Comeup DS-9.5 User manual

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Self-Recovery 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 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 lift, support or otherwise transport personnel.
3. A minimum of five (5) wraps of rope around the drum is 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
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 whatever the vehicle is stuck in.
WARNING

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F l e e t a n g l e
C e n t r e l i n e o f a n c h o r p o i n t
I. Safety Precautions
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 .
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.
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.
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, winches are rated
on their performance first layer of rope on the drum.
CAUTION

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II. Performance Data


Specifications
Model DS-9.5 DS-9.5i
Line Pull (first layer) 4,309 kg / 9,500 lb
Line Speed (first layer, no load) 19 mpm / 62.3 fpm
12V 380 A
Amp. Draw
24V 250 A
Type Series wound
12V 3,728 w / 5 hp
Motor Output
24V 2,240 w / 3 hp
Type 3 stage planetary
Gear Train
Ratio 159 : 1
Free-spool Rotating ring gear clutch
Brake Automatic full load cone brake
Control Detachable solenoid pack Integrated solenoid pack
Type A7 x 19 aircraft galvanized
Length 30 m / 100 ft
Wire Rope
Size 8 mm / 5 / 16 in


Performance
Model DS-9.5 DS-9.5i
Line pull (kg / lb) 4,309 / 9,500
Line speed (mpm / fpm) 2.12 / 7
1st layer
Rope cap (m / ft) 6.1 / 20
Line pull (kg / lb) 3,521 / 7,750
Line speed (mpm / fpm) 2.6 / 8.5
2nd layer
Rope cap (m / ft) 13.5 / 44.3
Line pull (kg / lb) 2,977 / 6,550
Line speed (mpm / fpm) 3.07 / 10.1
3rd layer
Rope cap (m / ft) 22.3 / 73.2
Line pull (kg / lb) 2,578 / 5,700
Line speed (mpm / fpm) 3.55 / 11.7
4th layer
Rope cap (m / ft) 32.4 / 106.3


Line speed and Amp. Draw
At the first layer of wire rope on the drum.
Model DS-9.5 / DS-9.5i
Line Pull Line Speed Amp.
Kg lb mpm fpm 12V 24V
0 0 19 62 60 35
909 2,004
4.7 15.4 115 70
1,818 4,008
3.5 11.5 210 110
2,727 6,012
2.8 9.2 245 145
3,636 8,016
2.3 7.6 280 190
4,309 9,500
2.1 6.8 380 250

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

Main Components

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D S - 9 . 5
D S - 9 . 5 i
BATTERY
BLACK(-)
R E D ( + )
CIRCUIT BREAKER (OPTION )
254
mm(10")
11
mm (7/16") in
dimension
114.3 mm
(4 1/2")
BATTERY
A
F 1
F 2
B L A C K
R E D
B L A C K ( - )
R E D ( + )
C I R C U I T B R E A K E R ( O P T I O N )
S O L E N O I D S R E M O T E
S W I T C H S O C K E T
WINCH
Ⅲ
ⅢⅢ
Ⅲ. Installation
Before using the winch, make sure all electrical components have no corrosion or damaged; the
environment should be clean and dry. The voltage drop from the battery connections to the winch
must not exceed 10% of the nominal voltage under normal operating condition.


Mounting
1. It is very important that the winch be
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 from
damaging winch or vehicle.
3. Four (4) M10 x 1.50 pitch 8.8 Grade High Tensile Steel Bolts must
be used for f astening the winch into mounting channel in
order to sustain the loads imposed on the winch mounting.
4. Two (2) M12 x 1.75 pitch 8.8 Grade High Tensile Steel
Bolts must be used for fastening the roller fairlead into
the mounting channel.


Battery Lead Connection
Battery lead specification:
Model
DS
-
9.5
DS
-
9.5i
Control Type Detachable solenoid pack Integrated solenoid pack
Red cable: 2 AWG x 1.83 m / 72〞Red cable: 2 AWG x 1.83 m / 72〞
Voltage
12V or
24V Black cable: 2 AWG x 1.83 m / 72〞Black cable: 2 AWG x 1.83 m / 72〞
1. Attach the black lead (grounding) firmly to the negative (–) battery terminal.
2. Attach the red lead to the circuit breaker, connect the other end to the positive (+) battery
terminal.
3. The circuit breaker shall be recommended to be fitted.
DS-9.5 DS-9.5i


Switch Connection
1. A trigger switch withψ0.75 mm X 6 C X
5 m (18 AWG X 6 C X 17′) cord supplied
2. Open the dust-proof cover of the winch, then
insert the switch plug into the socket .
Foot print
Print
g
\

