Comeup HV-8000SP User manual

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Hydraulic Recovery Winch
Thanks 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 snatch block or accessories.
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˙Don't use unsuitable wire rope in construction , strength or having any defects.
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˙Check the winch for smooth operation without load before winching operation.
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˙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 to
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 what ever the vehicle is stuck in.
WARNING

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I. Safety Precaution
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 unsuitable hook and snatch block for wire rope.
The operator of winch in some cases may be required to have
qualification 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. (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.
Hydraulic System Installation
(Powered by PTO / power take off unit driven pump)
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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As a general rule:
The hydraulic system shown above must contain over center valve, control valve and pressure
relief valve for having the winch operated correctly. Failure to use the correct valves may result in
damage to the winch, property, or personal injury.
The relief valve must be set at the winch operating pressure and doest not exceed the rated
pressure. Failure to use the correct pressure and flow may result in damage to the winch, property
or personal injury.
The hydraulic pressure or flow lower than those rated for the winch may result in a lower line pull
or lower line speed.
The bigger nominal bore hose, the better winch performance.


Keeping cleanliness and accuracy on the hydraulic system installation are essential to have
hydraulic system functioned properly
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
All hose lengths are kept to a minimum because pressure and flow loss is increased as hose length
increases
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Pressure and return lines in excess of 3.5 meter ( 11.5” ) should be compensated with an increase
in nominal bore size
Hydraulic System Specification:
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System type: Open system with filtered return line
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Over center valve: Give smoothly controlled winch out when under load and to provide full
dynamic barking. It must be installed to hold full load
Port A means the inlet port of oil from reservoir
Port B means the return port of oil to reservoir.
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Relief valve: Set at the winch operating pressure
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Pump: With a max. oil supply of 15.9 g / min ( 60 l /min ) at top motor rpm.
The pump must be capable of delivering a pressure of 170 bar ( 2,466 psi )
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Reservoir: Must 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.
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
Hoses: 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.
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Control valve: 4 way, 3-position with spring centered, open centre
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Pressure relief valve: Must be set at the winch operating pressure
( It should be mounted as closed to the winch as possible)
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Hydraulic motor: Heavy, industrial and long periods used Danfoss OMP80 for HV-8000SP,
OMP100 for HV-10000SP, OMP125 for HV-12000P and OMP160 for HV-15000P
It is recommended to have the motor drain line connected back to the reservoir

