Comeup DS-9.5 User manual

Self-Recovery 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.

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 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 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. 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

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 whatever the vehicle is stuck in.

WARNING

F l e e t a n g l e

C e n t r e l i n e o f a n c h o r p o i n t

I. Safety Precautions

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 .

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.

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.

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 first layer of rope on the drum.

CAUTION

II. Performance Data





Specifications

Model DS-9.5 DS-9.5i

Line Pull (first layer) 4,309 kg / 9,500 lb

Line Speed (first layer, no load) 19 mpm / 62.3 fpm

12V 380 A

Amp. Draw

24V 250 A

Type Series wound

12V 3,728 w / 5 hp

Motor Output

24V 2,240 w / 3 hp

Type 3 stage planetary

Gear Train

Ratio 159 : 1

Free-spool Rotating ring gear clutch

Brake Automatic full load cone brake

Control Detachable solenoid pack Integrated solenoid pack

Type A7 x 19 aircraft galvanized

Length 30 m / 100 ft

Wire Rope

Size 8 mm / 5 / 16 in





Performance

Model DS-9.5 DS-9.5i

Line pull (kg / lb) 4,309 / 9,500

Line speed (mpm / fpm)

2.12 / 7

1st layer

Rope cap (m / ft) 6.1 / 20

Line pull (kg / lb) 3,521 / 7,750

Line speed (mpm / fpm)

2.6 / 8.5

2nd layer

Rope cap (m / ft) 13.5 / 44.3

Line pull (kg / lb) 2,977 / 6,550

Line speed (mpm / fpm)

3.07 / 10.1

3rd layer

Rope cap (m / ft) 22.3 / 73.2

Line pull (kg / lb) 2,578 / 5,700

Line speed (mpm / fpm)

3.55 / 11.7

4th layer

Rope cap (m / ft) 32.4 / 106.3





Line speed and Amp. Draw

At the first layer of wire rope on the drum.

Model DS-9.5 / DS-9.5i

Line Pull Line Speed Amp.

Kg lb mpm fpm 12V 24V

0 0 19 62 60 35

909 2,004

4.7 15.4 115 70

1,818

4,008

3.5 11.5 210 110

2,727

6,012

2.8 9.2 245 145

3,636

8,016

2.3 7.6 280 190

4,309

9,500

2.1 6.8 380 250





Main Components

D S - 9 . 5

D S - 9 . 5 i

BATTERY

BLACK(-)

R E D ( + )

CIRCUIT BREAKER (OPTION )

254

mm(10")

mm (7/16") in

dimension

114.3 mm

(4 1/2")

BATTERY

F 1

F 2

B L A C K

R E D

B L A C K ( - )

R E D ( + )

C I R C U I T B R E A K E R ( O P T I O N )

S O L E N O I D S R E M O T E

S W I T C H S O C K E T

WINCH

Ⅲ

ⅢⅢ

Ⅲ. Installation

Before using the winch, 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 winch

must not exceed 10% of the nominal voltage under normal operating condition.





Mounting

1. It is very important that the winch be

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 from

damaging winch or vehicle.

3. Four (4) M10 x 1.50 pitch 8.8 Grade High Tensile Steel Bolts must

be used for f

astening the winch into mounting channel in

order to sustain the loads imposed on the winch mounting.

4. Two (2) M12 x 1.75 pitch 8.8 Grade High Tensile Steel

Bolts must be used for fastening the roller fairlead into

the mounting channel.





Battery Lead Connection

Battery lead specification:

Model

9.5

9.5i

Control Type Detachable solenoid pack Integrated solenoid pack

Red cable: 2 AWG x 1.83 m / 72〞Red cable: 2 AWG x 1.83 m / 72〞

Voltage

12V or

24V Black cable: 2 AWG x 1.83 m / 72〞Black cable: 2 AWG x 1.83 m / 72〞

1. Attach the black lead (grounding) firmly to the negative (–) battery terminal.

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

terminal.

3. The circuit breaker shall be recommended to be fitted.

DS-9.5 DS-9.5i





Switch Connection

1. A trigger switch withψ0.75 mm X 6 C X

5 m (18 AWG X 6 C X 17′) cord supplied

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

insert the switch plug into the socket .

Foot print

OUT

LED LIGHT

GREEN OUT

LED LIGHT

RED

F1 F2

(+)

BATTERY

REMOTE

CONTROL

SWITCH

RED

WHITE

BLACK

GREEN

YELLOW

BLUE GREEN

YELLOW

LED

THERMAL

CONTROL

SOLENOID

PACK

12V-1K

24V-2K

Ⅳ

ⅣⅣ

Ⅳ. Motor Temperature Indicator





Protective thermal sensor LED

Green LED signal on the trigger switch and aluminium casting ( for DS-9.5i only ) shows the winch

is operated under normal working condition.

Red LED signal shows on the trigger switch and aluminium casting ( for DS-9.5i only ) shows the

winch is operated under abnormal working condition

If a winch which is operated with red LED signal for a long period will certainly result in damaged

the winch. In this circumstance, you must power off the winch without delay.

DS-9.5

OUT

LED LIGHT

GREEN OUT

LED LIGHT

RED

(

((

(

Normal winching

Normal winchingNormal winching

Normal winching)

))

)

(

((

(Abnormal winching

Abnormal winchingAbnormal winching

Abnormal winching)

))

)

DS-9.5i

( Normal winching)

( Normal winching)( Normal winching)

( Normal winching) (Abnormal winching)

(Abnormal winching) (Abnormal winching)

(Abnormal winching)





Battery Recommendations

A fully charged battery and good connections are essential to the proper operation of your winch. The

minimum requirement for a 12 volt DC battery is 650 cold cranking amp.





Electrical Circuit Diagram

Ⅴ

ⅤⅤ

Ⅴ. Operation





Precautions

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 it is being operated.

The winches duty rating is S3 (intermittent – periodic)

If the winch fails to pull a load under normal conditions, stop the operation within 30 seconds

otherwise motor damage may occur.

Ensure that the winch is connected to the correct voltage. 12VDC or 24VDC only

Check that the free-spool T-handle is in the “Engaged” position during and after use.

Remove the switch from the winch when not in use.

Do not wrap the wire rope around the load and back onto it self. Always use a strap to ensure that

the wire rope does not fray or kink.

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 winching operations (winch speeds & direction).

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

Keep the switch cord clear of the wire rope at all times.

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





Cable-in/ Cable-out Operation

1). To determine “Cable - Out”, trigger →out

2). To determine “Cable - In”, trigger ←in

To stop winching, release the trigger

able-Out able-In





Free-spool Function

The free-spool allows rapid payout of the wire rope for hooking onto a load or anchor points and is

operated by the free-spool T-handle.

The free-spool T-handle must be in the “Engaged” position before winching.

1). To disengage the free-spool lift the free-spool T-handle up and turn it at 900clockwise rotation to

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

2). To engage the free-spool lift the free-spool T-handle up and turn it at 900counter-clockwise

rotation to the “Engaged” position.

3). If a free-spool T-handle can’t be properly locked in the “Engaged” position, rotate the drum to

make the free-spool coupled to the gear train.

4). Wear leather gloves and use a strap when guiding the wire rope off the drum.

(Engaged) (Disengaged)





Recovery 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 centre 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.

Ⅵ

ⅥⅥ

Ⅵ. Maintenance





Cable Replacement

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

replacement parts.

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

replacement.

1). Disengage the free-spool

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.

4). Tighten the screw downwards to secure the wire rope .

(Engaged) (Disengaged)





Brake 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 clutch base plate counter-clockwise by 150 – 180 degree

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