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OUT
IN
LED LIGHT
GREEN OUT
IN
LED LIGHT
RED
M
A
F1 F2
F1 F2
A
(+)
BATTERY
REMOTE
CONTROL
SWITCH
RED
WHITE
BLACK
GREEN
YELLOW
BLUE GREEN
YELLOW
LED
LED
THERMAL
CONTROL
SOLENOID
PACK
12V-1K
24V-2K
Ⅳ
ⅣⅣ
Ⅳ. Motor Temperature Indicator


Protective thermal sensor LED
Green LED signal on the trigger switch and aluminium casting ( for DS-9.5i only ) shows the winch
is operated under normal working condition.
Red LED signal shows on the trigger switch and aluminium casting ( for DS-9.5i only ) shows the
winch is operated under abnormal working condition
If a winch which is operated with red LED signal for a long period will certainly result in damaged
the winch. In this circumstance, you must power off the winch without delay.
DS-9.5
OUT
IN
LED LIGHT
GREEN OUT
IN
LED LIGHT
RED
(
((
( Normal winching
Normal winchingNormal winching
Normal winching)
))
) (
((
(Abnormal winching
Abnormal winchingAbnormal winching
Abnormal winching)
))
)
DS-9.5i
( Normal winching)
( Normal winching)( Normal winching)
( Normal winching) (Abnormal winching)
(Abnormal winching) (Abnormal winching)
(Abnormal winching)


Battery Recommendations
A fully charged battery and good connections are essential to the proper operation of your winch. The
minimum requirement for a 12 volt DC battery is 650 cold cranking amp.


Electrical Circuit Diagram

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Ⅴ
ⅤⅤ
Ⅴ. Operation


Precautions
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 it is being operated.
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 motor damage may occur.
Ensure that the winch is connected to the correct voltage. 12VDC or 24VDC only
Check that the free-spool T-handle is in the “Engaged” position during and after use.
Remove the switch from the winch when not in use.
Do not wrap the wire rope around the load and back onto it self. Always use a strap to ensure that
the wire rope does not fray or kink.
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 winching operations (winch speeds & direction).
To avoid insufficient power when winching a load, the vehicle should be running and in neutral.
Keep the switch cord clear of the wire rope at all times.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.


Cable-in/ Cable-out Operation
1). To determine “Cable - Out”, trigger →out
2). To determine “Cable - In”, trigger ←in
To stop winching, release the trigger
able-Out able-In

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

Free-spool Function
The free-spool allows rapid payout of the wire rope for hooking onto a load or anchor points and is
operated by the free-spool T-handle.
The free-spool T-handle must be in the “Engaged” position before winching.
1). To disengage the free-spool lift the free-spool T-handle up and turn it at 900clockwise rotation to
the “Disengaged” position, wire rope can now be free spooled off the drum.
2). To engage the free-spool lift the free-spool T-handle up and turn it at 900counter-clockwise
rotation to the “Engaged” position.
3). If a free-spool T-handle can’t be properly locked in the “Engaged” position, rotate the drum to
make the free-spool coupled to the gear train.
4). Wear leather gloves and use a strap when guiding the wire rope off the drum.
(Engaged) (Disengaged)


Recovery 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 centre 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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Ⅵ
ⅥⅥ
Ⅵ. Maintenance


Cable Replacement
Never use a rope of a different size or material and only use genuine
replacement parts.
If the winch is subjected to a high duty or excess load, the rope may require frequent
replacement.
1). Disengage the free-spool
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.
4). Tighten the screw downwards to secure the wire rope .
(Engaged) (Disengaged)


Brake 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 clutch base plate counter-clockwise by 150 – 180 degree

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

Lubrication
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.
.
Maintenance Schedule
Ensure that a responsible person carries out all inspections as per schedule.
Inspections are dived into Daily, Monthly and 3 Monthly.
Classification of check
Periodical
Daily
One
month
Three
month
Item Checking method Checking reference
Installation
Mounting bolts & alignment. Bolt tension & wear. Existence of abnormalities
Working Manual Reasonable actuation

Remote
control
Wearing in contact points Visual. Free of wear or damage.
Broken strands Visual, measuring Less than 10%
Decrease in rope diameter
Visual, measuring 7% of nominal diameter
max
Deforming or corrosion Visual Existence of abnormalities

Wire rope
Fastening condition of end Visual Existence of abnormalities
Free-spool
assembly
Wear in free-spool
assembly Visual evidence of wear Free of wear or damage.
Motor Staining, damage Visual evidence of wear Existence of abnormalities
Wearing of lining Visual evidence of wear Free of wear or damage.

Brake
Performance Visual Reasonable actuation
Gear Damage, wearing Visual evidence of wear Free of wear or damage.

