Comeup DV-2500i User manual

Utility Duty Winch
WARRANTY
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Limited Lifetime Warranty for Mechanical Components
Limited One (1) Year Warranty for Electrical Components
Industries Inc. ( ) warrants to the original purchaser that the mechanical components
of the Utility Duty Winch will be free of defects in material and workmanship for the lifetime of the winch
and the electrical components will be free of defects in material and workmanship for a period of one (1) year from
the original date of purchase. All mounting kits and other accessories carry a 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 advise or its authorized distributors on any claim. The purchaser
must provide a copy of the purchase receipt bearing the winch serial number, date of purchase, owners name, email
or Tel & Fax, address and purchaser vehicle details. Any products that determines to be accountable for
defective will be repaired or replaced or refund at sole discretion without charge to buyer upon buyer’s
compliance with these procedures. In the event of repair or replace, purchaser must send the defective winch or part,
with freight prepaid, to or its authorized distributor. And will send the serviced product back to
purchaser on ’s cost. This warranty does not cover the removal or reinstallation of the winch.
takes the responsibility for winch parts and components to be free from defects in materials
and workmanship, but the following portions are hereby excluded and disclaimed. or its authorized
distributors may make reasonable charges for parts and labour for repairs or resumption in the following portions
not covered by this limited warranty.
(1). All warranties of wire rope and synthetic 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, third party part
substitution, purchaser’s alteration or modification on winch. This warranty is void when
serial number plate is removed or defaced.
’s liability to the purchaser under the winch purchases for any loss or damage howsoever and
whatsoever arising shall not exceed the price of the initial winch purchase receipt. shall not in any event
be liable to the purchaser for any consequential and/or indirect loss or damage whether for loss or for profit or otherwise,
costs, expenses or other claims for consequential compensation whatsoever and whether caused by negligence of
employees, distributors and their employees or otherwise. 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.

Utility Duty Winch
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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. We reserve the right to make changes without notice because of continued product
improvement.
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.
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 and voltage
2. Serial Number
3. Item. No. and Part Number
4. Part Description
1. The winch is a very powerful machine. Treat with extreme care and observe all caution and warnings.
2. The winch is rated at the first layer of wire rope on the drum for intermittent-periodic duty.
3. The winch is not to be used to lift, support or otherwise transport personnel.
4. A minimum of five (5) wraps of steel wire rope around the drum is necessary to support the rated load.
5. Keep clear of winch, rope, hook, and fairlead while operating.
6. Wire rope can break without warning. Always keep a safe distance from the winch and rope while
under a load
7. Failure to adequately align, support, or attach the winch to a suitable mounting base could result in a
loss of efficiency of performance or damage to the winch, wire rope and mounting channel.
WARNING
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I.Safety Requirement
Confirm that the winch complies with the using conditions.
Because the maximum rope tensile force capable of loading decreases corresponding to the
increase of number of winding layers, please carry out rope winding according to the instruction
of this manual.
Don’t use rope that is unsuitable because of its construction, strength or having any defects.
Don’t use a hook or pulley block that are suited to the rope.
Precautions at the time of operation of winch are listing as follows:
The operator of winch in some cases is required to hold qualifications according to applicable
laws and ordinances.
Prior to starting of use, carry out the daily checking without fail.
During use five wraps of rope must remain on the drum at all times.
Even in the condition where the rope is feed out at most,
Do not use winch as a lifting device or a hoist for vertical lift (fig1).
Do not use winch to move people.
Do not exceed maximum line pull ratings shown. Do not shock load.
Keep hands clear of wire rope.
Pull from an angle below 15 degree to straighten up the vehicle
or boat (fig 2).
Run the engine during winching operations to keep battery charged.
Use leather gloves or a heavy rag when handling the wire rope.
Disconnect the remote switch from the winch when not in use.
When winching a heavy load, lay a heavy blanket over the wire
rope near the hook end.
Always operate your winch in an underwound orientation only (Fig 3).
The winch is designed to give safe and dependable service of trouble-free operation. Please read
and understand this Instruction Manual before installing your winch.
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Precautions before using of winch are listing as follows:

