Comeup GTD-650 User manual

2
Heavy Duty Hoist
Limited One (1) Year Warranty
WARRANTY
Comeup Industries Inc. (COMEUP) warrants to the original purchaser that COMEUP heavy duty
hoist will be free of defects in material and workmanship for a period of one (1) year from the original
date of purchase. All COMEUP 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 hoist. To obtain any warranty service,
the purchaser under this Limited Warranty is requested to advise COMEUP or its authorized
distributors on any claim. The purchaser must provide a copy of the purchase receipt bearing the
hoist serial number, date of purchase, owners name, email or Tel & Fax, address and purchaser
vehicle details. Any products that COMEUP determines to be accountable for defective will be
repaired or replaced or refund at COMEUP 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 hoist or part, with freight prepaid, to COMEUP or its authorized distributor. And COMEUP
will send the serviced product back to purchaser on COMEUP’s cost. This warranty does not cover
the removal or reinstallation of the hoist.
COMEUP takes the responsibility for COMEUP hoist parts and components to be free from
defects in materials and workmanship, but the following portions are hereby excluded and
disclaimed. COMEUP 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 assembly 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 COMEUP hoist. This warranty
is void when COMEUP serial number plate is removed or defaced.
COMEUP’s liability to the purchaser under the hoist purchases for any loss or damage howsoever
and whatsoever arising shall not exceed the price of the initial hoist purchase receipt. COMEUP
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 COMEUP employees, distributors
and their employees or otherwise. COMEUP reserves the right to change product design without
notice. In situations in which COMEUP has changed a product design, COMEUP shall have no
obligation to upgrade or otherwise modify previously manufactured products.

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Heavy Duty Hoist
Thank you for purchasing a Hoist. This manual covers operation and
maintenance of the hoist. 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.
It has been designed to give safe and dependable service if operated according to the
instructions. Read and understand this manual before installation and operation of hoist.
Careless hoist operation can result in serious injury or property damage.
When requesting information or ordering replacement parts, always give the following
information:
1.Hoist model and voltage
2.Serial Number
3.Item. No. and Part Number
4.Part Description
1. The hoist is rated at the first layer of wire rope on the drum for S3 Intermittent duty.
2. A minimum of five (5) wraps of rope around the drum is necessary to support the
rated load.
3. Keep clear of hoist, rope, and hook while operating.
4. Wire rope can break without warning. Always keep a safe distance from the hoist
and rope while under a load.
5. Failure to adequately align, support, or attach hoist to a suitable mounting base
could result in a loss of efficiency of performance or damage the hoist, rope and
mounting channel.
6. The hoist is a very powerful machine. Treat with extreme care and observe all
caution and warnings.
WARNING
4
I. Safety Requirement
WARNINGS
1. The owner and/or the operator shall have an understanding of these
operating instructions and the warning before operating the electrical
hoist. Failure to follow these warnings may result in loss of load,
damage to the hoist, property damage, personal, or fatal injury.
2. The owner shall retain this manual for further reference to important
warnings, installation, operating and maintenance instructions.
General Rules
The operator of a hoist in some cases is required to have qualifications according to applicable
laws and ordinances.
Check all safety and environmental conditions prior to and during use.
Don’t use unsuitable rope in construction, strength or having any defects.
Don’t use an unsuitable hook and snatch block for rope.
The operator must remain with the hoist when it is being operated.
The hoist is rated at S3 Intermittent duty only.
Do not use the hoist as moving people.
Ensure that the hoist is connected to the correct voltage. 12V DC or 24V DC only.
Do not exceed maximum line lifting shown in tables. Shock load must not exceed these ratings.
A rope should be replaced if it shows signs of excessive wear, broken strands, corrosion or any
other defects.
If the hoist fails to lift a load under normal conditions, stop the operation within 30 seconds
otherwise motor damage may occur.
Remove the switch from the hoist when not in use.
Keep hands and clothes away from the hoist and rope.
Never unplug the remote control when hoisting a load.
To avoid insufficient power when hoisting a load, the vehicle should be running and in neutral.
If noise or vibration occurs when running, stop the hoist immediately and return it for repair.
The rope shall be wound in according to drum rotation sticker or refer to owners manual,
otherwise, the brake will not function.
Ensure to use the insulating boots on the exposed connections to offer better insulations and to
prevent electrical shorting.

