Comeup DP-10000 User manual

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2
Electric Recovery Winch
Thanks 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
AWinch is designed to give safe and dependable service if operated according
to the instructions. Read and understand this manual before installation and operation of
winch.
Follow these general safety precautions:
․Don't use unsuitable pulleys or accessories.
․Don't use unsuitable rope in construction , strength or having any defects.
․Check the winch for smooth operation without load before winching operation.
․Make sure the wire rope is wound evenly on the first layer on the drum, rewind it if not
evenly wound.
1. The winch is rated for intermittent-periodic duty.
2. The winch is not to be used to life, support or otherwise transport personnel.
3. Aminimum of five (5) wraps of rope around the drum are necessary to support the
rated load.
4. When choosing the right winch, you need to consider the vehicle size and weight.
As a general guide, you need a winch with a maximum load rating of at least one to
one and a half times greater than the gross vehicle weight.
5. The rated line pull of the winch must be powerful enough to overcome the added
resistance caused by what ever the vehicle is stuck in.
WARNING

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I. Safety Precaution
Please read and understand this Instruction Manual before installing your winch.
Don’t use unsuitable rope in construction, strength or having any defects.
Don’t use unsuitable hook and pulley block for rope.
The operator of winch in some cases, is required to have qualifications according to applicable
laws and ordinances.
Do not use winch as a lifting device or a hoist for vertical lifting
(Fig1)
Do not use winch to move people
Do not exceed maximum line pull ratings shown in tables.
Shock load must not exceed these ratings.
Keep hands clear of wire rope and fairlead opening.
Pull from an angle below 15 degree to straighten up the vehicle
or load. (Fig2)
Use leather gloves or a heavy rag when handling the wire
rope.
When winching a heavy load lay a heavy blanket or jacket
over the wire rope near the hook end.
(Fig1)
(Fig2)

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II. Performance Data
XSpecification
MODEL DP-10000
Line Pull 4,535 k
g
/ 10,000 lb
Moto
r
12V 3,430 w / 4.6 h
p
24V 2,237 w / 3.0 h
p
Control Han
d
-held Remote Switch
Gear Train 4 Sta
g
e Planetar
y
Gear Ratio 277:1
Clutch Rotatin
g
Rin
g
Gea
r
Brake Patent Cone Loa
d
-Holdin
g
Brake & Auxiliar
y
Ma
g
netic Brake
Wire Ro
p
e Recommende
d
9.5 mm X 40 m / 3/8”X 131’
XLine speed and Amp. Draw (1st layer of wire rope on the drum)
MODEL DP-10000
Voltage 12 V 24 V
Line Pull Line Speed Line Speed
Kg / lb mpm fpm Amp.
Draw mpm fpm Amp. Draw
No Load 6.2 20.3 60 8.0 26.2 40
907 / 2,000 4.3 14.1 120 6.5 21.3 80
1,814 / 4,000 2.3 7.5 170 5.1 16.7 105
2,722 / 6,000 1.6 5.2 250 3.8 12.5 135
3,629 / 8,000 1.1 3.6 300 3.1 10.5 165
4,535 / 10,000 0.9 3.0 400 2.4 7.0 210
XLine Pull And Rope Capacity
MODEL DP-10000
Layer of Wire Rope Line Pull
kg / lb Total Rope on the Drum m / ft
1st Layer 4,535 / 10,000 7.5 / 25
2nd Layer 3,772 / 8,315 16.4 / 54
3nd Layer 3,230 / 7,120 26.9 / 88
4th Layer 2,824 / 6,225 38.9 / 128
5th Layer 2,508 / 5,530 40 / 131
XStandard Accessories
Hand-held remote switch w/5m (17’) cord, 4 way roller fairlead, Handsaver bar
XDIMENSION
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XHow the winch is rated
Load and speed vary according to how
much wire rope is on the drum. The first
layer of wire 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, winches are rated on their
performance
first layer of wire rope on the drum.
Ⅲ. Installation
Before using the winch, make sure all electrical
Components Have no corrosion or defect; the
environment should be clear and dry.
Voltage drop from the battery connections to the winch
Must not exceed 10% of the nominal voltage under
normal operating condition.
XMounting
1. It is very important to the winch mounted on a flat and hard
surface in order to make sure the motor, drum and gearbox
housing are aligned correctly.
2. It is recommended that you use a mounting channel to prevent to the possibility of
damage to the winch or vehicle.
3. It is also recommended that a roller fairlead be fitted to prevent excessive wear of the
wire rope.
4. Sixteen 16) M10x1.50 pitch 8.8 grade high tensile steel bolts must be used in order to
sustain the load imposed on the winch mounting.

