Comeup DV-6000 User manual

1

2
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 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 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

3
I. Safety Precautions
Please read and understand this Instruction Manual before installing your winch.
Don’t use unsuitable wire rope in construction, strength or having any defects.
Don’t use an unsuitable hook and snatch block for wire rope.
The operator of a winch in some cases, is required to have qualifications according to
applicable laws and ordinances.
Do not use the 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.
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.
(Fig1)
Fleet angle
(Fig2)
Centre line of anchor point
CAUTION

4
II. Performance Data
Specifications
Model DV-6000 DV-6000i DV-9000 DV-9000i DV-12000 DV-15000
Line Pull (first layer) 2,722 kg / 6,000 lb 4,082 kg / 9,000 lb 5,443kg / 12,000lb
6,803kg / 15,000lb
Line Speed (first layer, no load) 14.6mpm / 48 fpm 13.4mpm / 44 fpm 8.3mpm / 27fpm 6.9mpm / 22fpm
12V 350 A 440 A 460 A
Amp. Draw 24V 400A 12 volt only 210 A 290 A 340 A
Type Series wound
12V 3,430 w / 4.6 hp 4,175 w / 5.6 hp
Motor Output 24V
2,685 w / 3.6 hp
12 volt only 1,940 w / 2.6 hp 2,684 w / 3.6 hp
Type 3 stage planetary
Gear Train Ratio 156:1 156:1 261:1 315:1
Free spool Rotating ring gear
Brake Automatic, full load cone brake
Control Detachable
solenoid pack
Integrated
solenoid pack
Detachable
solenoid pack
Integrated
solenoid pack
Detachable
Solenoid pack
Type A7 x 19 aircraft galvanized 6 x W(19)
Length 24.4 m / 80 ft 30 m / 100 ft 38 m / 125 ft 27 m / 89 ft
Wire Rope
Size 8 mm / 5/16 in 8 mm / 5/16 in 9.5 mm / 3/8 in 11 mm / 7/16 in
Performance
Model DV-6000 DV-6000i DV-9000 DV-9000i DV-12000 DV-15000
Line pull (kg / lb) 2,722 / 6,000 4,082 / 9,000 5,443 / 12,000 6,803 / 15,000
Line speed (mpm / fpm) 3.1 / 10 2.0 / 6.6 1.2 / 4 0.76 / 2.5
1st layer
Rope cap (m / ft) 6.1 / 20 6.1 / 20 6.2 / 20.3 5.3 / 17.4
Line pull (kg / lb) 2,224 / 4,903 3,335 / 7,352 4,561 / 10,056 5,575 / 12,292
Line speed (mpm / fpm) 3.7 / 12.1 2.4 / 7.9 1.43 / 4.7 0.92 / 3.01
2nd layer
Rope cap (m / ft) 13.5 / 44.3 13.5 / 44.3 13.6 / 44.6 11.8 / 38.7
Line pull (kg / lb) 1,880 / 4,144 2,820 /6,217 3,926 / 8,657 4,723 / 10,413
Line speed (mpm / fpm) 4.3 / 14.1 2.9 / 9.5 1.67 / 5.47 1.09 / 3.57
3rd layer
Rope cap (m / ft) 22.3 / 73.2 22.3 / 73.2 22.1 / 72.5 19.5 / 64
Line pull (kg / lb) 1,628 /3,589 2,442 / 5,383 3,446 / 7,599 4,097 / 9,033
Line speed (mpm / fpm) 5.0 / 16.4 3.3 / 10.8 1.9 / 6.23 1.26 / 4.13
4th layer
Rope cap (m / ft) 24.4 / 80 30 / 100 31.9 / 105 27 / 89
Line pull (kg / lb) 3,070 / 6,770
Line speed (mpm / fpm) 2.13 / 6.98
5th layer
Rope cap (m / ft) 38 / 125