I I .Winching Principles
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Calculating Fleet Angle
To obtain the best wire rope service, the direction of pull will be on a horizontal within ±15
degrees and perpendicular to be centerline of the winch drum within ±5 degrees. If the fleet
angle is bigger than the recommended angles, a good spooling cannot be obtained as the rope
will spoon onto one side of the rope drum and possible damage to the rope or winch.
Load Rating
Load and speed varies according to how much
wire/synthetic 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 utility duty winches are rated at
their first layer capacities.
Required Pulling Force
You need a winch powerful enough to overcome the weight of your vehicle with the added
resistance caused by the obstacle, moving water, mud, snow, sand or on a steep hill.
As a general guide, you need a winch with a maximum line pull of at least 1.5 times greater
than the gross vehicle weight.
There are three factors listed that influence the line pull effect required to recover the vehicle.
The values and calculations in this section are approximate and are for reference only.
a). Gross vehicle weight
b). Type of the surface to be traversed
c). Gradient to overcome
In recovery and loading the winch is used to pull something, the required pulling force (RPF)
can be calculated according to the formula:
RPF = (Wt X S) + (Wt X G)
Where: Wt = The gross vehicle weight
S = The type of the surface to be traversed
G = The gradient to overcome
Surface Type Surface Drag (S)
Metal
0.15
Sand
0.18
Gravel
0.20
Soft Sand
0.22
Mud
0.32
Marsh
0.52
Clay
0.52
Gradient Angle ( ) Gradient (G)
5%
3°
0.06
10%
6°
0.11
20%
11°
0.2
30%
17°
0.3
50%
26°
0.44
70%
35°
0.58
100%
45°
0.71
°

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For example, if a vehicle weighing 1,200 kg is winched up an incline by 100% on the marsh
road, the above formula would be used as follows:
Where Wt: 1,200 kg, S: 0.52 G: 0.71
RPF = (Wt X S) + (Wt X G)
= (1,200 kg X 0.52) + (1,200 kg X 0.71)
= 624 kg + 852 kg
= 1,476 kg of effect required to recover the vehicle.
Winching V.S. Hoisting. A pulling winch should not be used for lifting.
Please refer to our website to view our full range of lifting winches
A gradient of 10% is a rise
of one meter in ten meters
(High / Distance)
Securing Anchor Point
When choosing an anchor point, select a safe and firm point such as a tree, stump or rocks.
If using a winch to retrieve another vehicle, the rescue vehicle is considered the anchor point
and should be made secure.
The anchor point must be strong enough to hold the gross weight of the vehicle and be
positioned to keep the fleet angle between the centre of the anchor point and the wire rope
maintained less than 15°. Always use a tree trunk protector strap to prevent ring barking the
tree and damaged to the wire/synthetic rope.
III .Accessories
Roller Fairlead
The use of 4 ways roller fairlead can eliminate the contacting
friction because the fairlead rollers contact with the wire rope. But the
fairlead does not insure the wire rope will wind onto the drum in an
orderly manner. The proper fleet angle within 15° must be maintained
for the wire rope to wind onto the drum in an orderly manner.
Recovery Damper
A recovery damper is a safety device designed to help eliminated
the possibility of injury or property damage in the event of a wire/synthetic
rope failure. Place in the middle third of a live rope.
The damper can help absorb the energy in the rope and reduce
the likelihood of injury or damage.

