Comeup HV-8 User manual

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Industrial Winch
Limited One (1) Year Warranty
WARRANTY
Comeup Industries Inc. (COMEUP) warrants to the original purchaser that COMEUP Industrial
Winch 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 winch. 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
winch 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 winch 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 winch.
COMEUP takes the responsibility for COMEUP winch 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 winch. This warranty
is void when COMEUP serial number plate is removed or defaced.
COMEUP’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.
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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Hydraulic Recovery Winch
Thank you for purchasing a COMEUP 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.
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 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 rated at the first layer of wire rope on the drum 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. Keep clear of winch, rope, hook, and fairlead while operating.
5. Winch rope can break without warning. Always keep a safe distance from the winch and rope
while under a load.
6. Failure to adequately align, support, or attach winch to a suitable mounting base could result in
a loss of efficiency of performance or damage the winch, rope and mounting channel.
WARNING
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I. Safety Requirement
XGeneral Rules
The operator of a winch 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 winch when it is being operated.
The winches’ duty rating is S3 (intermittent-periodic).
Do not use the winch as a lifting device or a hoist for vertical lifting and moving people
Do not exceed maximum line pull ratings shown in tables. Shock load must not exceed these
ratings.
Keep hands clear of rope and fairlead opening.
Pull from an angle below 3° on horizontal direction to straighten
up the vehicle or load.
Use leather or heavy duty gloves when handling the wire rope.
When winching a heavy load, lay a heavy blanket or jacket over
the wire rope near the hook end.
A rope should be replaced if it shows signs of excessive wear,
broken strands, corrosion or any other defects.
If the winch fails to pull a load under normal conditions, stop the
operation within 30 seconds, or motor damage may occur.
Check that the clutch T-handle is in the “Engaged” position during and after use.
Remove the switch from the winch when not in use.
Do not warp 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, rope, and roller fairlead.
Never unplug the remote control when
winching a load.
To avoid insufficient power when
winching a load, the vehicle should be
running and in neutral.
If noise or vibration occurs when running,
stop the winch immediately and return it
for repair.
The rope shall be wound in according to drum rotation
sticker or refer to owners manual.

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II. Hydraulic System Installation
(Powered by PTO / power take off unit driven pump)
XHydraulic Fluid
xThe hydraulic fluid should be a high grade, petroleum based fluid, with rust, oxidation and wear
resistance. Fluid cleanliness and operating viscosity are critical to winch reliability, efficiency
and service lift.
XHydraulic Pump
xTo maintain the maximum performance, the hydraulic pump must supply the maximum flow of
hydraulic fluid at the hydraulic pressure stated in specification.
xWith a max. oil supply of 15.9 g/min (60 l/min) at top motor rpm and the pump must be capable
of delivering a pressure of 170 bar (2,466 psi).
XHydraulic Control Valve
xThe control valve must have a four-way spring return to neutral feature, which provides for open
flow from the pressure ports of the winch to the reservoir in neutral position of the control (motor
spool).
XHydraulic Pressure Relief
xThe hydraulic system requires a pressure relief set at the operating pressured.
xFailure to use the correct pressure and flow may result in damage to the winch, property or
personal injury.
Advantage: Professional winch system for “Working”
applications, cost effective, extremely
powerful, reliable, light weight and
variable line speed for high work rate.
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XHydraulic Reservoir
xThe hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to
prevent over-heating of the hydraulic fluid.
xMust be fitted with an oil filler device comprising strainer and filter and a dip stick. The capacity
of the tank should be at least 60 liters.
XOver-Center Valve
xGive smoothly controlled winch out when under load and to provide full dynamic braking. It
must be installed to hold full load.
xThe Port A of over-center valve means the inlet port of oil from reservoir and the Port B
meaning the return port of oil to reservoir.
XHydraulic Hoses
xThe following hydraulic hoses are recommended for maximum efficiency of the hydraulic winch.
The bigger nominal bore hose, the better winch performance.
xAll hose lengths are kept to a minimum because pressure and flow loss is increased as hose
length increases.
xPressure and return lines in excess of 3.5 meter (11.5”) should be compensated with an
increase in nominal bore size.
Inlet line ………….…... 1 1/4” – 1 1/2” nominal bore (N.B.) from reservoir to pump
Return line …………… 1” (N.B.) from control to reservoir
Pressure hoses …....... 1/2” (N.B.) from control valve to over-center valve
Motor drain line pipe… 1/4” BSP N.B.
IV. Winching Principles
XLinePull(lb)V.S.Pressure(psi) XLine Speed (fpm) V.S. Flow (g/min)

