Comeup 883423 Wireless Remote Control User Manual

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Document ID	3965619
Application ID	o25hL06msuVFQG6dIrA2RQ==
Document Description	User Manual
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Document Type	User Manual
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Date Submitted	2018-08-16 00:00:00
Date Available	2018-08-17 00:00:00
Creation Date	2018-08-15 10:20:54
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Document Author:	alexlin

Utility Duty Winch
Limited Lifetime Warranty for Mechanical Components
Limited One (1) Year Warranty for Electrical Components
WARRANTY
Comeup Industries Inc. (COMEUP) warrants to the original purchaser that the mechanical
components of the COMEUP Utility Duty Winch will be free of defects in material and workmanship for
the lifetime of the winch and the electrical components will be free of defects in material and
workmanship for a period of one (1) year from the original date of purchase. All COMEUP mounting
kits and other accessories carry a one (1) year limited warranty against defects in material
workmanship.
This warranty applies only to the original purchaser of the winch. To obtain any warranty service,
the purchaser under this Limited Warranty is requested to advise COMEUP or its authorized
distributors on any claim. The purchaser must provide a copy of the purchase receipt bearing the
winch serial number, date of purchase, owners name, email or Tel & Fax, address and purchaser
vehicle details. Any products that COMEUP determines to be accountable for defective will be
repaired or replaced or refund at COMEUP sole discretion without charge to buyer upon buyer’s
compliance with these procedures. In the event of repair or replace, purchaser must send the
defective winch or part, with freight prepaid, to COMEUP or its authorized distributor. And COMEUP
will send the serviced product back to purchaser on COMEUP’s cost. This warranty does not cover the
removal or reinstallation of the winch.
COMEUP takes the responsibility for COMEUP winch parts and components to be free from
defects in materials and workmanship, but the following portions are hereby excluded and disclaimed.
COMEUP or its authorized distributors may make reasonable charges for parts and labour for repairs
or resumption in the following portions not covered by this limited warranty.
(1). All warranties of wire rope and synthetic rope assemblies after initial use
(2). All warranties of fitness for a particular purpose
(3). All warranties of the product’s finish
(4). All warranties of merchantability
The limited warranty does not cover any failure that results from improper installation/operation,
third party part substitution, purchaser’s alteration or modification on COMEUP winch. This warranty is
void when COMEUP serial number plate is removed or defaced.
COMEUP’s liability to the purchaser under the winch purchases for any loss or damage howsoever
and whatsoever arising shall not exceed the price of the initial winch purchase receipt. COMEUP shall
not in any event be liable to the purchaser for any consequential and/or indirect loss or damage
whether for loss or for profit or otherwise, costs, expenses or other claims for consequential
compensation whatsoever and whether caused by negligence of COMEUP employees, distributors
and their employees or otherwise. COMEUP reserves the right to change product design without
notice. In situations in which COMEUP has changed a product design, COMEUP shall have no
obligation to upgrade or otherwise modify previously manufactured products.
I. Safety Precaution
Utility Duty Winch
The winch is designed to give safe and dependable service of trouble-free operation. Please read
and understand this Instruction Manual before installing your winch.
fPrecautions before using of winch are listing as follows:
Confirm that the winch complies with the using conditions.
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 the winch. Careless winch operation can result in serious injury or property
damage.
When requesting information or ordering replacement parts, always give the following
information:
1. Winch model and voltage
2. Serial Number
3. Item. No. and Part Number
4. Part Description
Because the maximum rope tensile force capable of loading decreases corresponding to the
increase of number of winding layers, please carry out rope winding according to the
instruction of this manual.
Don’t use rope that is unsuitable because of its construction, strength or having any defects.
Don’t use a hook or pulley block that is suited to the rope.
fPrecautions at the time of operation of winch are listing as follows:
The operator of winch in some cases is required to hold qualifications according to applicable
laws and ordinances.
Prior to starting of use, carry out the daily checking without fail.
During use five(5) wraps of wire rope and ten (10) synthetic rope must remain on the drum at
all times. Even in the condition where the rope is feed out at most,
Do not use winch as a lifting device or a hoist for vertical lift (fig1).
Do not use winch to move people.
Do not exceed maximum line pull ratings shown. Do not shock load.
Keep hands clear of wire/synthetic rope.
