Come.up Winch DV-6000S Manuale utente

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 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 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.

6.Operate the winch cable in and cable out at no load if a winch has had any ingress of

water.

WARNING

Fleet angle

15°

Centre line of anchor point

I. Safety Precautions

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 an unsuitable hook or snatch block for wire rope.

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

applicable laws and ordinances.

Do not use the 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。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.

Do not operate the winch under the water.

(Fig1)

(Fig2)

II. Performance Data





Performance

Model DV-6000S DV-6000L / DV-6000SL

Line pull ( kg / lb) 2,722 / 6,000 2,722 / 6,000

Line speed (mpm / fpm) 2.0 / 6.5 2.0 / 6.5

1st layer

Rope cap ( m / ft) 3.6 / 11.8 6.7 / 22

Line pull ( kg / lb) 2,264 / 4,991 2,264 / 4,991

Line speed (mpm / fpm) 2.4 / 7.8 2.4 / 7.8

2nd layer

Rope cap ( m / ft) 7.8 / 25.6 14.7 / 48.2

Line pull ( kg / lb) 1,938 / 4,273 1,938 / 4,273

Line speed (mpm / fpm) 3.1 / 10.1 3.1 / 10.1

3rd layer

Rope cap ( m / ft) 12.8 / 42 24 / 78.7

Line pull ( kg / lb) 1,694 / 3,735 1,694 / 3,735

Line speed (mpm / fpm) 3.7 / 12.1 3.7 / 12.1

4th layer

Rope cap ( m / ft) 18.5 / 60.7 30 / 100

Line pull ( kg / lb) 1,505 / 3,318

Line speed (mpm / fpm) 4.2 / 13.7

5th layer

Rope cap ( m / ft) 24.4 / 80

Line speed and Amp. Draw Main Components

At the first layer of wire rope on the drum

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 shall 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

in order to sustain the loads imposed on the winch mounting.

4. Two(2) M12x1.75 pitch 8.8 Grade High Tensile Steel Bolts must be used for

fastening the roller fairlead into the mounting channel.

Line Pull Line Speed Amp

Kg lb mpm

fpm 12v 24v

0 0 8.0 26.2 60 35

907 2,000 5.2 17 150 90

1,814 4,000 3.1 10.2 240 140

2,722 6,000 2.0 6.5 300 200





Battery cables connection

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

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

to the positive (+) battery terminal.

3. The circuit breaker must be fitted.





Switch Connection

1. A remote switch withψ1.25 mm X 3C X 5 m(16AWG X 3C X 17ft) cord supplied.

2. Open the dust-proof cover of the winch, then insert the switch plug into the socket.

Ⅳ

ⅣⅣ

Ⅳ. 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 be occurred.

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

Check that the freespool knob 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 itself. 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 roller fairlead.

Never unplug the remote control 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 remote control 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 (fig.4)

2). To determine “Cable - In”, trigger ←in (fig.5)

To stop winching, release the trigger

(Fig4) (Fig5)





Freespool Function

The freespool allows rapid pay-out of the wire rope for hooking onto a load or anchor points and is

operated by a freespool knob.

The freespool knob must be in the “Engaged” position before winching.

1). To disengage the freespool lift the freespool knob up and turn it at 90。clockwise rotation to

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

2). To engage the freespool lift the freespool knob up and turn it at 90。counter-clockwise rotation

to the “Engaged” position.

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

the freespool device coupled to the gear train.

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

(Engaged) (Disengaged)

Cable-Out Cable-In

Ⅴ

ⅤⅤ

Ⅴ. Maintenance

Wire Rope Replacement

Never use a wire 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 freespool. (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).

(Engaged) (Disengaged)

(Fig 6) (Fig 7)





Brake adjustment

Over time, the load-holding brake in your winch will wear. Should you find the load

beginning to slip, adjustments can be made to the brake mechanism as follows:

1). Loosen the 3 retaining bolts and remove the brake cover.

2). Remove the two retaining rings.

3). lnsert washers to maintain a spacing of 2.54 +/- 0.25mm ( .1〃+/- .01〃 )

between the ring grooves and the brake actuating cam.

4). Re-install the two rings and brake cover.





Lubrication

All moving parts in the winch are permanently lubricated at the time of assembly. Under

normal conditions factory lubrication will suffice. If re-lubrication of gear box is

necessary after repair or disassembly use Shell EP2 or equivalent grease with 0.15 litre.

Freespool knob lubricates regularly with light oil. It is not allowed to have brake ass’y

lubricated.





