassembly. Consult your local
lubricant distributor on the selection that best fits your climate and application.
fix plate
spring pin
2nd / 4th shaft
ratchet
1st / 3rd gear
Gear Oil
Quantity
Intervals
CWL-80 CWL-200
CWL-200L
CWL-301
CWL-301L
Castrol Alpha
series SP-460
100 cc 300 cc 300 cc 300 cc 300 cc
1 Year or
250
Working
hours
Shell Omala 460
BP Energol GR-XP
460
Mobil XMP 460
Esso Spartan
EP460

VI. Cart Puller Capacity
12
Choose the Right Winch
In most pulling applications you are dealing with a rolling load rather than pulling a dead
weight. Resistance to rolling is mostly influenced by the load, rolling resistance, track gradient,
track curvature, track conditions etc.
● Load: Calculate the total weight of the loaded cart to be moved simultaneously.
● Rolling resistance: Resistance to rolling is influenced by the wheel journals, type of
lubrication used and the ambient temperature.
● Track gradient: For each one percent gradient, a rise of one meter for every 100 meter of
track, the running line pull must be increased by 10 kg per ton.
● Track curvature: To overcome the effects of wheels binding against rails on curved sections
of track, running line pull must be increased. For each degree of curvature,
the running line pull must be increased by 1kg per ton.
● Track conditions: The condition of substandard track can vary considerably.
Application Condition Example
1).Pulling of a rolling cart in and out of an oven using a single wire rope
2).5 ton total load being moved included weight of cart
3).Steel cart wheels with precision wheel bearing
4).New track, 5°curvature and 2% gradient
Horizontal Load Reversing
The horizontal load reversing allows 2 pieces of wire rope to be spooled onto the first layer of
grooved drum. As one rope winds onto the drum and the other rope winds off an equal amount.
It is important to know how each of the wire rope will be coming off of the drum, that allows the
correct grooving to be provided.
Pulling Capacity Required
5 ton…..…….….………Total weight being moved
x (10 kg+20 kg+5 kg) 10kg…......Pull required per ton being moved
175 kg 20kg…......For each one percent gradient, the running line pull
must be increased by 10 kg/ton
5kg……......For each one degree of curvature, the running line
pull must be increased by 1 kg/ton
x 1.2 20%…….. contingency for unpredictable track or cart conditions
210 kg …..…...........Minimum calculated cart puller capacity

VII. Wiring Diagram
13
CWL-80 Winch
+ -
5
3
1
6
4
2
DOWN
UP
SWITCH CORD RECEPTACLE
CPB-413
MOTOR
POWER SOURCE
GROUNDING ZNR1
D-RESISTOR
RL
1 2 653 4 7
Red Black YellowGrayBrownBlue x
1 2 653 4 7
Red Black YellowGrayBrownBlue x
Standard Version
110V or 220V – 240V 1ph
Switch with an emergency stop button
110V or 220V – 240V 1ph
CWL-200/301/200L/301L Winches
Standard Version
110V or 220V – 240V 1ph for CWL-200/200L
220V – 240V 1 ph for CWL-301/301L
Switch with an emergency stop button
110V or 220V – 240V 1ph for CWL-200/200L
220V – 240V 1 ph for CWL-301/301L
Down
Up
SWITCH CORD RECEPTACLE
PB-316A
12 3
456
789
1 2 653 4 7
Red Black YellowGrayBrown Blue x
1 2 6
5
347
Red Black Yellow
GrayBrown Bluex
+ - MOTOR
POWER SOURCE
GROUNDING ZNR1
D-RESISTOR
RL
+ -
-+
Down
Up
SWITCH CORD RECEPTACLE
PB-417
Motor
Power Source
Grounding
Bridge Rectifier
Znr1
Resistor D-Resistor
RL
12 3
456
789
1 2 653 4 7
Red Black YellowGrayBrown Blue x
1 2 6
53 47
Red Black Yellow
GrayBrown Blue x
Emergency Stop