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Ⅶ
ⅦⅦ
Ⅶ. Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault, check the
the following:
Symptom Possible Cause Remedy
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 wirings 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
Dropt or lost motor wirings. Replace wirings or tight it.
Broken wirings or bad connections Reconnect or replace wirings
Damaged or stuck solenoid Replace solenoid
Switch inoperative Replace switch
Motor runs in one
direction.
Dropt or lost wirings. Replace wirings and tighten.
Free-spool does not disengaged Engaged free-spool
Damaged 1st shaft Replace 1st shaft
Damaged brake cam and disc Replace brake cam and disc
Drum will not
free-spool.
Damaged output shaft Replace output shaft
Damaged brake cam and disc Replace brake cam and disc
Damaged gear box Replace gear box
Dropt snatch ring Replace snatch ring
Oil leakage at brake cavity Clean oil leakage
No brake
Damaged or inoperative spiral spring Replace and position spiral spring
Worn or damaged brake Replace or adjust brakeBrake distance is
too long Oil leakage at brake cavity Clean oil leakage
Too much brake powder Clean brake ass’y
Over pre-pressed spiral spring Adjust pre-pressed spiral spring
Brake will be
locked
Stuck between brake lining and gear box Replace a new winch
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 winch
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
ⅦⅦ
ⅦI
II
I. Replacement parts List
DS-9.5
No. Description Q’ty No. Description Q’ty No. Description Q’ty
1 Motor 1 21 Cone brake disc 1 42 Detachable solenoid pack 1
2 Motor support rack 1 22 Spiral spring 1 -1 Control box upper cover 1
3 Gearbox support rack 1 23 Brake cover 1 -2 Control box base cover 1
4 Drum bushing 2 24 Bearing 1 -4 Rubber cover 1
5 Drum 1 25 Bearing 1 -5 Round cross bolt 2
6 Gear box 1 26 Spring washer 1 -6 Remote socket plate 1
7 Connecting socket 1 27 Hex. bolt 6 -7 Nut 2
8 1st shaft 1 28 Hex. bolt 4 -8 Solenoid pack 1
9 1st pinion 1 29 Hex. lockbolt 1 -9 Cross bolt 4
10 1st stage carrier 1 30 Hex. bolt 2 -10 Cross bolt 2
11 1st & 2nd ring gear 1 31 Retaining ring 2 -11 Spring washer 2
12 2nd stage carrier 1 32 Anti-leakage seal 1 -12 Plain washer 6
13 3rd stage carrier 1 33 Spring pin 1 -13 Remote socket assembly 1
14 3rd ring gear 1 34 Spring pin 1 -14 Boot 3
15 Free-spool barrel 1 35 Foot print 1 43 Hex. bolt 4
16 Free-spool lever 1 36 Wire rope w/hook 1 44 Spring washer 4
17 Pressed spring 1 37 Roller fairlead 1 45 Tie bar 2
18 Free-spool T-handle 1 38 Mounting hardware 1 46 Grounding lead 1
19 Brake free-spool base 1 39 Remote control 1
20 Brake cam A 1 40 Handsaver strap 1

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DS-9.5i
No. Description Q’ty No. Description Q’ty No. Description
Q’ty
1 Motor 1 22 Spiral spring 1 -2 Solenoid lower plate 1
2 Motor support rack 1 23 Brake cover 1 -4 Rubber cover 1
3 Gearbox support rack 1 24 Bearing 1 -5 Round cross bolt 2
4 Drum bushing 2 25 Bearing 1 -6 Remote socket plate 1
5 Drum 1 26 Spring washer 1 -7 Solenoid pack 1
6 Gear box 1 27 Hex. bolt 6 -8 Remote socket assembly 1
7 Connecting socket 1 28 Hex. bolt 4 -9 LED 1
8 1st shaft 1 29 Hex. lockbolt 1 -10 Hex. bolt 7
9 1st pinion 1 30 Hex. bolt 2 -11 Spring washer 10
10 1st stage carrier 1 31 Retaining ring 2 -12 Cross bolt 6
11 1st & 2nd ring gear 1 32 Anti-leakage seal 1 -13 Plain washer 6
12 2nd stage carrier 1 33 Spring pin 1 -14 Boot 3
13 3rd stage carrier 1 34 Spring pin 1 -15 Clamp 4
14 3rd ring gear 1 35 Foot print 1 43 Hex. bolt 4
15 Free-spool barrel 1 36 Wire rope w/hook 1 44 Spring washer 4
16 Free-spool lever 1 37 Roller fairlead 1 45 Tie bar 2
17 Pressed spring 1 38 Mounting hardware 1 46 Grounding lead 1
18 Free-spool T-handle 1 39 Remote control 1 47 Motor side cover 1
19 Brake free-spool base 1 40 Handsaver strap 1 48 Hex. bolt 4
20 Brake cam A 1 42 Integrated solenoid pack 1 49 Fastener 1
21 Cone brake disc 1 -1 Solenoid upper box 1

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, 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.

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