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Compact 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 the winch.
Follow these general safety precautions:
˙ Confirm that the winch complies with the using conditions.
˙ Keep the winch secure strongly and the rope is not wound to be deviated to the drum.
˙ Don't use unsuitable pulleys or accessories concerned.
˙ Don't use unsuitable rope in construction , strength or having any defects.
˙ Pay attention to the grounding , it provides a path of least resistance for electric current to reduce the risk of shock.
˙ Check the winch for smooth operation without load before loading operation.
˙ Make sure the wire rope to be wound evenly in the first layer on the drum, rewind it if a mixed windings in existence.
WARNING
1.The winch is not to be used to life, support or otherwise transport personnel.
2.A minimum of five(5) wraps of rope around the drum is necessary to support the load rated.
3.Come-Up takes no responsibility for the subsequent performance of mechanical components if oil possessing properties other than what Come-Up recommends is used
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I.SPECIFICATION
MODEL
Lifting capacity kg
Wire rope top layer
Lifting speed m/min first layer top layer
Motor k w×A
110V
220V~240V
Lifting height m
Wire rope ψ mm x M
STANDARD
ACCESSORIES
Power cord
Switch cord
Swivel hook
CWS-80
80
CWS-160
160
CWS-230
230
30
18
0.
8 × 8
0.
8 × 4
1.
1.
2
22
15
× 12
2 × 6
1.
1.
14
9
3 × 13
3 × 6.5
23
4 x 24
CHW-0032 x 1
30
4.8 x 31
2.0 mm
2
x 3c x 5M
1.25 mm
2
x 6c x 10M
CHW-0033 x 1
24
5 x 25
WARNING
1.The owner and/or the operator shall have an understanding of these operating instructions and the
following warning before operating the electrical winch. Failure to follow these warnings may
result in loss of load, damage to the winch, property damage, personal, or fatal injury.
2.Warning information shall be emphasized and understood. If the user is not fluent in English,
Instructions and warnings shall be read to and discussed with the user in the user’s native language
by the owner to make sure that the user comprehends the contents.
3.The owner shall retain this manual for further reference to important warnings, installation,
operating and maintenance instructions.
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II. INSTALLMENT PRECAUTION
2.1 ENVIRONMENT PRECAUTION
WARNING
● The following environmental conditions may result in the possible causes of winch trouble.
● Low temperature below -10 o
C, ● In a organic chemistry or
high temperature above 40 o
C or explosive power conditions.
humidity above 90% conditions.
● In heavy acid or salty conditions ※ Cause explosion.
※ Cause malfunction of spare
part.
● In the rain or snow ● In a heavy general powder
conditions.
※ Cause rust or short circuit.
※ Cause malfunction of
performances.
2.2 CONTINUOUS RATING
WARNING
● Never hoist over the rated percentage duty cycle.
The life of the winch is depending on the conditions of the load and working frequency.
In the long time operation, make sure to use the machine within its continuous ratings.
Continuous ratings means the working duty cycle (%ED) is subject to the rated voltage, rated frequency and a 63% of rated load.
Tb
Percentage duty cycle (%ED) ＝ ------------------ X 100 (%)
Tb + Ts
Tb: total sum of overall loadings operating hours.
Ts: total sum of stopping hours.
Tb+Ts=approximately 1 to 10 min
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2.3 MOUNTING
The winch designed to be hanged or mounted on a firm or stable bar or a bracket CRH-0710 (as an option).
When hanging, do not allow the body or load to be caught by any construction of frame, or other obstruction.
Be sure to lock the hanger for extra safety.
2.4 PLUG INSERTION
2.4.1 Power core insertion
Insert the power plug into the power receptacle of
the winch, and tighten it by turning the locking ring,
clockwise.
Be sure to lock the cord by a holder. Do not allow
the cords to be caught by wire rope and drum.
The length of power cord is subject to the
distance of 20 meter, for any other case, please
use a power cord by 3.5 mm
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to prevent a
considerable voltage drop to be happened.
The selection of power cord section
Section
2.0 mm
2
3.5 mm
2
Maximum Length
20 m
35 m
2.4.2 Grounding
To prevent the risk of electric shock, the power plug must be
plugged into a matching outlet and grounded in good condition.
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2.4.3 Switch cord connection
1)Insert the switch plug into the switch receptacle of the
winch and tighten it by turning the locking ring clockwise.
Be sure to hook the cord by a holder.
2)To extend the length of to switch cord EXC-0010 as an option, please adopt a switch extention cord.
III. WORKING METHODS
3.1 PREPARATION BEFORE WORKING
● Be sure to carefully check all safety and environmental conditions.
● A minimum of five (5) wraps of wire rope wound around the drum is necessary.
A wire rope should be discarded and not be used again if rope shows sign
of excessive wear, too many broken wires, corrosion or other defects.
● Make sure to connect the main power source and grounding.
● It’s not safe to lift loads exceeding the rated load.
● Connect power source at rated voltage.