VIII. Checking and Trouble Shooting
14
Checking Reference
Remark：1. The specified person performs the checking of winch.
2. Divide the checking into daily checking and periodic checking.
3. The checking items and checking method in daily and periodic checking shall
be carried out and different according to the using frequency.
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲ ▲▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
▲
Checking items Checking Methods
Classification of Checks
Daily
periodical
3 Months/
20 Hours
1
year
3 Years
or 250
Hours
1 Brake
Performance
Brake or escaping of spring
Visual
Decomposition check
Decomposition check
2 Carbon brush
Wearing
Decomposition check
3 Motor
Condition of insulation
Staining , damage
Carbon powder accumulation
Measuring,1MΩmin
Visual
Decomposition check
4 Remote
control
Working
Outer damage of switch cords
Attac
hing condition of earth line
Condition of insulation
Manual
Visual
Visual
Measuring,1MΩmin
5 Safety device
Over
-prevention function
Reverse winding prevention
function
Distortion of over winding lever
Visual
Visual
Visual
Visual
6 Wire rope
Kink phenomena
Broken wires
Decreasing of diameter more
than 10%
Deforming or corrosion
Visual
Visual
Visual
Visual
7 Weight hook
and hanger
Distortion
Damage
Loosening
Visual
Visual
Visual
8 Drum
Rupture of flange
Wearing
Visual
Visual
9 Gear trains
Damage , warning
Condition of oil feeding
Lubrication for couplings
Visual
Measuring
Measuring
10 Fastenings
Loosening
Manual
11 Marking
Label and the like
Manual
Wearing of lining, and pressed plate
Wrong rotary direction-winding

15
Trouble Shootings
Checking the winch for smooth operation by pressing ↑ or ↓ button of pendant switch.
When winch fails to start after several attempts, or if any defective operation to be happened,
check followings.
Symptom
Possible cause
Remedy
No reaction or
open circuit
Open circuit on power lead or switch cord
Check power lead or switch cord
Burnt rectifier at power source side Replace rectifier and pay attention to its poles
Burnt motor
Replace motor
Burnt or communicated motor resulting from
over load.
Replace motor
Improper installation or wearing of carbon brush Check or replace carbon brush
Escape or open circuit of carbon brush lead
Check or replace carbon brush lead
Can lift, but fail to
lower
Brunt diode
Replace diode and pay attention to its poles
Burnt rectifier at motor side
Replace rectifier and pay attention to its poles
Malfunction of the Down contact of the pendant
switch Replace pendant switch
Can lower, but fail
to lift
Loose adjustable nut
Adjust
Burn diode Replace diode and pay attention to its poles
Burnt rectifier at motor side
Replace rectifier and pay attention to its poles
Malfunction of the Up contact of the pendant
switch Replace pendant switch
Short circuit
Melted B contact of pendant switch
Replace pendant switch
Burnt diode Replace diode and pay attention to its poles
Short circuit on rectifier at motor side
Replace rectifier and pay attention to its poles
Burnt D type resistor Replace resistor
Having too much carbon powder on carbon
brush holder
Disassembly the winch and clean carbon
powder
Burnt motor Replace motor
Damaged circuit board resulting from the
winding-in of rope Replace circuit board
Fail to lift the load
rated
Overload
Reduce load
Short circuit on the commutator of the armature
core or burnt parts of armature coils. Replace commutator of the armature core
Burnt parts of armature winding.
Replace armature winding
Incorrect carbon brush specification or too short
Replace carbon brush
Burnt, deformation of carbon brush holder
Replace carbon brush holder
Fail to hold the
load after
stopping
The gap of ratchet brake is too large Adjust the ratchet brake
Malfunction of pressed spring of ratchet brake
Replace pressed spring
The oil is too dirty or includes contamination Replace oil
Having too much oil in gear box
Reduce the quantity of oil
Brake distance is
too long at no
load
Malfunction of D type resistor Check or replace D type resistor
Having smell or
smoke
Malfunction of pressed spring of ratchet brake Replace pressed spring
Burnt D type resistor
Replace D type resistor
Malfunction of B contact of the pendant switch Replace pendant switch
Too noise whiling
lifting
The noise result from the click between ratchet
stopper and wheel
It is normal

NOTES
17

PN 881412 Ver:03
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