Line speed and Amp. Draw
At the first layer of wire rope on the drum.
Model DV-6000/DV-6000i DV-9000/DV-9000i DV-12000 DV-15000
Line Pull Line Speed Amp. Line Speed Amp. Line Speed Amp. Line Speed Amp.
Kg lb mpm fpm 12V mpm fpm 12V 24V mpm fpm 12V 24V mpm fpm 12V 24V
0 0 14.6 48 60 13.4 44 55 30 8.3 27 60 50 6.9 22 60 50
907 2,000 7 23 170 4.6 15 110 65 * * * * * * * *
1,814 4,000 4 13 320 3.4 11 200 100 2.6 8.6 200 100 1.6 5.4 180 90
2,722 6,000 3.1 10 400 2.7 9 230 130 * * * * * * * *
3,629 8,000 * * * 2.3 7.5 260 170 1.7 5.8 310 190 1.2 3.8 280 190
4,082 9,000 * * * 2.0 6.4 350 210 * * * * * * * *
4,535 10,000 * * * * * * * 1.4 4.4 370 230 1.0 3.3 330 220
5,443 12,000 * * * * * * * 1.2 4.0 440 290 0.9 2.9 385 260
6,805 15,000 * * * * * * * * * * * 0.8 2.5 460 340

5
7
3
5
2
1
6-2
4
8
6-1
DV-6000/DV-9000/DV-12000/DV-15000
4:Roller Fairlead
6-1:Mounting Hardware for DV-6000/DV-9000
5:Handsaver Strap
2:Remote control
1:Winch Ass'y with Wire Rope
3:Motor Lead
7.Detachable Solenoid Pack
8.Snatch Block
6-2:Mounting Hardware for DV-12000/DV-15000
(only for DV-6000/DV-9000)
1
2
56
4
3
6:Mounting Hardware
DV-6000i/ DV-9000i
5:Handsaver strap
4:Roller Fairlead
2:Remote control
3:Motor Lead
1:Winch Ass'y with Wire Rope
7.Snatch Block
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Main Components

6
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
will be mounted on a flat and hard
surface, mounting channel, in
order to make sure the motor,
drum and gearbox housing are
aligned correctly.
2. The roller fairlead doesn’t mount
to winch directly.
3. Four (4) M10 x 1.50 pitch 8.8 Grade High Tensile Steel Bolts must be used for
DV-6000/9000/6000i/9000i in order to sustain the loads imposed on the winch mounting.
4. Eight (8) M12 x 1.75 pitch 8.8 Grade High Tensile Steel Bolts must be used for
DV-12000/15000 in order to sustain the load imposed on the winch mounting.
5. 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 leads connection
Battery leads specification:
Model DV-6000 DV-9000 DV-6000i DV-9000i DV-12000 DV-15000
Control Type Detachable solenoid pack Integrated solenoid pack Detachable solenoid pack
Red lead: 2AWG x 1.83 m/ 72” Red lead: 2AWG x 1.83 m/ 72” Red lead: 2AWG x 1.83 m/ 72”
Volt 12V or 24V
Black lead: 2AWG x 1.83 m/ 72” Black lead: 2AWG x 1.83 m/ 72” Black lead: 2AWG 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.
CIRCUIT BREAKER (OPTION) (OPTION)
DV-6000/9000/12000/15000 DV-6000i/9000i


Remote control Connection
1. A remote switch withψ1.25 mm X 3c X
5 m (16AWG X 3c X 17’) lead supplied
2. Open the dust-proof cover of the winch, then
insert the switch plug into the socket (fig3). (Fig3)
DV
-
6000 / 9000
DV-6000i / 9000i DV-12000/15000

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Cable-Out Cable-In
Ⅳ
ⅣⅣ
Ⅳ. 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 be occurred.
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 itself. 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 roller fairlead.
Never unplug the remote control 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 remote control 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 (fig.4)
2). To determine “Cable - In”, trigger ←in (fig.5)
To stop winching, release the trigger
(Fig4) (Fig5)

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

Free-spool Function
The free-spool allows rapid pay-out of the wire rope for hooking onto a load or anchor points and is
operated by a free-spool T-handle.
The free-spool T-handle must be in the “Engaged” position before winching.
1). To disengage, lift the free-spool T-handle up and turn it at 900clockwise rotation to the
“Disengaged” position, wire rope can now free-spool off the drum.
2). To engage, 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 device 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.