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XBattery cable wiring diagram
Battery cable specification:
Model DP-10000
Control Type Detachable solenoid pack
Red cable: 2 AWG x 72”(1.83 m)
Volt 12V or 24V Black cable: 2 AWG x 72”(1.83 m)
1. Attach the black cable (earth) firmly to the chassis of the vehicle or to the negative(-)battery
terminal.
2. Attach the red cable to the circuit breaker, connect the other end to the positive(+) battery
terminal.
3. The circuit breaker can be fitted as optional.
XSwitch Connection
1. A hand-held remote switch with 1/12”x 3c x 10’
(ψ2.0 mm x 3c x 3m) Cord supplied
2. Open the dust-proof cover of the winch, then insert the
switch plug into the socket (fig3).
XDetachable Solenoid Pack Wiring Diagram
(Fig3)

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Ⅳ. Operation
XPrecaution
Check all safety and environmental conditions prior and during use.
A wire rope should be replaced if it shows signs of excessive wear, broken wires, corrosion or
any other defects.
The operator must remain with the winch when is being operated.
The winches duty rating is S 3 (intermittent-periodic)
If the winch fails in pulling a load under normal conditions, stop the operation within 30
seconds otherwise motor damage may occur.
Ensure that winch is connected to the correct voltage.
Check that the clutch lever is in the “Engaged” position during and after use .
Remove the pendant from the winch when not in use.
Do not wrap the wire rope around load and hook to it.
Keep hands and clothes away from the winch, wire rope, and fairlead.
Never unplug the pendant when winching a load.
Before use, ensure that you are familiar with all winch operations (winch speeds & direction).
To avoid insufficient power when winching a load, the vehicle should be running and in
neutral.
Keep the pendant cord clear of the winch cable at all times.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.
XCable-in/ Cable-out Operation
1). To determine “Cable - Out”, depress ↑button (fig.4)
2). To determine “Cable - In” depress ↓button (fig.5)
To stop winching, release the button
(Fig4) (Fig5)

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XFree Wheel (Clutch) Function
The clutch allows rapid unspooling of the wire rope for hooking onto a load or anchor points and is
operated by a clutch handle.
The clutch handle must be in the “Engaged” position before winching.
1).To disengage the clutch lift the clutch handle up and turn it at 900clockwise rotation to the
“Disengaged” position, wire rope can now be free spooled on the drum.
2).To engage the clutch lift the clutch handle up and turn it at 900counter-clockwise rotation to the
“Engaged” position.
3).If a clutch handle can’t be properly locked in the “Engaged” position, rotate the drum to make
the clutch couple to the gear train .
4).Wear leather gloves and use a handsaver bar when guiding the wire rope out of the drum
(Engaged) (Disengaged)
XRecovery Procedures
Followings are some safety tips to get out
of trouble during a recovery.
1).Using a snatch block will increase the
capacity, but the speed will decrease
accordingly.
2).Experience has shown the best wire rope
service is obtained when the maximum fleet
angle is not more than 15 degree. Keep the wire
rope as close as possible to the center line of the
anchor point
3).It is the best to work with the most of wire rope
unreeled from the drum to get more pulling
power , but a minimum of five(5) wraps of wire
rope should be wound around the drum to
support the rated load.