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Snatch Block
An important aid to successful winching is the use of snatch block,
which can be used to increase the pulling power of a winch or change
the direction of a pull.
A winch double lined with a snatch block creates a mechanical
leverage cutting the effort required by nearly half.
The double line pull shows self recovery using a snatch block
attached to an anchor point; the pull applied to the vehicle is almost
twice as much as the line pull of the winch.
The use of one snatch block shows an indirect pull where the
vehicle is limited due to unsuitable ground or obstruction. The pull on
the load is the actual line pull of the winch.
If more than one snatch block is used, they must be located at
least 100 cm (40″) apart.
Mounting
1). Use the mounting hardware (M10 bolt, nut and washer) to mount the winch on a flat
surface (fig 5).
2).The motor, drum and gear housing must be properly aligned (fig 6).
IV.Installation
Before using the winch, make sure all electrical parts have no corrosion or damage; relative
environment should be clear and dry.
The voltage drop from the point of supply to the load of machine must not exceed 10% of the
nominal voltage under normal operating condition.

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Battery Leads Connection
1). Battery leads specification is listing as follows:
2). Use a 5/16˝ bolt, nut and washer to attach the black lead (negative -) firmly to the
base plate of the vehicle (fig 7).
3). Attach the red lead (positive +) tightly to the circuit breaker marked AUX, meanwhile,
connect copper plate to the other end of the circuit breaker, marked BAT (fig 8).
4). Connect the copper plate to the connector of battery (fig 8).
Switch Connection:
1). A hand-held remote switch w / 1.25mm2 x 3C x 3m cord supplied
2). Open the rubber gland of the winch, then insert the switch plug into the socket of the
winch (fig 9).
Model DV-2500i DV-3500i DV-4500i
Control Type Solenoid/Indirect
12V 6 AWG × 5’ (1.5 m) 6 AWG × 5’(1.5 m) 6 AWG × 5’(1.5 m)
24V 8 AWG × 5’ (1.5 m) 8 AWG × 5’(1.5 m) 8 AWG × 5’(1.5 m)
Volt

V. Operation
Be sure to check all safety and environmental conditions.
A wire rope should be discarded and not to be used again if rope shows sign of excessive
wear too many broken wires, corrosion or other defects.
The operator of winch must remain with the winch at all times whist the unit is being operated.
The type of duty is intermittent-periodic duty S3 and the load time never exceeds 2 minutes.
If a winch fails in pulling a load at a normal condition, stop the operation within 30 seconds,
otherwise you will damage the motor.
Ensure that only the rated voltage is applied to the winch (ie. 12VDC or 24VDC).
Do not wrap the wire rope around load and hook it to itself. Always use a strap to insure that
the wire rope does not fray or kink.
Keep hands and clothes away from the drum area, wire rope and roller fairlead.
Never unplug the remote control when winching a load.
Determine that the winch is operating correctly before use.
To avoid insufficient power in pulling a load, the vehicle should be running and in neutral.
The handbrake should be also on.
If noise or vibration occur while running, stop the winch immediately and send it for repaired.
Don’t use it again before trouble shooting completely.
If the winch is not to be used for a long time, we recommend disconnecting the battery lead
from winch.
1). To determine “Cable - Out”, depress ↑ button (fig. 10)
2). To determine “Cable - In” depress ↓ button (fig.11)
3). To stop winching, release the button
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Precaution
Cable-in/ Cable-out Operation

VI. Maintenance
The free-spool allows rapid wire rope payout for hooking onto the load or anchor points
and is operated by a free-spool level.
The free-spool level must be in the “Engaged” position before winching (fig 12)
1). To disengage the free-spool by lifting a free-spool lever in the “Disengaged” position, wire
rope can now be free spooled on the drum (fig13)
2). To engaged the free-spool, press a free-spool level in the “Engaged” position.
3). If a free-spool lever can’t be properly locked in the “Disengaged” position, rotate the drum
to make the pole free-spool to couple the gear train completely.
4). Wear leather gloves and use a handsaver strap when guiding the wire rope out of the drum.
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Clutch Function
The proper usage of a snatch block will nearly double the capacity of the winch but the
speed will decay 50%.
It is recommended to use snatch block for loading over the rated load.
When a snatch block is applied, be sure that the anchor point of the hook is secured to
withstand the double line rated capacity of the winch.
Use a Snatch Block Assembly
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 only use marine type grease.
Lubrication
Never substitute a heavier or lighter wire rope. Never use rope made of any material other
than wire.
1). Spool the entire wire rope, then cut and take it out from the drum.
2). Put the replacement wire rope through the fairlead opening, pass below the drum, and
insert it into the hole of drum core.
3). Tighten the screw downwards to secure the wire rope(fig14).
4). Secure the wire rope to the hook with 2 sets of cable clip, tighten the screw completely (fig 15).
Wire Rope Replacement