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XCalculating FleetAngle
To obtain the best wire rope service, the direction of pull will be on a horizontal within ±3
degrees and perpendicular to be centerline of the winch drum within ±3 degrees. If the fleet angle
is bigger than the recommended angles, a good spooling cannot be obtained as the rope will
spoon on to one side of the rope drum.
XLoad Rating
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 delivers the
maximum speed and the minimum load.
For this reason, all industrial winches are rated at their first layer capacities.
According to EN 14492-1 Section 5.7.2, 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.
XDuty Cycle Ratings
Duty cycle ratings usually specify continuous, intermittent, or special duty (typically expressed
in minutes).
xS1 - Continuous duty.
The motor works at a constant load for enough time to reach temperature equilibrium.
xS2 - Short-time duty.
The motor works at a constant load, but not long enough to reach temperature equilibrium,
and the rest periods are long enough for the motor to reach ambient temperature.
xS3 - Intermittent periodic duty.
Sequential, identical run and rest cycles with constant load. Temperature equilibrium is never
reached. Starting current has little effect on temperature rise.
For this reason, all industrial winches are rated at S3 intermittent periodic duty.
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XSecuring Anchor Point
Select a safe and firm anchor point. The usual point is a tree, stump or rocks, but if using a
winch to help a stuck vehicle overcome the obstacles, then the rescue vehicle can be treated as
an anchor point.
The selection of an anchor point shall be strong enough to hold the gross weight of the vehicle
and the fleet angle between center of anchor point and wire rope shall maintained less than 3°.
Securing the tree, never hook the wire rope back onto itself. You could damage the wire rope
and tree, Use a tree trunk protector and recovery strap to protect.
XRequired 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=Thetypeofthesurfacetobetraversed
G=Thegradienttoovercome
Surface Type Surface Drag (S) Gradient Angle (θ)Gradient (G)
Metal 0.15 5% 3° 0.06
Sand 0.18 10% 6° 0.11
Gravel 0.20 20% 11° 0.2
Soft Sand 0.22 30% 17° 0.3
Mud 0.32 50% 26° 0.44
Marsh 0.52 70% 35° 0.58
Clay 0.52 100% 45° 0.71

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For example, if a vehicle weighing 3,000 kg is winched up an incline by 100% on the marsh
road, the above formula would be used as follows:
WhereWt:3,000kg, S:0.52 G:0.71
RPF = (Wt X S) + (Wt X G)
=(3,000kgX0.52)+(3,000kgX0.71)
=1,560kg+2,130kg
= 3,690 kg of effect required to recover the vehicle
XWinching V.S. Hoisting. Apulling winch should not be used for lifting.
Please refer to our website to view our full range of lifting winches
V. Standards Compliance
XComeup Industrial Winches comply with the following regulations
1. European Standards of EN 14492-1 for Power Driven Winches came to effect from 29th.
December 2009
2. The latest Machinery Safety regulations of 2006/42/EC for machinery Directive.
3. SAE International Surface Vehicle Standard J706
XExtracts from the Directive & Comeup compliance:
1. EN 14492-1 Section 5.15.6 Wire Rope
Wire rope minimum break to be twice winch 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 winch rating
Rope must have at least two wraps winding before fixing point
4. EN 14492-1 Section 5.15.5 Brake
Winch to hold full rated load
5. EN 14492-1 Section 5.15.2 Rated Capacity limiters
The pressure relief valve limit the hydraulic pressure to prevent overloading of the winch
To comply with EN 14492-1, the following optional accessories must be fitted to all winches
•Wire rope with 1,960 N/mm2grade
•Rope drum cover
•Emergency stop valve
•Flow limiting valve
When using and installing a winch, the owner or end user shall ensure that all legal
requirements are completely complied with.
A gradient of 10% is a rise of one
meter in ten meters (High / Distance)
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VI. Accessories
XRoller 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 3° must be maintained for the wire rope to wind
onto the drum in an orderly manner. If the proper fleet angle is
not maintained, it can result in damage to the winch and wire
rope.
XCable Tensioner
The purpose of cable tensioner device is to keep the wire
rope tight on the drum while the winch is in free spool mode or
while there is no load on the wire rope. The cable tensioner
shall be treated as optional to winches.
XSnatch 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.