WARNING
Pull from an angle below 15 degree to straighten up the vehicle or boat (fig 2).
Run the engine during winching operations to keep battery charged.
1. The winch is a very powerful machine. Treat with extreme care and observe all
caution and warnings.
2. The winch is rated at the first layer of wire/synthetic rope on the drum for
intermittent-periodic duty.
3. The winch is not to be used to lift, support or otherwise transport personnel.
4. A minimum of five (5) wraps of steel wire rope and of ten (10) wraps of synthetic rope
around the drum is necessary to support the rated load.
5. Keep clear of winch, rope, hook, and fairlead while operating.
6. Wire/synthetic rope can break without warning. Always keep a safe distance from the
winch and rope while under a load
7. Failure to adequately align, support, or attach the winch to a suitable mounting base
could result in a loss of efficiency of performance or damage to the winch, wire rope
and mounting channel.
Use leather gloves or a heavy rag when handling the wire rope.
Disconnect the remote switch from the winch when not in use.
When winching a heavy load, lay a heavy blanket over the wire/synthetic
rope near the hook end.
Always operate your winch in an underwound orientation only (Fig 3).
For example, if a vehicle weighing 1,200 kg is winched up an incline by 100% on the marsh road,
the above formula would be used as follows:
II. Winching Principles
XCalculating Fleet Angle
To obtain the best wire/synthetic rope service, the direction of pull will be on a horizontal within
Âą15 degrees and perpendicular to be centerline of the winch drum within Âą5 degrees. If the fleet
angle is bigger than the recommended angles, a good spooling cannot be obtained as the rope
will spoon onto one side of the rope drum and possible damage to the rope or winch.
X Load Rating
Load and speed varies according to how much
wire/synthetic 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, all utility duty winches are rated at their first
layer capacities.
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.
You need a winch powerful enough to overcome the weight of your vehicle with the added
resistance caused by the obstacle, moving water, mud, snow, sand or on a steep hill.
As a general guide, you need a winch with a maximum line pull of at least 1.5 times greater than
the gross vehicle weight.
There are three factors listed that influence the line pull effect required to recover the vehicle.
The values and calculations in this section are approximate and are for reference only.
a). Gross vehicle weight
b). Type of the surface to be traversed
c). Gradient to overcome
In recovery and loading the winch is used to pull something, the required pulling force (RPF) can
be calculated according to the formula:
RPF = (Wt X S) + (Wt X G)
Where: Wt = The gross vehicle weight
S = The type of the surface to be traversed
G = The gradient to overcome
Surface Drag (S)
0.15
0.18
0.20
0.22
0.32
0.52
0.52
Gradient
5%
10%
20%
30%
50%
70%
100%
A slope of 10% is a rise of one meter
in ten meters (High / Distance)
X Securing Anchor Point
X Required Pulling Force
Surface Type
Metal
Sand
Gravel
Soft Sand
Mud
Marsh
Clay
Where Wt: 1,200 kg,
S: 0.52
G: 0.71
RPF = (Wt X S) + (Wt X G)
= (1,200 kg X 0.52) + (1,200 kg X 0.71)
= 624 kg + 852 kg
= 1,476 kg of effect required to recover the vehicle.
Angle (ș)
3°
6°
11°
17°
26°
35°
45°
Gradient (G)
0.06
0.11
0.2
0.3
0.44
0.58
0.71
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/synthetic
rope maintained less than 15°. Always use a tree trunk protector strap to prevent ring barking the
tree and damaged to the wire rope.
X Winching V.S. Hoisting. A pulling winch should not be used for lifting.
Please refer to our website to view our full range of lifting winches.
III. Accessories
X Roller Fairlead
The use of 4 ways roller fairlead can eliminate the contacting
friction because the fairlead rollers contact with the wire/synthetic
rope. But the fairlead does not insure the wire/synthetic rope will
wind onto the drum in an orderly manner. The proper fleet angle
within 15° must be maintained for the wire/synthetic rope to wind
onto the drum in an orderly manner. If the proper fleet angle is not
maintained, it can result in damage to the winch and wire/synthetic
rope.
X Hawse Fairlead
The basic hawse fairlead is designed to guide the synthetic rope to
and from the winch drum. Do not use cast steel hawse fairleads as
they have sharp edges and they do not have enough radius for the
rope to bend over.