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II. Handing Precautions
Operation Precaution
＊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.
＊Hoists are not to be used for lifting or lowering people.
＊Don’t work, walk or stand under an operating hoist.
＊Always remain in control. Never neglect the hoist while actually hosting a load.
＊While working, never stand under a lifting load or within the conveying area.
＊Always look up when working around hoist, 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.
＊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 duty cycle 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 hoist by fixing so securely that the rope around the drum is even.
＊Be sure to fix a rope in the centre 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 remote switch positioned immediately after use.
＊Make sure that the load being lifting are well balanced and secured before starting.
＊Avoid water splashes on the remote switch.
＊Never wrap the load with the wire rope.
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It is forbidden to
lift loads above
the rated
capacity of the
hoist
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 hoisting
operation
Never submerge
winch in water as
winch rated at
IP44.

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III. Environment Precautions
DANGER
The following environmental conditions may result in the possible causes of hoist
trouble.
Low temperature below -10°C, high
temperature above 40°C or humidity
above 90% conditions.
※Cause malfunction of spare parts
In an organic chemistry or explosive
powder condition.
※Cause explosion
In the rain or snow conditions.
※Cause malfunction of spare parts.
In a heavy general powder.
※Cause malfunction of performances.
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IV. Hoisting Principles
Load Rated
Load and speed varies 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. The top layer of rope
on the drum delivers the maximum speed and
the minimum load. For this reason, all hoists
are rated at their top layer capacities.
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.
Calculating Head Load
P: Rope tension
η: Sheave coefficient
θ: Angle
W: Load
μ: Friction factor

Calculating Fleet Angle
The hoist 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 centred 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. This could cause failure of the hoist or wire rope, resulting in damage,
injury or death.
Experience has shown that the best wire rope service is obtained when the maximum fleet
angle is not more than 1.5°for smooth drums.
Therefore the correct distance between centre of drum and of should be derived as a fleet
angle of 1.5°is the equivalents of approximately 19 cm of lead for each centimetre of
overall drum length.For example, the correct distance varies according to drum length.
Model GTD-650 GTD-800 GTD-1200 GTD-2200 GTD-2800
Drum Length 61.2 mm 68 mm 89 mm 108 mm 135 mm
Correct
Distance
1.16 m
at least
1.29 m
at least
1.69 m
at least
2.05 m
at least 2.57 m
at least
No. of sheaves 1 2
Roller bearing 0.98 0.96
Sleeve bearing 0.96 0.92