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II. Performance Date


Specification
Model HV-8000SP HV-10000SP HV-12000P HV-15000P
Line Pull kg / lb 3,629 / 8,000 4,535 / 10,000 5,443 / 12,000 6,803 / 15,000
Line Speed mpm / fpm 15 / 49 12 / 39.45 11 / 35.4 9 / 28.8
Operation pressure 140 bar / 2,030 psi
Max. oil flow 15.9 g / min ( 60 l / min)
Displacement
77.8 cm3 / rev
4.7 in3 / rev
97.3 cm3 / rev
5.9 in3 / rev
125 cm3 / rev
7.6 in3 / rev
156 cm3 / rev
9.5 in3 / revMotor
Rotation Anti-clockwise
Type 2 stage planetary gear
Gear
train Ratio 16:1 19.4:1
Free-spool One way rotating ring gear free-spool
Brake Spring applied drag brake
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Line Pull and Speed
Model HV-8000SP HV-10000SP HV-12000P HV-15000P
Line pull kg / lb 3,629 / 8,000 4,535 / 10,000 5,443 / 12,000 6,803 / 15,000
Line speed mpm / fpm 15 / 49 12 / 39.45 11 / 35.4 9 / 28.8
1st
layer
Rope cap m / ft 5.6 / 18 7.5 / 25 8.8 / 28.8 7.6 / 25
Line pull kg / lb 3,019 / 6,655 3,770 / 8,320 4,641 / 10,232 5,677 / 12,516
Line speed mpm / fpm 18 / 59 14.6 / 47.9 12.6 / 41.3 10.5 / 34.4
2nd
layer
Rope cap m / ft 12.3 / 40 16.4 / 54 19.2 / 63 16.8 / 55.1
Line pull kg / lb 2,585 / 5,698 3,330 / 7,120 4,045 / 8,919 4,869 / 10,736
Line speed mpm / fpm 21 / 69 17.1 / 56.1 14.5 / 47.6 12.3 / 40.4
3rd
layer
Rope cap m / ft 20.2 / 66 26.9 / 88 31.3 / 102 27 / 89
Line pull kg / lb 2,259 / 4,981 2,820 / 6,225 3,585 / 7,905
Line speed mpm / fpm 24.1 / 79 19.7 / 64.6 16.4 / 53.8
4th
layer
Rope cap m / ft 29.2 / 96 38.9 / 128 40 / 131
Line pull kg / lb 2,007 / 4,425 2,505 / 5,530
Line speed mpm / fpm 27.1 / 90 22.2 / 72.8
5th
layer
Rope cap m / ft 30 / 100 40 / 131
The performance listed is applicable only when using the recommended wire rope.
HV-8000SP … 9.5 mm X 30 m ( 3/8”X 100’) galvanized aircraft
HV-10000SP .. 9.5 mm X 40 m ( 3/8”X 131’) galvanized aircraft
HV-12000P . 12 mm X 40 m ( 1/2”X 131’ ) 6 X W(19) + IWRC
HV-15000P . 14 mm X 27 m ( 9/16”X 89’) 6 X W(19) + IWRC
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
How Winch Are Rated
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 on the first layer of wire rope
on the drum.

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Ⅲ
ⅢⅢ
Ⅲ.Installation
Before using the winch, make sure all
components have no corrosion or defect;
the environment should be clear and dry.
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Mounting
1. It is very important to have the winch and roller fairlead mounted on a flat and hard surface
within 0.5 mm in order to make sure the motor, drum and gearbox housing are aligned
correctly. Failure toialign iticouldidamage winch performance
of winch, wire rope or mounting channel.
2. A minimum of 6.4 mm thick steel mounting channel is absolutely required to prevent to the
possibility of damage to the winch or vehicle.
3. The winch should be mounted as closed to center and as perpendicular as possible to the
direction of the line pull. This will keep the wire rope fleet angle centered on the drum as small
as possible
4. The tie bars supplied with the winch must remain attached when winch is foot mounted.
Unless a roller fairlead is used, one of tie bar can be removed.
5. The Roller fairlead does not mount to winch directly.
6. All the twelve (12) M10 X35, 12.9 grade high tensile steel bolts must be used for HV-8000SP
and HV-10000SP in order to sustain the loads imposed on the winch mounting
7. All the eight (8) M12 X35, 12.9 grade high tensile steel bolts must be used for HV-12000P and
HV-15000P in order to sustain the loads imposed on the winch mounting
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Free-spool Function
The free-spool allows rapid unwinding of the wire rope for hooking onto a load or anchor points
and is operated by a T-handle.
The T-handle must be in the “Engaged” position before winching.
1).To disengage, lift the T-handle up and turn it at 900clockwise rotation to the “Disengaged”
position, wire rope can now be free spooled from the drum.
2).To engage, lifts the T-handle up and turns it at 900counter-clockwise rotation to the “Engaged”
position.
3).If a T-handle can’t be properly locked in the “Engaged” position, rotate the drum to make the
free-spool couple to the gear train.
4).Wear leather gloves and use a hand-saver strap when guiding the wire rope out of the drum.
HV-8000SP/10000SP HV-12000P/15000P