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Ⅴ. Maintenance
XCable Replacement
¾Never use a rope of a different size or material and only use genuine
replacement parts.
¾If the winch is subjected to a high duty or excess load, the rope may require
frequent replacement.
1). Disengage the clutch (Fig6)
2). Spool the entire wire rope, and then remove it from the drum.
3). Place the replacement wire rope through the fairlead opening, pass below the
drum, and insert it into the hole on the drum core. (Fig7)
4). Tighten the screw downwards to secure the wire rope (Fig7).
5). Secure a clevis hook to the wire rope by using a clevis pin and cotter pin.
(Engaged) (Disengaged)
(Fig6) (Fig7)
XBrake adjustment
When the brake wears to the point that the load begins to slip. The brake can be
adjusted as follows:
1). Loosen the bolt on the brake cover and take out c-rings
2). Insert few washers to maintain the brake spacer between to be 2.2 ±0.25 mm
3). Make sure to keep the brake plate counter-clockwise by 150 – 180 degree

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XLubrication
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.
XMaintenance Schedule
¾Ensure that a responsible person carries out all inspections as per schedule.
¾Inspections are dived into Daily, Monthly and 3 Monthly.
Classification of check
Periodical
Daily One
month Three month
Checking item Checking method Checking reference
cInstallation
Loosening and center
run-out of foundation Checking of installing bolts Existence of abnormalities
cWorking Manual Reasonable actuation
c
Switch
Wearing of contact point Decomposition checking To be free from noticeable
wear and damage
cBreaking of base wire Visual Less than 10%
ccDecreasing of diameter Visual, measuring(one month) 7%of nominal diameter max
cDeforming or corrosion Visual To be not noticeable
c
Wire rope
Fastening condition of end Visual To be sufficient for hanging
up of load
cClutch Wearing of spring Decomposition checking To be free from noticeable
wear and damage
cMotor Staining, damage Decomposition checking Existence of abnormalities
cWearing of disc Decomposition checking To be free from noticeable
wear and damage
c
Brake
Performance Visual Reasonable actuation
cGear Damage, wearing Decomposition checking To be free from noticeable
wear and damage

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Ⅵ. Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault while
operating check the following:
Symptom Possible Cause Remedy
Cut circuit Check battery cable.
Weak battery Recharge or replace battery (at least
650CCA)
Damaged over load protector Replace over load protector
Bad connection of wiring Reconnect tightly
Damaged solenoid Replace solenoid
Cut circuit on switch Replace switch
Damaged motor or worn carbon brush. Replace motor or carbon brush
Winch will not
operate
Lost motor wiring. Secure wiring
Broken wiring or bad connection Reconnect or replace wiring
Damaged or stuck solenoid Replace solenoid
Switch inoperative Replace switch
Motor runs in one
direction.
Lost wiring. Secure wiring.
Clutch not disengaged Disengage clutch
Damaged 1st shaft Replace 1st shaft
Drum will not free
spool.
Damaged output shaft Replace output shaft
Damaged block A&B Replace block A&B
Damaged gear box Replace gear box
Missed snatch ring Replace snatch ring
Oil leakage at brake Cure oil leakage
Damaged or inoperative spiral spring Replace and position spiral spring
No brake
Incorrect paying-out direction of wire rope Correct the paying-out direction
Worn or damaged brake disc Replace or adjust brake discToo long brake
distance Oil leakage at brake. Cure oil leakage
Too much brake powder Clean brake ass’y
Over pre-pressed spiral spring Adjust pre-pressed spiral spring
Brake stuck
Stuck between brake lining and gear box Replace brake
Hit by certain exterior force. Replace the damaged components
Damaged gear train. Replace the damaged components
Damaged gear box
Over load operation. Replace a new gear box
Long period of operation Allow to cool
Damaged motor Replace or repair motor
Motor runs
extremely hot
Damaged or inoperative brake Replace or repair brake