X Recovery Damper
A recovery damper is a safety device designed to help eliminated
the possibility of injury or property damage in the event of a
wire/synthetic rope failure. Place in the middle third of a live rope.
The damper can help absorb the energy in the rope and reduce the
likelihood of injury or damage.
Fleet angle
fBattery Leads Connection
X 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 nearly 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.
The use of one snatch block shows an indirect pull where the
vehicle is limited due to unsuitable ground or obstruction. The pull
on the load is the actual line pull of the winch. If more than one
snatch block is used, they must be located at least 100 cm (40Ǝ)
apart.
1).Battery leads specification is listing as follows:
Model
Utility winch 5000si
6 AWG × 5’(1.5 m)
6 AWG × 5’(1.5 m)
6 AWG × 5’(1.5 m)
8 AWG × 5’(1.5 m)
8 AWG × 5’(1.5 m)
DV-3500i
12V
6 AWG × 5’ (1.5 m)
24V
8 AWG × 5’ (1.5 m)
Control Type
Volt
DV-4500i
DV-2500i
Contactor/Indirect
Solenoid/Indirect
2).Use a 5/16Ý bolt, nut and washer to attach the black lead (negative -) firmly to the
base plate of the vehicle (fig 7).
3).Attach the red lead (positive +) tightly to the circuit breaker marked AUX, meanwhile, connect
copper plate to the other end of the circuit breaker, marked BAT (fig 8).
4).Connect the copper plate to the connector of battery (fig 8).
fSwitch Connection:
1).A hand-held remote switch w /1.25mm2 x 3C x 3 m cord supplied.
IV. Installation
2).Open the rubber gland of the winch, then insert the switch plug into the socket of the winch
Before using the winch, make sure all electrical parts have no corrosion or damage; relative
environment should be clear and dry.
The voltage drop from the point of supply to the load of machine must not exceed 10% of the
nominal voltage under normal operating condition.
(fig 9).
fMounting
1).Use the mounting hardware (M10 bolt, nut and washer) to mount the winch on a flat surface
(fig 5).
2).The motor, drum and gear housing must be properly aligned (fig 6).
f Paring the wireless remote control: (for Utility winch 5000si)
9 2SHUDWLRQ
fPrecaution
Be sure to check all safety and environmental conditions.
A wire/synthetic rope should be discarded and not to be used again if rope shows sign of
excessive wear too many broken wires, corrosion or other defects.
The operator of winch must remain with the winch at all times whist the unit is being operated.
The type of duty is intermittent-periodic duty S3 and the load time never exceeds 2 minutes.
If a winch fails in pulling a load at a normal condition, stop the operation within 30 seconds,
otherwise you will damage the motor.
Your wireless remote control is already paired to your winch.!
You can follow the below procedures for pairing your new wireless remote transmitter.
1).Press the cutout switch button to activate the winch operation. Verify a red light appears
around the button. Wireless receiver icon blinking for 1 minute.
2).Press and hold the power button for about 5 seconds, the LED indicator illuminates green
permanently.
3).Press either cable in button or cable out button for 1 second for pairing.
4).If pairing was successful, the wireless receiver icon will go off, and it is ready to operate.
f Take out the wireless remote transmitter
Ensure that only the rated voltage is applied to the winch (ie. 12VDC or 24VDC).
Do not wrap the wire/synthetic rope around load and hook it to itself. Always use a strap to
insure that the wire/synthetic rope does not fray or kink.
Keep hands and clothes away from the drum area, wire/synthetic rope and roller fairlead.
Never unplug the remote control when winching a load.
Determine that the winch is operating correctly before use.
To avoid insufficient power in pulling a load, the vehicle should be running and in neutral. The
handbrake should be also on.
If noise or vibration occur while running, stop the winch immediately and send it for repaired.
Don’t use it again before trouble shooting completely.
If the winch is not to be used for a long time, we recommend disconnecting the battery lead
from winch.
1). Press the button and release the transmitter.
2). Pull it up.