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

Item Checking method Checking reference

Installation

Mounting bolts & alignment.

Bolt tension & wear. Existence of abnormalities

Working Manual Reasonable actuation



Remote

control

Wearing in contact points Visual. Free of wear or damage.

Broken strands Visual, measuring Less than 10%

Decrease in rope diameter

Visual, measuring 7% of nominal diameter

max

Deforming or corrosion Visual Existence of abnormalities



Wire rope

Fastening condition of end

Visual Existence of abnormalities

Freespool Wear in spring Visual evidence of wear Free of wear or damage.

Motor Staining, damage Visual evidence of wear Existence of abnormalities

Wearing of brake disc Visual evidence of wear Free of wear or damage.



Brake

Performance Visual Reasonable actuation

Gear Train

Damage, wearing Visual evidence of wear Free of wear or damage.

Ⅶ

ⅦⅦ

Ⅶ. Trouble Shooting

When the winch fails to operate after several attempts, or if there is any fault while

Symptom Possible Cause Remedy

Cut circuit Check battery lead.

Weak battery Recharge or replace battery (at least 650CCA)

Damaged over-load protector(option) Replace over-load protector(option)

Bad connection of wirings Reconnect tightly

Damaged solenoid Replace solenoid

Cut circuit on switch Replace switch

Damaged motor or worn carbon brush. Replace motor or carbon brush

Winch will not

operate

Dropt or lost motor wirings. Replace wirings or tight it.

Broken wirings or bad connections Reconnect or replace wirings

Damaged or stuck solenoid Replace solenoid

Switch inoperative Replace switch

Motor runs in one

direction.

Dropt or lost wirings. Replace wirings and tighten.

Freespool not disengaged Engaged freespool

Damaged 1st shaft Replace 1st shaft

Damaged brake cam and disc Replace brake cam and disc

Drum will not

freely spool.

Damaged output shaft Replace output shaft

Damaged brake cam and disc Replace brake cam and disc

Damaged gear box Replace gear box

Dropt retaining ring Replace retaining ring

Oil leakage at brake Clean oil leakage

No brake

Damaged or inoperative spiral spring Replace and position spiral spring

Worn or damaged brake Replace or adjust brakeBrake distance is

too long Oil leakage at brake. Clean oil leakage

Too much brake powder Clean brake ass’y

Over pre-pressed spiral spring Adjust pre-pressed spiral spring

Brake will be

locked

Stuck between brake lining and gear box

Replace a new winch

Hit by certain exterior force. Replace the damaged components

Damaged gear train. Replace the damaged components

Damaged gear box

Over load operation. Replace a new winch

Long period of operation Allow to cool

Damaged motor Replace or repair motor

Motor runs

extremely hot

Damaged or inoperative brake Replace or repair brake

Ⅶ

ⅦⅦ

Ⅶ. Replacement parts List

DV-6000S、

、、

、DV-6000L

No.

Description Q’ty

No.

Description Q’ty

No.

Description Q’ty

Motor 1

Freespool lever 1

Mounting hardware 1

Motor support rack 1

Gasket 2

Spring pin 1

Gearbox support rack

Tie bar 2

Bearing 1

Drum bushing 1

Gear box 1

Bearing 1

Drum 1

Brake cover 1

Retaining ring 1

Drum bushing A 1

Remote control 1

Retaining ring 2

Cable tensioner 1

Solenoid pack 1

Retaining ring 1

Hex bolt 2

-1

Upper solenoid box 1

Hex nut 1

Motor coupling 1

-2

Remote switch socket 1

Hex nut 2

1st shaft 1

-3

Socket gland 1

Hex bolt 1

1st pinion 1

-4

Cross screw 2

Hex bolt 4

1st stage carrier 1

-5

Nut 2

Hex bolt 2

2nd stage carrier 1

-6

Solenoid ass'y 1

Hex bolt 1

1st & 2nd ring gear 1

-7

Cross screw 4

Hex bolt 9

3rd ring gear 1

-8

Lower solenoid plate 1

Hex bolt 3

Brake cam B 1

-9

Hex bolt 3

Spring washer 1

Cone brake disc 1

-10

Socket packing 1

Spring washer 4

Brake cam A 1

-11

Battery lead 1

Spring washer 2

Brake freespool base 1

Handsaver strap 1

Spring washer 3

Spiral spring 1

Handle 1

Foot print 1

Freespool knob 1

Handle plate 1

Roller fairlead 1

Freespool sleeve 1

Wire rope w/hook 1

Pressed spring 1

Snatch block 1

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