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Maintenance Schedule
Item Checking
method Checking reference
Daily
Periodical
Monthly Quarterly
Installation
Mounting bolts &
alignment
Bolt tension &
wear Existence of abnormalities
Remote
control
Working Manual Reasonable actuation
Wearing in
contact points Visual Free of wear or damage
Wire
rope
Broken strands Visual,
measuring
Less than 10%
Decrease in rope
diameter
Visual,
measuring
7% of nominal diameter
max
Fastening
condition of end Visual Existence of abnormalities
Deforming or
corrosion Visual Existence of abnormalities
Clutch
assembly
Damaged clutch
assembly
Visual evidence
of wear Free of wear or damage
Motor Staining,
damage
Visual evidence
of wear Existence of abnormalities
Brake
Wearing of brake
disc
Visual evidence
of wear Free of wear or damage
Performance Visual Reasonable actuation
Gear Damage,
wearing
Visual evidence
of wear Free of wear or damage

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If the winch fails to operate after several attempt, or if there is any fault whilst operation:
Remedy
Winch will not
operate
Cut circuit
Check battery lead
Weak battery
Recharge or replace battery, 650CCA
Damaged circuit breaker
Replace circuit breaker
Bad connection of wiring
Reconnect tightly
Damaged DC solenoid
Replace DC solenoid
Cut circuit on switch
Replace switch
Damaged motor or carbon brush. Replace motor or carbon brush
Poor or lost connections to motor
Replace wiring or tighten it
Motor runs in one
direction.
Broken wiring or bad connections
Reconnect or replace wiring
Damaged or stuck DC solenoid
Replace DC solenoid
Switch inoperative
Replace switch
Drum will not
clutch.
Clutch does not disengage
Replace clutch
Damaged 1
st
shaft
Replace 1
st
shaft
Damaged brake cam and disc
Replace brake cam and disc
Damaged output shaft
Replace output shaft
No brake
The gear train is mechanically binding
up
Check to insure the winch is mounted on
a flat, rigid surface
Damaged brake cam and disc
Replace brake cam and disc
Damaged gear box
Replace gear box
Broken retaining ring
Replace retaining ring
Oil leakage into brake cavity Repair and clean oil leakage
Damaged or inoperative spiral spring
Replace and position spiral spring
Brake distance is
too long
Worn brake disc or loose brake
spacer
Replace brake disc or adjust brake spacer
according to brake adjustment procedures
Oil leakage into brake cavity
Repair and clean oil leakage
Brake will be
locked
Too much brake disc powder in the
brake hub
Clean brake hub
Over tensioned spiral spring
Adjust tension on spiral spring
Stuck between brake disc and gear
box
Replace with new brake assembly
Damaged gear
box
Hit by certain exterior force
Replace the damaged components
Damaged gear train
Replace the damaged components
Over load operation
Stop the winch operation and reduce the
load
Motor runs
extremely hot
Long period of operation
Allow to cool
Damaged motor
Replace or repair motor
Damaged or inoperative brake
Replace or repair brake
Possible Cause
Symptom

NOTES
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COMEUP INDUSTRIES INC.
No.112, Nanyang St., Xizhi Dist., New Taipei City, Taiwan 22152
Tel: [phone] / Fax: [phone]
Email: [email protected]
http://www.comeupwinch.com
PN 882365 Ver:00
Specifications subject to change without notice