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IV.Maintenance
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Lubrication
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For Gear Box
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 Castrol Alpha Spheerol L-EP 2 grease, 150 Viscosity (cSt) at 40 degree C. 0.3 liter for
HV-8000SP/10000SP and 0.6 liter for HV-12000P/15000P
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
For Brake Assembly
Gear lubrication is an important component in insuring the long life of your winch. The type of
lubricant will have a great influence. The gear oil your winch was shipped with is Castrol Alpha
Series, SP-460, a viscosity ( cSt ) is 457.81/29.83 at 40℃/100℃. 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 of 0.3 liter should be scheduled
every 250 hours of operation or annually.
Wire Rope Replacement
Before installing a new wire rope, wrap the end of the wire rope with tape to prevent fraying. Wind
the wire rope on the drum by pull a force to keep the tension constant. Never use a wire rope of a
different size or material and only use genuine wire ropes.
1). Disengage the free-spool.
2). Spool the old wire rope, and then remove it from the drum.
3). Take horizontal roller and bolts of roller fairlead apart, then 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). Use a hex wrench to tighten the screw downwards to secure the wire rope.
5). Tighten the horizontal roller and bolt of roller fairlead
6). Wear leather gloves and use a strap when guiding the wire rope off the drum.
Note:
Roller fairlead does
not mount to winch

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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
Checking item Checking method Checking reference
Installation
Loosening
and center
run-out of
foundation
Checking of
installing bolts Existence of abnormalities
Breaking of
base wire
Visual Less than 10%
Decreasing
of diameter
Visual,
measuring(one
month)
7%of nominal diameter max
Deforming
or corrosion
Visual To be not remarkable
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Wire rope
Fastening
condition of
end
Visual To be sufficient for hanging
up of load
Free-spool
Wearing of
handle Operating To be free from remarkable wearing and damage
Motor Staining,
damage
decomposition
checking Existence of abnormalities
Wearing of
lining
Decomposition
checking
To be free from remarkable
wearing and damage
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Brake
Performance Visual Reasonable actuation
Gear Damage,
wearing
Decomposition
checking
To be free from remarkable
wearing and damage
Incorrect oil,
flow oil Visual Add, replace or clean oil

Oil
Low oil level Visual Replenish oil

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ⅤⅤ
Ⅴ.Trouble Shooting
When winch fails to respond after several attempts, or if there are any defective
operation check followings:
Symptom Possible Cause Remedy
Overload Reduce load
The hydraulic system 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
The brake is not releasing
This requires disassembly of the
brake assembly. Remove and
replace of the brake assembly
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 T-handle linkage Replace or remove the free-spool
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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VI. Replacement Parts List
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
HV-8000SP/10000SP
No. Description Qty No. Description Qty No. Description Qty
1 Hydraulic motor 1 18 Plain washer 1 35 Oil Seal 1
2 Motor support rack 1 19 Brake free-spool base 1 36 Hex bolt 2
3 Drum Support rack 1 20 Spiral spring 1 37 Hex bolt 6
4 Gear Box 1 21 Cam A 1 38 Hex bolt 6
5 Socket 1 22 Brake ass’y 1 39 Hex bolt 3
6 Drum Bushing 2 23 Free-spool barrel 1 40 Hex bolt 1
7 Tie bar 3 24 Free-spool lever 1 41 Hex bolt 1
8 Connecting shaft 1 25 Pressed spring 1 42 Spring washer 2
9 Connecting socket 1 26 T-handle 1 43 Spring washer 6
10 Drum 1 27 Plain washer 1 44 Spring washer 6
11 1st gear train 1 28 Spring pin 1 45 Spring washer 4
12 1st planetary gear 1 29 Snatch ring 2 46 Nylon screw 1
13 2nd planetary gear 1 30 O ring 1 47 Nut 1
14 Ring 1 31 Bushing 1 48 Double round key 2
15 Brake cover 1 32 Bushing 1 49 Roller fairlead 1
16 Anti-leakage packing 1 33 Bearing 1 50 Cap screw 2
17 Plain washer 2 34 Bearing 1