Industrial 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. 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 winch.
I . Safety Requirement General Rules ！ In some cases, the operator of a winch may be required to have qualifications according to applicable laws and ordinances. ！ Check safety and environmental conditions prior to and during use. ！ Only use correctly rated wire rope in construction, strength. Inspect for damage and/or defects before use. ！ Don’t use an unsuitable hook and snatch block for rope. ！ The operator must remain with the winch during operation.
I I . Hydraulic System Installation (Powered by PTO / power take off unit driven pump) For HV winch Advantage: Professional winch system for “Working” applications, cost effective, extremely powerful, reliable, light weight and variable line speed for high work rate.
Hydraulic Fluid ● The 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. Hydraulic Pump ● ● To maintain the maximum performance, the hydraulic pump must supply the maximum flow of hydraulic fluid at the hydraulic pressure stated in specification. With a max.
III . Electric System Installation Attach the black lead firmly to the negative (–) battery terminal and red lead to the positive (+) battery terminal. The voltage drop for the winch motor must not exceed 10% of the nominal voltage of 12/24V DC. The recommended battery shall be 650 CCA minimum and battery lead shall be 2 AWG ( America Wire Gauge for 38 mm2 in area ) at least, otherwise a considerable voltage drop will be happened.
IV . Winching Principles Calculating Fleet Angle 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. Load Rating Load and speed varies according to how much wire rope is on the drum.
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 3°.
V . Standards Compliance Comeup 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. The latest Machinery Safety regulations of 2004/108/EC for EMC Directive. 4. SAE International Surface Vehicle Standard J706 Extracts from the Directive & Comeup compliance: 1. EN 14492-1 Section 5.15.
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 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.
● For HV Winch (Engaged) (Disengaged) Air Clutch Function The air clutch must be in the “Engaged” position before winching. 1). Apply air pressure to the PF-1/8”-28 fitting for HV winch or PF-1/4’-19 fitting for Bison winch with 120 psi (8.3 bar). 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.
Lubrication ● ● ● 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 shall be filled 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 initial lubricant should be changed after the first 10 hours of operation.
● For Yak Winch ● For HV Winch 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. VIII . Electric Operation ( For Rhino Winch and Wolf Winch ) Control with Thermal Sensor – Warning LEDs (for Rhino Winch Only) The warning LEDs are shown on the remote control.
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 for Rhino Winch and turn it at 90° counter-clockwise rotation to the “Disengaged” position, wire rope can now clutch off the drum. 2).
Brake Adjustment ● For Rhino Winch with Cone Brake System 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 bolts and remove the brake cover, take of retaining rings. 2). Insert a few washers to maintain the brake spacer between to be 2.2 ± 0.25 mm. 3).
IX . Maintenance Schedule ● Ensure that a responsible person carries out all inspections as per schedule. ● Inspections are divided into Daily, Monthly and Quarterly.
X . Trouble Shooting For Hydraulic Winch (Yak Winch, HV Winch and Bison 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.
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 Confirm pump is running to a higher setting to winch Winch is Overload Reduce load to within rated capacity The pressure is not adequate to Winch will power the load, or the back not pull load pressure is too high Winch is mechanically binding up The brak
For Electric Winch (Rhino Winch and Wolf Winch) Symptom Remedy Check battery lead Recharge or replace battery (at least Weak battery 650CCA) Damaged over-load protector(option) Replace over-load protector(option) Reconnect tightly Winch will not Bad connection of wiring operate Damaged contactor Replace contactor Cut circuit on switch Replace switch Damaged motor or worn carbon Replace motor or carbon brush brush Poor or lost connections to motor Replace wiring or tighten it Broken wiring or bad connection
COMEUP INDUSTRIES INC. No.112, Nanyang St., Xizhi Dist., New Taipei City, Taiwan 22152 Tel: +886-2-2694-7011 / Fax: +886-2-2694-7053 Email: info@comeup.com.tw http://www.comeupwinch.