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VII. Hydraulic Operation
XManual Clutch Function
The clutch allows rapid pay-out of the wire rope for hooking onto a load or anchor points and is
operated by a clutch T-handle.
The clutch T-handle must be in the “Engaged” position before winching.
1).To disengage, lift the clutch T-handle up and turn it at 90° counter-clockwise rotation to the
“Disengaged” position, wire rope can now clutch off the drum.
2).To engage, lifts the clutch T-handle up and turn it at 90° clockwise rotation to the “Engaged”
position.
3).If a clutch T-handle can’t be properly locked in the “Engaged” position, rotate the drum to make
the clutch device engage to the gear train.
4).Wear leather gloves and use a strap when guiding the wire rope on and off the drum.
(Engaged) (Disengaged)
XAir Clutch Function
The air clutch must be in the “Engaged” position before winching.
1). Apply air pressure to the 125-27 NPT port with 80 psi at minimum to 150 psi at maximum.
2).To disengage the drum by operating the air control valve to pull out the wire rope by hand. Pull
out the wire rope but leave at least 5 wraps on the drum.
3).To engage the drum by moving the control valve lever to the appropriate position. Do not
attempt to pull a load until the air clutch in the “Engaged” position.
4).Wear leather gloves and use a strap when guiding the wire rope on and off the drum.
5).It cannot be clutched when the load is under load.
HV-20000/30000
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XLubrication
•For Gear Box
All moving parts in the winch are permanently lubricated at the time of assembly. Under
normal conditions factory lubrication will suffice. The lubricant for gear box was
recommended by Castrol Alpha Spheerol L-EP 2 grease recommended, 150 Viscosity (cSt)
at 40°C or similar quality after repair or disassembly.
•For Brake Assembly
The lubrication is an important component in insuring the long life of your winch and the type
of lubricant will have a great influence. The oil of brake assembly for your winch was
shipped with Castrol Alpha Series, SP-460, a viscosity (cSt) is 457.81/29.83 at 40°C / 100°C.
Consult your local lubricant distributor on the selection that best fits your climate and
application.
The initial lubricant should be changed after the first 10 hours of operation. Subsequent
changes should be scheduled annually.
•For T-handle, Roller Fairlead and Wire Rope
The lubrication for clutch, roller fairlead and wire rope can use light oil in the temperature of
-10°C to 50°C.
XLubricant Quantity
Winch Components Gear Box BrakeAssembly T-handle, Roller
Fairlead, Wire Rope
Lubrication Type Grease Oil Light Oil
HV-8 0.3 litre 0.12 litre little
HV-10 0.3 litre 0.12 litre little
HV-12 0.6 litre 0.3 litre little
HV-15 0.6 litre 0.3 litre little
HV-20000 0.75 litre Nil little
HV-30000 1 litre Nil little
Yak 5 0.6 litre Nil little
Quantity
Yak 7 0.6 litre Nil little
HV-8/10/12/15