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Percentage Duty Cycle
WARNING
Never hoist over the rated percentage duty cycle.
The life of the hoist is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its %ED ratings.
Tb
Percentage duty cycle (%ED)＝------------------ X 100 (%)
Tb+Ts
Tb: total sum of overall loadings operating hours.
Ts: total sum of stopping hours.
Tb + Ts = approximately 1 to 10 minutes.
The duty cycle of heavy duty hoist varies according to the rated lifting.
Rated lifting
kg / lb
GTD-650
min / 10 min
GTD-800
min / 10 min
GTD-1200
min / 10 min
GTD-2200
min / 10 min
GTD-2800
min / 10 min
12V 24V 12V 24V 12V 24V 12V 24V 12V 24V
No load 3.0 3.0 2.5 Cont. Cont.
147 / 320 2.0 －2.3 －－－－
181 / 400 －2.0 －Cont. 8.0 －－
227 / 500 －－－－－9.0 7.0
272 / 600 1.5 －2.0 －－－－
362 / 800 －1.5 －8.0 6.0 －－
408 / 900 －－1.8 －－－－
454 /1000 －－－－－7.0 4.5
544 / 1,200 －－1.5
6.0 4.0 －－
771 / 1,700 4.5 3.0 5.0 3.0
998 / 2,200 －－－3.0 2.0 3.5 2.5
1,270 / 2,800 －－－－－2.5 2.0
D/d Ratio
The drum diameter to wire rope diameter ratio (D/d) determines the wire rope size
required. Minimum hoist drum root diameter = wire rope diameter x ANSI B30.5* ratio minus
rope diameter. The greater the ratio the longer the wire rope life.
* In compliance with standard of ANSI B 30.5, the rope safety factory shall maintain at least
18:1
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Rope Safety Factor
The working coefficient shall be determined from the ratio of the minimum breaking force
of the rope and the maximum possible lifting force.
* In compliance with standard of ANSI B 30.5, the rope safety factory shall maintain at least
3.5:1
Standard compliance of EC Directives
The EC directive includes the following individual directives
Machinery Directive 2006/42/EC
It applies to independently functional machinery or the interlinking machines to form
entire systems. The complete machine and plant must always fulfill the directive.
Electromagnetic Compatibility Directive (EMC) 2004/108/EC
It applies to most electrical and electronic apparatus, that is, finished products and
systems that include electrical and electronic equipment to ensure that the electromagnetic
disturbance generated by apparatus does not exceed a level allowing radio and
telecommunications equipment and other apparatus to operate as intended, and that
apparatus has an adequate level of intrinsic immunity to electromagnetic disturbance to
enable it to operate as intended.
Extracts from the EC Directive & Comeup compliance:
1. EN 14492-1 Section 5.15.6 Wire Rope
Wire rope minimum break to be twice hoist 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
3. EN 14492-1 Section 5.7.6 Rope Fastening onto the rope drum
Rope attachment to withstand 2.5 times the hoist rating
Rope must have at least two wraps winding before fixing point
4. EN 14492-1 Section 5.15.5 Brake
Hoist to hold full rated load
5. EN 14492-1 Section 5.15.2 Rated Capacity Limiters
The thermal overload cutout limit the driving power of the motor prevents hoist overloading
To comply with EN 14492-1, the following optional accessories must be fitted to all hoists
‧Overload protection device ‧Rope drum cover
‧Emergencystopkit ‧Battery isolator switch
‧Up and Down limits protection device
When using and installing a hoist, the owner or end user shall ensure that all legal
requirements are completely complied with.

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V. Operation
Electrical Wiring Diagram
Before using the hoist, 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 hoist must not exceed 10% of the nominal voltage under normal operating condition.
SwitchConnection
1. A remote switch with 1.25 mm (diameter) X 3C X 5 m (16AWG X
3C X 17ft) cord supplied.
2. Open the dust-proof cover of the hoist and then insert the switch
plug into the socket.
Battery Recommendations
A fully charged battery and good connections are essential for the proper operation of your
hoist. The minimum requirement for battery is 650 cold cranking amp.
Cable-in / Cable-out Operation
1. To determine “Cable - Out”, trigger
→out
2. To determine “Cable - In”, trigger
←in
3. To stop hoist, release the trigger
Lubrication
All moving parts in the hoist 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 marine type grease.
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VI. Maintenance
Tip for prolonging the life of wire rope
1). Do not wind out past the red paint section of the rope to secure the anchorage of the rope
on the drum.
2). Make sure the first layer of wire rope is tight and maintain a freeboard at least 1.5 x rope
diameter on the drum
3). To compensate for uneven spooling and the decrease in line pull capacity as the drum fills
up, use as short a wire rope as practical.
4). A minimum of five wraps of rope around the drum load is necessary to support the rated
load.
Wire Rope Replacement
For GTD-650/800/1200
Before installing a new wire/synthetic rope, wrap the end of the wire
rope with tape to prevent fraying. Wind the wire rope on the drum by
pulling a force to keep the tension constant. Never use a wire/synthetic
rope of a different size or material.
1). Spool the old wire rope, and then remove it from
the drum.
2). Pass it below the drum. Insert rope into pocket
opening and through wedge pocket.
3). Loop rope end around wedge and feed rope back through wedge pocket.
4). Once slack is taken up, the wire rope is properly installed.
5). Tighten the horizontal roller of the roller fairlead and bolts of the roller/hawse fairlead
6). Wear leather gloves and use a strap when guiding the wire/synthetic rope off the drum.
7). Rewind wire/synthetic rope on the drum correctly, it is necessary to keep a slight load on the
wire/ rope while cable in.
For GTD-2200/2800
1). Feed the end of the wire rope into No. 1 anchor hole in the drum
and wind about 1/4 wrap of rope on the drum. Insert the wire rope
into No. 2 hole and tighten the set screw securely.
2). Make sure the first layer of wire rope is tight and maintain a
freeboard at least 1.5 x rope diameter.
3). Wire rope shall be wound in an under-wound orientation only.
4). To compensate for uneven spooling and the decrease in line pull
capacity as the drum fills up, use as short a wire rope as practical.