1. Wireless Control Module烉
1.1. Press and hold the cable in button of the transmitter for rope winding in operation.
1.2. Press and hold the cable out button of the transmitter for rope winding out operation.
1.3. Stop winching, release the cable in or cable out buttons.
fCable-in/ Cable-out Operation
Cable Out
1). To determine “Cable - Out”, depress Ļ button (fig. 10)
2). To determine “Cable - In” depress Ĺ button (fig.11)
3). To stop winching, release the button
Cable In
2. Additional Emergency Stop Function:
The power button also works as an emergency stop if the radio control is in malfunction of
any reason. While the radio control is in operation (either winch in or winch out, the red light is on),
once power button is pressed, the radio control will be forced to power off immediately. Winch
will stop running accordingly.

f Wireless remote control module烉(for Utility winch 5000si)
f Power on the winch (Getting started): (for Utility winch 5000si)
1). Turn on / off:
1.1 Press the cutout switch to start up the winch, and verify a red light appears around the
button.
1.2 The wireless receiver icon is blinking.
1.3 Vehicle battery life icon will light on
Applicable models
Utility winch 5000si
LED
Transmitter LED
Turn on
Blinking
Press Transmitter for 5 seconds
on
on
Turn on Green
Programming
Vehicle Battery Life
Wireless Signal
Rocker switch
Cutout Switch
off
If programming failed , Winch will automatically use the previous programming after 1 minute.
Cable in/out
2). Rocker Switch:
Directly control winch in and out.
3). Wireless Transmitter烉
Your Utility winch 5000si can be operated by wireless remote control.
Press and hold the power button for 5 seconds to activate winch operation. The green
LED Indicator lights up.
No operation
Low voltage on transmitter
Cable Out
Red
Green
on
off
on
Blinking Green
Poor signal warning
Press the power button for 5
seconds to turn transmitter off.
Press the power button to turn
winch off.
LED Indicator
on
off
Blinking
Blinking Red
off
off
off
Power Button
Wireless Transmitter
Cable In
1.2 B attery replacementÄĄ
ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ When the green LED Indicator is flashing indicates an extreme low battery level
of wireless transmitter’s.The battery should be replaced.
ĥ ĥ ĥ ĥ ĥ ĥ ĥ ĥ ĥ ŢĪį Loose the three screws from the back cover of the wireless transmitterĥ
ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ĹŁÄŞÄŻ Separate the top section and remove the old battery and dispose it.
ŤĪį Insert new 3V lithium battery and join the top section with the bottom section.ĥ
ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ÄĄ ĹĽÄŞÄŻ Make sure to fasten the three screws.ÄĄ
ÄĄ
ÄĄ
1. Cutout Switch烉
Your Utility winch 5000si has a cutout switch,it is to activate or deactivate the winch.
The cutout switch could also cut out the battery draw of wireless control models when the engine
is not running.
2. Vehicle Battery Level烉
The dash board of your Utility winch 5000si is with battery indicator to show the status of
vehicle battery level.
1st Icon (Green): Fully charged around 12V level
2nd Icon (Green): Fair charged around 11V
3rd Icon (Green): Fair charged around 10 V
4th Icon (Green): Low charged around 9V
5th Icon (Blinking Red): Extreme low below 8V
ÄĄ
Lithium Battery: CR2032 (3V)


fClutch Function
X Wireless Receiver & Transmitter Operation
This wireless remote control device complies with CE mark, FCC and Industry Canada (IC) rules.
CE Mark Warning
• This is a Class B product, in a domestic environment, this product may cause radio
interference, In which case the user may be required to take adequate measures
FEDERAL COMMUNICATIONS COMMISSION INTERFERENCE STATEMENT
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and can
radiate radio frequency energy and, if not installed and used in accordance with the instructions, may
cause harmful interference to radio communications. However, there is no guarantee that interference
will not occur in a particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
-Reorient or relocate the receiving antenna.
-Increase the separation between the equipment and receiver.
-Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
-Consult the dealer or an experienced radio/ TV technician for help.
CAUTION:
Any changes or modifications not expressly approved by the grantee of this device could void the
user's authority to operate the equipment.
RF exposure warning (Model No烉883423 )
This equipment must be installed and operated in accordance with provided instructions and the
antenna(s) used for this transmitter must be installed to provide a separation distance of at least 20
cm from all persons and must not be co-located or operating in conjunction with any other antenna or
transmitter. End-users and installers must be provide with antenna installation instructions and
transmitter operating conditions for satisfying RF exposure compliance.