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Remark: 1. The purpose of drum drag brake is to prevent the drum from overrunning the wire
rope when “free-spooling” and it will not be replied on to control or hold a load
2. The drum drag brake is only available for HV-8/10.
XWire Rope Replacement
Never use a wire rope of a different size or material. The wire rope end shall be inserted
through a hole in the drum and a screw is used to clamp the wire rope in place. This rope
attachment is simple and ingenious.
1). Disengage the clutch T-handle.
2). Spool the entire wire rope, and then remove it from the drum.
3). Place the replacement wire rope through the roller 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.
5). The red paint markings on the wire rope means 3 metres remains on the drum.
(Engaged) (Disengaged)
XWire Rope Recommendation
Model HV-
8 HV- 10 HV- 12 HV- 15 HV- 20000
HV-
30000
Yak
5 Yak 7
Grade 1,960 N/mm21,770 N/mm21,960 N/mm2
mm 10 11 12 14 14 16 8 10
Dia. inch 3/8 7/16 1/2 9/16 9/16 5/8 5/16
3/8
Std
Drum
30 /
98
27 /
89
39 /
128
27 /
128
80 /
265
91 /
300
40 /
131
24 /
79
Cap.
m/feet Long
Drum
40 /
131
60 /
197
35 /
115
Breaking
Strength KN 69.8 84.4 100.5 137 129 169 44.7
69.8
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IX. Maintenance Schedule
xEnsure that a responsible person carries out all inspections as per schedule.
xInspections are dived into Daily, Monthly and Quarterly.
Classification of check
Periodical
Daily
Monthly Quarterly
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
Remote
control Wearing in contact
points Visual Free of wear or
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 remarkable
c
Wire rope
Fastening condition of
end Visual To be sufficient for
hanging up of load
cClutch Wearing of handle Operating
To be free from
remarkable
wearing and
damage
cMotor Staining, damage
Decomposition
checking Existence of abnormalities
cWearing of brake disc Decomposition
checking
To be free from
remarkable
wearing and
damage
c
Brake
Performance Visual
Reasonable
actuation
cDamage, wearing
Decomposition
checking
To be free from
remarkable
wearing and
damage
cc
Gear
Low oil level Visual Replenish oil

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X. Trouble Shooting
XFor Hydraulic Winch
In most cases, the cause of malfunction is found in the hydraulic system. Before the winch is
removed from its mounting and disassembled, all of hydraulic system components should be
check for proper function. When checking oil pressure and volume in the hydraulic system, make
certain that the hydraulic reservoir is filled to the top level.
1. Hydraulic Oil Volume
The hydraulic oil volume relates to the line speed or rpm of the winch. Therefore if the winch
does not produce the specified maximum line speed or drum rpm, a loss of hydraulic flow in
the hydraulic system can be analysed. In this condition exists, install a flow meter into the
hydraulic system to check the volume supplied to the pressure port of the hydraulic winch
motor when the winch control is completely opened.
2. Hydraulic Pressure
The hydraulic pressure relates to the line pull of the winch. Therefore if the winch does not
produce the specified maximum line pull, a loss of hydraulic pressure in the hydraulic system
can be analysed. In the condition exists, install a pressure gauge into the pressure line leading
to the pulling port on the hydraulic winch motor.
3. Troubleshooting chart
Only if the hydraulic system has been checked and found to be in order, use the following
indications for possible causes of failure in the winch.
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Symptom Possible Causes Remedy
Motor may be damaged Remove and disassembly motor and examine all
parts and replace any that are worn or damaged
No oil supply to winch Check oil supply line connections and hoses
System not delivering full pressure
to winch Confirm pump is running to a higher setting
Winch is Overload Reduce load to within rated capacity
The pressure is not adequate to
power the load, or the back
pressure is too high
Check the pressure on each side of the
hydraulic motor
Winch is mechanically binding up
Loosen, but not remove, the bolts that are
attaching the tie bar and support racks. Rotate
the drum, making sure that it turns freely without
sticking. Tighten the bolts.
Winch will
not pull load
The brake is not releasing
This requires disassembly of the brake
assembly. Remove and replace of the brake
assembly.
Poor locking of 2nd stage ring
gear Clean any burs left on the ring gear
The gear train is mechanically
bundling up
This requires disassembly of the brake
assembly. Remove and replace of the brake
assembly.
Winch is mechanically binding up Same as above
Winch will
not pay out
Damaged clutch T-handle linkage Replace or remove the clutch assembly
Damaged drum seals Replace drum seal
Damaged drum flanges Replace drum
Oil leakage
Front seal in the hydraulic motor
shaft has failed Replace or repair the motor
Low oil level Refill oil
Excessive
noise Oil flow too high Check oil flow rate
Fail in installing or damaged over-
center valve Check over-center valve
Wrong oil flow direction of port A &
B on the over-center valve Check over-center valve
Fail in
immediate
stop after
power off Damaged brake assembly Replace or repair brake assembly
Insecure mounting Check mounting
Low oil flow Check flow rate
Drum noise
Low relief Check relief valve setting

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