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BrakeAdjustment
For GTD-650/800
It do not require any adjustment for GTD-650/800 at any circumstance.
For GTD-1200/2200/2800
Under normal use, the brake mechanism will not require any adjustment. If the
brake fails to hold a load, the brake disc may be worn and require replacement.
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 the retaining rings.
2). Insert spacers/washers to maintain the brake spacer between to be for 2.-0.5 for
GTD-1200 and 2.2 ± 0.25 mm for GHD-2200/2800.
3). Make sure to keep the clutch base plate is rotated counter-clockwise by 140
degree tor GTD-1200 and 150 – 180 degree for GTD-2200/2800.
For GTD-1200
For GTD-2200/2800
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Maintenance Schedule
1. Ensure that a responsible person carries out all inspections as per schedule.
2. Inspections are dived into Daily, Monthly and Quarterly.
3. Always keep the hoist and accessories free of dirt, oil, grease, water and other substances.
Classification of check
Item Checking
method Checking reference
Daily
Periodical
Monthly Quarterly
Installation
Mounting bolts &
alignment
Bolt tension
& wear
Existence of
abnormalities

Remote
control /
contactor
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
Deforming or
corrosion Visual Existence of
abnormalities
Fastening condition
of end Visual Existence of
abnormalities
Wirings
Fastening condition
of terminals Visual Free of corrosion and
tightening terminals
Motor Staining, damage
Visual
evidence of
wear
Existence of
abnormalities

Brake
Wearing of lining
Visual
evidence of
wear
Free of wear or damage
Performance Visual Reasonable actuation
Gear train Damage, wearing
Damage,
wearing Free of wear or damage

Housing
Tie bar Visual Mounting surface is flat
to within ± 0.5 mm
Support racks Visual Free of bent or crack

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VII. Trouble Shooting
When the hoist fails to operate after several attempts, or if there is any fault while
Symptom Possible Cause Remedy
Hoist will not
operate
Cut circuit Check battery lead
Weak battery Recharge or replace battery (at least
650CCA)
Damaged circuit breaker Replace circuit breaker
Bad connection of wirings Reconnect tightly
Damaged contactor Replace contactor
Cut circuit on switch Replace switch
Damaged motor or worn carbon brush Replace motor or carbon brush
Dropt or lost motor wiring Tighten wirings
Motor runs in one
direction
Broken wiring or bad connection Reconnect or replace wiring
Damaged or stuck contactor Replace contactor
Switch inoperative Replace switch
Dropt or lost wiring Replace wiring and tighten, wirings
Hoist won’t lift
rated load
Considerable voltage drop exceeds by
10% of the rated voltage of 12V DC or 24V
DC.
Correct leads size
Replace battery as bad condition
Clean and tighten the wirings
No brake
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 Clean oil leakage
Damaged or inoperative spiral spring Replace and position spiral spring
Damaged or stuck solenoid Replace solenoid
Brake distance is
too long
Worn or damaged brake Replace or adjust brake
Oil leakage at brake Clean oil leakage
Damaged or stuck solenoid Replace solenoid
Damaged gear
train
Hit by certain exterior force Replace the damaged components
Damaged gear train Replace the damaged components
Over load operation Replace a new hoist
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
Hoist vibrates
badly or is noisy
Damaged brake
Replace or repair brake
Mounting surface is not flat Make sure mounting surface is flat
Tie bar is bent Replace tie bar
Crack on the motor and gearbox support
racks Replace racks
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