9
Ⅴ
ⅤⅤ
Ⅴ. Maintenance
Wire rope Replacement
Never use a wire rope of a different size or material and only use genuine
replacement parts.
The wire rope end is inserted through a hole in the drum and an allen set screw is
sued to clamp the wire rope in place. This rope attachment is simple and
ingenious.
1). Disengage the free-spool T-handle (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).
5). 5).
5). The paints red markings on the wire rope to indicate 3 meters should remain on
the drum.
(Engaged) (Disengaged)
(Fig 6) (Fig 7)


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 retaining rings
2). Insert few washers to maintain the brake spacer between to be 2.2 ±0.25 mm
3). Make sure to keep the free-spool 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 of gear box is
necessary after repair or disassembly use Shell EP2 or equivalent grease with 0.25
litres. Free-spool T-handle lubricates regularly with light oil. It is not allowed to have
brake ass’y lubricated.


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

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Free spool Wear in spring Visual evidence of wear Free of wear or damage.
Motor Staining, damage Visual evidence of wear Existence of abnormalities
Wearing of brake disc 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.
Ⅶ
ⅦⅦ
Ⅶ. Trouble Shooting
When the winch fails to operate after several attempts, or if there is any fault while

12
Ⅶ
ⅦⅦ
Ⅶ. Replacement parts List
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 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 retaining ring Replace retaining ring
Oil leakage at brake 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. 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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Ver:26
DV-6000/9000
No. Description Q’ty No. Description Q’ty No. Description Q’ty
Motor 12V 23 Brake disc 1 Solenoid pack 12V
1
Motor 24V 1 24 Spiral spring 1 46 Solenoid pack 24V 1
2 Motor support rack 1 25 Brake cover 1 -1 Solenoid upper plate 1
3 Gearbox support rack 1 26 Bearing 1 -2 Solenoid lower plate 1
4 Drum bushing 2 27 Bearing 1 -3 Remote switch socket 1
5 Drum 1 28 Spring washer 1 -4 Socket gland 1
6 Gear box 1 29 Hex. bolt 6 -5 Screw 2
7 Motor coupling 1 30 Hex. bolt 3 -6 Nut 2
8 1st shaft 1 31 Hex. bolt 1 Solenoid 12V
9 1st pinion 1 32 Hex. bolt 1 -7 Solenoid 24V 1
10 1st stage carrier 1 33 Hex. bolt 1 -8 Hex bolt 5
11 1st & 2nd ring gear 1 35 Retaining ring 2 -9 Toothed washer 5
12 2nd stage carrier 1 36 Retaining ring 2 -10 Hex bolt 2
13 3rd stage carrier 1 37 Gasket 2 -11 Nut 4
14 3rd ring gear 1 38 Spring pin 1 -12 Spring 2
15 3rd bushing 1 39 Foot print 1 -13 Lead gland 3
16 Free-spool barrel 1 40 Wire rope 1 -14 Socket plate 1
17 Free-spool lever 1 41 Roller fairlead 1 47 Motor lead 1
18 Spring 1 42 Mounting hardware 1 48 Tie bar 2
19 Free-spool T-handle 1 43 Remote control 1 49 Hex bolt 4
20 Brake free-spool base 1 44 Handsaver strap 1 50 Spring washer 4
21 Brake cam 1 45 Snatch block 1 51 Free-spool ass’y 1