(It will cause maladjusted working if input voltage
falls out of rated voltage by +/- 10%)
3.2 UP AND DOWN SWITCHING
To lift a load, press ↑ button and drum will rotate as shown below operation.
To lower a load, press ↓ button and drum will rotate as shown below.
When the button is released , the drum will strop moving.
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IV. HANDLING PRECAUTION
4.1 ENVIORNMENT PRECAUTION
WARNING
● Pay best attention to the following instruction . Obvious mistakes in operation may result in personal inquiry or equipment damage.
● Never try to lift a load ● Never hitch a ride on the
more than the rated cap. hook, sling or load being
moving.
※ Winches are not to be
used for lifting or
lowering people.
● Don’t work, walk or stand ● Always remain in
under an operating winch.. control. Never neglect
the winch while
actually hosting a
● While working , never stand load.
Under a lifting load or
Within the conveying area.
● Always look up when
working around winch,
there is potential ● Never gravitate a load
danger overhead. freely.
※ Be sure to lift a load
vertically. Slack may
allow wires to be caught
in the drum.
● A minimum of five (5) wraps ● Prior to starting of use,
of rope around the drum is carry out the daily checking
necessary to support the without fail, and after
load rated. confirming the safety of
function.
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● If having a counter rotation incurred, make sure to correct its rotation direction.
● Prior to lifting. Make sure to have a precise performance of brake. If any malfunction
of brake happened, stop the operation immediately.
● When load suspended ● Wire rope with one
in air, it will not or more of the following
allow to be welding. defects shall be removed
Never weld a load or replaced immediately.
while actually lifting 1)kink.
a load. 2)distortion.
3)corrosion.
4)showing sings of excessive
wear or of having broken
wires not less than 10 pcs.
● Stop the operation if there is any queer noise or vibration in the gear box to be happened.
● Do not connect the wire rope with the grounding of welding machine.
● While welding, do not have any contact with the welding objects because of having spark.
● Do not pull the switch ● Never plugging (instant
cord to move a load. reverse-wind) and inching.
● Do not over continuous
ratings.
● In order to prevent the layer down due to over loosening of rope,
irregular winding, etc., operate according to the suitable operating method.
● Use a winch by fixing so securely that the rope around the drum is
uneven.
● Be sure to fix a rope in the center of swivel hook.
● Be sure to stop operation immediately when the
wire rope become fully slackened.
● Avoid catching the hook or lifting a load on a fixed obstruction.
● Always leave the push button switch positioned
immediately after use.
● Make sure that the load being lifting are well
balanced and secured before starting.
● Avoid water splashes on
the push button switch.
● Never wrap the load with the wire rope.
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V. MAINTENANCE AND REPLACEMENT
5.1 WIRE ROPE REPLACEMENT
5.1.1 Swivel hook
● Put a new wire rope through the hole of the round plate of swivel hook.
● Insert a sleeve pin through the thimble of wire rope.
● Insert a pin through the sleeve pin and bent it by a pliers.
5.1.2 Drum
● Let a new wire rope w/clamp through the limit lever and insert it into the
hole of the drum.
● Put a P.T. screw into the hole of the drum and tighten it by a hexagon wrenth.
● Press the ↑ button to rotate the drum in the lifting direction.
● A uneven winding of wire rope may cause the load to be swing, thus
damaging the rope and reducing its life.
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5.2 OIL LUBRICATION
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-220, a viscosity ( cSt ) is 226.14/19.5 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 100 cc for CWS-80 and
250 cc for CWS-160/230 should be scheduled every 250 hours of operation or annually.
5.3 CARBON BRUSH REPLACEMENT
WARNING
● Clean the accumulated powder of carbon brush periodically to ascertain the insulation resistance up to 1 MΩ.
● It is essential to check the carbon brush periodically.
If its length is left less than 7.5 mm resulting from
wearing, it is absolute necessary to replace carbon
brush immediately.
● While replacing, smoothly insert carbon brush into
carbon holder in the first place, then put brush cap
into the hole.
● Before tightening the carbon brush holder, make sure to
position O-ring.
● A set of carbon brush consists 2 piece of carbon brush.
Ascertain to replace 2 pcs of carbon brush on opposite
sides of winch body at the same time.
5.4 BRAKING
● Braking device are composed of a mechanic brake and a electronic generated
brake. The brake distance from the time of braking until stopping completely
should be within 1.5% of rope length to the wound in during 1 minute.
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● Owing to the rope speed on no load is faster than that on rated load,
the brake distance on no load will be longer, but still within 1.5% of
rope length.
● The rope speed on no load is 1.5-1.8 times of rated speed on rated load.
5.5 OVER-WINDING LIFT PREVENTION DEVICE
● A special mechanism prevents a over-winding when lifting.
● When the swivel hook touches the limit lever. Lifting is automatically stopped.
● However, if the limit lever is set too close to the
winch body, it will cause serious damage to the
limit lever and the winch body.
● A suggested distance (5) between the limit lever
and winch body is as follows.