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Ⅶ. Replacement Parts List For DP-10000
PN. Description Q'ty PN. Description Q'ty
Motor 4.6HP 12V 50 Oil seal 1
1 Motor 3.0HP 24V 1 51 O-ring 1
2 Motor flange 1 52 O-ring 1
3 Motor base 1 53 Spring pin 1
4 Drum bushing 2 54 Cap bolt 2
5 Anti-dust ring 2 55 Hex bolt 8
6 Front tie bar 1 56 Hex bolt 3
7 Socket 1 57 Hex bolt 8
8 Drum 1 58 Nylon hex. bolt 1
9 Gear box base 1 59 Hex bolt 1
10 Gear box A 1 60 Hex bolt 1
11 Gear box 1 61 Nut 1
12 Clutch sleeve 1 62 Spring washer 15
13 Clutch lever 1 63 Spring washer 8
14 Clutch spring 1 64 Plain washer 8
15 Clutch handle 1 65 Mounting board 1
16 Plain washer 1 66 Retaining ring 2
17 1st shaft 1 67 Roller fairlead 1
18 1st pinion 1 68 Remote switch ass'y 1
19 1st stage carrier 1 Detachable solenoid pack 12V
20 1st planet gear 6 69 Detachable solenoid pack 24V 1
21 1st shaft bushing 6 -1 Upper cover 1
22 1st planet gear pin 6 -2 Down cover 1
23 1st driving plate 2 -3 Connector ass'y 1
24 3rd shaft 1 -4 Anti-water glove 1
25 Hex bolt 6 -5 Cross screw 2
26 2nd shaft 1 -6 Nut 2
27 2nd planetary gear 3 Solenoid wiring 12V
28 Bearing 3
-7 Solenoid wiring 24V 1
29 2nd planet gear pin 3 -8 Hex. cross bolt 5
30 2nd driving plate 1 -9 Dented washer 5
31 Output shaft 1 -10 Hex bolt 2
32 Hex bolt 3 -11 Nut 4
33 Plain washer 3 -12 Spring washer 2
34 Plain washer 1 -13 Cord gland 3
35 2nd ring gear 1 -14 Socket packing 1
36 Grounding cable 1 70 Cap 1
37 Braking clutch base 1 71 brake coil 1
38 Brake cam 1 72 Transmitting sleeve 1
39 Brake pad 1 73 Conductor disc 1
40 Cone brake disk 1 74 Brake disc 1
41 Spiral spring 1 75 Motor fix plate 1
42 Brake cover 1 76 Hex bolt 3
43 Gasket 1 77 Hex bolt 2
44 Hex bolt 6 78 Rear tie bar 1
45 Bearing 1 79 Hex bolt 6
46 Plain washer 1 80 Cap 1
47 Bearing 1 81 Cross screw 1
48 Bearing 1 82 Oil seal 1
49 Spring washer 2

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Limited Warranty
This Limited Warranty is given by the Comeup Industries Inc. (the "Seller") to the
original purchaser (the "Purchaser") of a Winch specified in this
manual. This Limited Warranty is not transferable to any other party.
The Seller takes the responsibility for all parts and components, with the
exception of the wire rope, motor and electric parts to be free from defects in
materials and workmanship appearing under normal use for as long as the said
Purchaser owns the vehicle that the winch was originally mounted on. Electrical
components are warranted for 1 Year from date of purchase under the same
conditions. Any Winch, which is defective, will be repaired or
replaced without charge to the Purchaser.
Upon discovering any defect, the Purchaser under this Limited Warranty is
requested to return the complete winch and inform the seller or their authorised
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 and
address, vehicle details and registration number.
The Limited Warranty does not cover any failure that results from improper
installation, operation or the Purchaser’s modification in design. The winch is
designed for vehicle self-recovery use only and should not be used in industrial
applications or for moving people. The Seller does not warrant them to be
suitable for such use.