14
Ver:25
DV-6000i/9000i
No. Description Q’ty No. Description Q’ty No. Description Q’ty
Motor 12V 23
Brake disc 1 Solenoid pack 12V
1
Motor 24V 1 24
Spiral spring 1 46
Solenoid pack 24V
1
2 Motor support rack 1 25 Brake cover 1 -1 Solenoid left cover 1
3 Gearbox support rack 1 26 Bearing 1 -2 Solenoid right cover 1
4 Drum bushing 2 27 Bearing 1 -3 Upper box 1
5 Drum 1 28 Spring washer 1 -4 Rubber gland 1
6 Gear box 1 29 Hex. bolt 6 -5 Hex bolt 6
7 Motor coupling 1 30 Hex. bolt 3 Solenoid 12V
8 1st shaft 1 31 Hex. bolt 1 -6 Solenoid 24V 1
9 1st pinion 1 32 Hex. bolt 1 -7 Remote switch socket 1
10 1st stage carrier 1 33 Hex. bolt 1 -8 Bolt 2
11 1st & 2nd ring gear 1 35 Retaining ring 2 -9 Nut 2
12 2nd stage carrier 1 36 Retaining ring 2 -10 Socket gland 1
13 3rd stage carrier 1 37 Gasket 2 -11 Lead gland 3
14 3rd ring gear 1 38 Spring pin 1 -12 Tie bar screw 2
15 3rd bushing 1 39 Foot print 1 -13 Socket plate 1
16 Free-spool barrel 1 40 Wire rope 1 47 Hex bolt 4
17 Free-spool lever 1 41 Roller fairlead 1 48 Spring washer 4
18 Spring 1 42 Mounting hardware 1 49 Motor lead 1
19 Free-spool T-handle 1 43 Remote control 1 50 Free-spool ass’y 1
20 Brake free-spool base 1 44 Handsaver strap 1
21 Brake cam 1 45 Snatch block 1

13
Ver:8
DV-12000/15000
No. Description Q’ty No. Description Q’ty No. Description Q’ty
Motor 12V 27 Brake free-spool base 1 53 Solenoid pack 24V 1
1
Motor 24V 1 28 Brake cover 1 -1 Solenoid upper plate 1
2 Motor support rack 1 29 Tie bar 3 -2 solenoid lower plate 1
3 Gearbox support rack 1 31 Retaining ring 1 -3 Remote switch socket 1
4 Drum bushing 2 32 Handsaver strap 1 -4 Socket gland 1
5 Drum 1 33 Wire rope 1 -5 Screw 2
6 Motor coupling 1 34 Bearing 1 -6 Nut 2
7 1st shaft 1 35 Gasket A 2 Solenoid 12V
8 1st pinion 1 36 Gasket B 1 -7 Solenoid 24V 1
9 1st stage carrier 1 37 Retaining ring 2 -8 Hex bolt 5
10 2nd stage carrier 1 38 Hex. bolt 6 -9 Toothed washer 5
11 3rd stage carrier 1 39 Hex. bolt 10 -10 Hex bolt 2
12 1st & 2nd ring gear 1 40 Hex. bolt 9 -11 Nut 4
13 3rd ring gear 1 41 Hex. bolt 1 -12 Spring 2
14 Gear box 1 42 Hex. bolt 1 -13 Lead gland 3
15 Plain washer 1 43 Hex. bolt 1 -14 Socket plate 1
16 Free-spool lever 1 45 Hex. bolt 10 54 Foot print 1
18 Spring 1 46 Spring washer 10 55 Hook 1
19 Free-spool barrel 1 47 Spring washer 6 56 Motor lead 1
20 Spring pin 1 48 Spring washer 10 57 Bearing 1
21 Free-spool T-handle 1 49 Spring washer 9 58 Packing 1
22 Spiral spring 1 50 Mounting hardware 1 59 O-ring 1
24 Brake cam 1 51 Roller fairlead 1 60 Free-spool ass’y 1
25 Brake disc 1 52 Remote control 1
26 Brake base 1 53 Solenoid pack 12V 1

MEMO

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.