MODEL CWS-80 CWS-160 CWS-230
DISTANCE 80-100 0 mm 70-90 0 mm 70-90 0 mm
5.6 REVERSE-WINDING PREVENTION DEVICE
● A special mechanism prevents a over reverse-winding when lowering.
● When lowering, a wire rope is fully extended, the wire rope will be shifted
its position from O to
×
.
● When a wire rope touches the limit lever of over-winding prevention device.
Lowing will be automatically stopped.
● When the wire rope is shifted to the position of
×
, pull it and press the ↑button
to return its position to O.
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VI. CHECKING AND TROUBLE SHOOTING
6.1 CHECKING REFERENCE.
CLASSIFICATION OF CHECKS
CHECKING ITEMS
CHECKING
METHODS
1 ● BRAKE
Performance
Wearing of lining, and pressed plate
Brake or escaping of spring
Visual
Decomposition check
Decomposition check
2 ● CARBON BRUSH Wearing Decomposition check
PERIODICAL
DAILY
▲
3 MONTH/
20 HOURS
1
YEAR
3
YEAR
▲
▲
▲
3
4
5
6
7
●
●
●
●
MOTOR
CONTROL ASS’Y
SAFETY DEVICE
WIRE ROPE
● SWIVEL HOOK &
HANGER
Condition of insulation
Staining , damage
Carbon powder accumulation
Working
Outer damage of switch cords
Attaching condition of earth line
Condition of insulation
Over-prevention function
Reverse winding prevention function
Distortion of over winding lever
Wrong rotary direction-winding
Kink phenomena
Broken wires
Decreasing of diameter more than 10%
Deforming or corrosion
Distortion
Damage
Loosening
Measuring,5 0MΩmin
Visual
Decomposition check
Manual
Visual
Visual
Measuring,5 0MΩmin
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
Visual
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●
●
DRUM
GEAR CASE
Rupture of flange
Wearing
Damage , waring
Condition of oil feeding
Lubrication for couplings
Visual
Visual
Visual
Measuring
Measuring
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11 ● MARKING Label and the like Manual
Remar k：1.The specified person performs the checking of winch.
2. Divide the checking into daily checking and periodic checking.
3. The checking items and checking method in daily and periodic checking
are to be carried out and different according to the using frequency.
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6-2. TROUBLE SHOOTINGS
Checking the winch for smooth operation by pressing up and down button
of push button switch.
When winch fails to start after several attempts, or if any defective operation
to be happened, check followings.
OBSERVED
ANOMALY
POSSIBLE CAUSE SOLUTION
Check power source
No reaction after pressing the buttons of switch
No power
Disconnection of plug, power cord or switch cord
Burnt or communicated motor resulting from over load.
Replace or repair
Replace
Burnt diode ass’y.
Replace
Clean motor
Considerable voltage drop.
Wearing of carbon brush.
Wearing of lining, pressed plate and pawl
Adjust to rated voltage
Replace carbon brush
Replace
Brake distance too long Repair nut and cord
No over-winding
prevention while swivel hook touches limit lever
Disconnection of electronic generated feed-back braking
Too high voltage
Disconnection of electronic generated feed-back braking
Malfunction of limit switch
Replace D type resistor
Repair of nut and cord
Replace D type resistor
Replace
Lifting speed too slow
Electricity leakage or shock
Overload
Considerable voltage drop
Burnt motor resulting from overload
Wearing of carbon brush
Reduce load
Adjust to rated voltage
Check the section of power cord
Replace motor
Replace carbon brush and Clean carbon powder left in the motor
Abnormal sound in gear box
Water invaded in motor or push button switch
Insufficient oil resulting from oil leakage
Distortion of gear box
Dry it
Replace motor if too heavy water invaded
Replace oil seal
Fill with sufficient oil
Repair
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VII. WIRING DIAGRAM
7.1. FOR 100V~120V
7.2. FOR 200~240V
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VIII. Replacement Parts List
CWS-80
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CWS-160/230
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Limited Warranty
This Limited Warranty is given by the COMEUP INDUSTRIES INC (the
“Seller”) to the original purchaser (the “Purchaser”) of a
Winch
specified in this manual. This Limited Warranty is not transferable to any other party.
The Seller takes the responsibility for all parts and components, with the exception of the wire rope, to be free from defects in materials and workmanship appearing under normal use for as long as the said
Purchaser owns the vehicle that the winch was originally mounted on.
Electrical components are warranted for 1 Year from date of purchase under the same conditions. Any Winch, which is defective, will be repaired or replaced without charge to the Purchaser.
Upon discovering any defect, the Purchaser under this Limited Warranty is requested to return the complete winch and inform the seller or their authorised distributors of any claims. The Purchaser must provide a copy of the proof of purchase bearing the winch serial number, date of purchase, owners name and address, vehicle details and registration number.
The Limited Warranty does not cover any failure that results from improper installation, operation or the Purchaser’s modification in design.
The winch is designed for vehicle self-recovery use only and should not be used in industrial applications or for moving people. The Seller does not warrant them to be suitable for such use.
