Comeup DP-10000 User manual

Electric 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

AWinch 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 life, support or otherwise transport personnel.

3. Aminimum 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

I. Safety Precaution

Please read and understand this Instruction Manual before installing your winch.

Don’t use unsuitable rope in construction, strength or having any defects.

Don’t use unsuitable hook and pulley block for rope.

The operator of winch in some cases, is required to have qualifications according to applicable

laws and ordinances.

Do not use 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.

(Fig1)

(Fig2)

II. Performance Data

XSpecification

MODEL DP-10000

Line Pull 4,535 k

/ 10,000 lb

Moto

12V 3,430 w / 4.6 h

24V 2,237 w / 3.0 h

Control Han

-held Remote Switch

Gear Train 4 Sta

e Planetar

Gear Ratio 277:1

Clutch Rotatin

Rin

Gea

Brake Patent Cone Loa

-Holdin

Brake & Auxiliar

netic Brake

Wire Ro

e Recommende

9.5 mm X 40 m / 3/8”X 131’

XLine speed and Amp. Draw (1st layer of wire rope on the drum)

MODEL DP-10000

Voltage 12 V 24 V

Line Pull Line Speed Line Speed

Kg / lb mpm fpm Amp.

Draw mpm fpm Amp.

Draw

No Load 6.2 20.3 60 8.0 26.2 40

907 / 2,000 4.3 14.1 120 6.5 21.3 80

1,814 / 4,000 2.3 7.5 170 5.1 16.7 105

2,722 / 6,000 1.6 5.2 250 3.8 12.5 135

3,629 / 8,000 1.1 3.6 300 3.1 10.5 165

4,535 / 10,000 0.9 3.0 400 2.4 7.0 210

XLine Pull And Rope Capacity

MODEL DP-10000

Layer of Wire Rope Line Pull

kg / lb Total Rope on the Drum

m / ft

1st Layer 4,535 / 10,000 7.5 / 25

2nd Layer 3,772 / 8,315 16.4 / 54

3nd Layer 3,230 / 7,120 26.9 / 88

4th Layer 2,824 / 6,225 38.9 / 128

5th Layer 2,508 / 5,530 40 / 131

XStandard Accessories

Hand-held remote switch w/5m (17’) cord, 4 way roller fairlead, Handsaver bar

XDIMENSION

XHow the winch is rated

Load and speed vary according to how

much wire rope is on the drum. The first

layer of wire 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 wire rope on the drum.

Ⅲ. Installation

Before using the winch, make sure all electrical

Components Have no corrosion or defect; the

environment should be clear and dry.

Voltage drop from the battery connections to the winch

Must not exceed 10% of the nominal voltage under

normal operating condition.

XMounting

1. It is very important to the winch mounted on a flat and hard

surface in order to make sure the motor, drum and gearbox

housing are aligned correctly.

2. It is recommended that you use a mounting channel to prevent to the possibility of

damage to the winch or vehicle.

3. It is also recommended that a roller fairlead be fitted to prevent excessive wear of the

wire rope.

4. Sixteen 16) M10x1.50 pitch 8.8 grade high tensile steel bolts must be used in order to

sustain the load imposed on the winch mounting.

XBattery cable wiring diagram

Battery cable specification:

Model DP-10000

Control Type Detachable solenoid pack

Red cable: 2 AWG x 72”(1.83 m)

Volt 12V or 24V Black cable: 2 AWG x 72”(1.83 m)

1. Attach the black cable (earth) firmly to the chassis of the vehicle or to the negative(-)battery

terminal.

2. Attach the red cable to the circuit breaker, connect the other end to the positive(+) battery

terminal.

3. The circuit breaker can be fitted as optional.

XSwitch Connection

1. A hand-held remote switch with 1/12”x 3c x 10’

(ψ2.0 mm x 3c x 3m) Cord supplied

2. Open the dust-proof cover of the winch, then insert the

switch plug into the socket (fig3).

XDetachable Solenoid Pack Wiring Diagram

(Fig3)

Ⅳ. Operation

XPrecaution

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 is being operated.

The winches duty rating is S 3 (intermittent-periodic)

If the winch fails in pulling a load under normal conditions, stop the operation within 30

seconds otherwise motor damage may occur.

Ensure that winch is connected to the correct voltage.

Check that the clutch lever is in the “Engaged” position during and after use .

Remove the pendant from the winch when not in use.

Do not wrap the wire rope around load and hook to it.

Keep hands and clothes away from the winch, wire rope, and fairlead.

Never unplug the pendant when winching a load.

Before use, ensure that you are familiar with all winch operations (winch speeds & direction).

To avoid insufficient power when winching a load, the vehicle should be running and in

neutral.

Keep the pendant cord clear of the winch cable at all times.

If noise or vibration occurs when running, stop the winch immediately and return it for repair.

XCable-in/ Cable-out Operation

1). To determine “Cable - Out”, depress ↑button (fig.4)

2). To determine “Cable - In” depress ↓button (fig.5)

To stop winching, release the button

(Fig4) (Fig5)

XFree Wheel (Clutch) Function

The clutch allows rapid unspooling of the wire rope for hooking onto a load or anchor points and is

operated by a clutch handle.

The clutch handle must be in the “Engaged” position before winching.

1).To disengage the clutch lift the clutch handle up and turn it at 900clockwise rotation to the

“Disengaged” position, wire rope can now be free spooled on the drum.

2).To engage the clutch lift the clutch handle up and turn it at 900counter-clockwise rotation to the

“Engaged” position.

3).If a clutch handle can’t be properly locked in the “Engaged” position, rotate the drum to make

the clutch couple to the gear train .

4).Wear leather gloves and use a handsaver bar when guiding the wire rope out of the drum

(Engaged) (Disengaged)

XRecovery 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 center 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.

Ⅴ. Maintenance

XCable Replacement

¾Never use a rope of a different size or material and only use genuine

replacement parts.

¾If the winch is subjected to a high duty or excess load, the rope may require

frequent replacement.

1). Disengage the clutch (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). Secure a clevis hook to the wire rope by using a clevis pin and cotter pin.

(Engaged) (Disengaged)

(Fig6) (Fig7)

XBrake 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 c-rings

2). Insert few washers to maintain the brake spacer between to be 2.2 ±0.25 mm

3). Make sure to keep the brake plate counter-clockwise by 150 – 180 degree

XLubrication

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 a marine type grease.

XMaintenance Schedule

¾Ensure that a responsible person carries out all inspections as per schedule.

¾Inspections are dived into Daily, Monthly and 3 Monthly.

Classification of check

Periodical

Daily One

month Three

month

Checking item Checking method Checking reference

cInstallation

Loosening and center

run-out of foundation Checking of installing bolts Existence of abnormalities

cWorking Manual Reasonable actuation

Switch

Wearing of contact point Decomposition checking To be free from noticeable

wear and 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 noticeable

Wire rope

Fastening condition of end Visual To be sufficient for hanging

up of load

cClutch Wearing of spring Decomposition checking To be free from noticeable

wear and damage

cMotor Staining, damage Decomposition checking Existence of abnormalities

cWearing of disc Decomposition checking To be free from noticeable

wear and damage

Brake

Performance Visual Reasonable actuation

cGear Damage, wearing Decomposition checking To be free from noticeable

wear and damage

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