The free-spool allows rapid wire/synthetic rope payout for hooking onto the load or anchor points
and is operated by a free-spool level.
The free-spool level must be in the “Engaged” position before winching (fig 12)
1).To disengage the free-spool by lifting a free-spool lever in the “Disengaged” position, wire
rope can now be free spooled on the drum (fig13)
2).To engaged the free-spool, press a free-spool level in the “Engaged” position.
3).If a free-spool lever can’t be properly locked in the “Disengaged” position, rotate the drum to
make the pole free-spool to couple the gear train completely.
4).Wear leather gloves and use a handsaver strap when guiding the wire rope out of the drum.
fUse a Snatch Block Assembly
The proper usage of snatch block will nearly double the capacity of the winch but the speed will
decay 50%.
It is recommended to use snatch block for loading over the rated load.
When a snatch block is applied, be sure that the anchor point of the hook is secured to withstand
the double line rated capacity of the winch.
VI. Maintenance
fLubrication
RF exposure warning (Model No烉881102))
The equipment complies with FCC RF exposure limits set forth for an uncontrolled environment.
The equipment must not be co-located or operating in conjunction with any other antenna or
transmitter.
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
only use marine type grease.
fWire Rope Replacement
Never substitute a heavier or lighter rope. Never use rope made of any material other than wire.
1).Spool the entire wire rope, then cut and take it out from the drum.
2).Put the replacement wire rope through the fairlead opening, pass below the drum, and
insert it into the hole of drum core.
3).Tighten the screw downwards to secure the wire rope (fig14).


4).Secure the wire rope to the hook with 2 sets of cable clip, tighten the screw completely
(fig 15).
X Maintenance Schedule
Classification of check
Daily
Periodical
Installation Mounting bolts & Bolt tension & Existence of abnormalities
alignment
wear
Manual
Reasonable actuation
Visual
Free of wear or damage
Visual,
Visual,
measuring
Less than 10%
7% of nominal diameter
max
Fastening
condition of end
Visual
Existence of abnormalities
Deforming or
corrosion
Visual
Existence of abnormalities
Broken strands
Visual,
measuring
Two or more adjacent
strands are cut
Visual,
measuring
25% of nominal diameter
max
Visual
Existence of abnormalities
Visual
Existence of abnormalities
Working
Remote
control Wearing in contact
points
Broken strands
Do not wind out past the red paint section of the rope to secure the rope anchorage on the drum.
1). Disengage the clutch shift, remove existing rope and replace hawse if necessary.
2). Remove the set-screw on the drum and spool out the rope from the drum.
3). Cut the lateral side of the end by 45° andĥapply 2-3 wraps of electrical tape to hold cut strands
in place
4). Thread rope through a roller fairlead and under the drum, insert the rope through the hole on
the drum with 6 – 7 cm / 2.4” – 2.8”.
5). Place rope across the drum and tape the end down to hold it in place. Lightly tighten the
set-screw to squeeze the rope, do not over tighten.
Wire
rope
Fastening
condition of end

Decrease in rope
diameter
Decrease in rope
diameter
Synthetic
rope
Fused or melted
fibers
6). A minimum of ten (10) wraps of rope around the drum is necessary to support the rated load
X Tip for prolonging the life of Synthetic rope
1.Regular maintenance and periodically check the rope for damage or wear
2.Since too much abrasion can damage or weaken your synthetic rope, protect your rope from
rubbing against sharp objects or edge
3.Keeping your synthetic rope clean and dry. To clean it after a muddy ride, spool out the rope,
rinse it with a hose, and let it dry completely before re-spooling
Checking reference
Monthly Quarterly
X Synthetic Rope Replacement
Checking
method
Item
Clutch Damaged clutch Visual evidence Free of wear or damage
assembly
assembly
of wear
Motor
Brake
Staining, damage Visual evidence Existence of abnormalities
of wear
Wearing of brake Visual evidence Free of wear or damage
disc
of wear
Performance
Gear
Visual
Reasonable actuation
Damage, wearing Visual evidence Free of wear or damage
of wear

If the winch fails to operate after several attempt, or if there is any fault whilst operation:
Symptom
Possible Cause
Cut circuit
Weak battery
Damaged circuit breaker
Winch will not Bad connection of wiring
Damaged DC solenoid
operate
Cut circuit on switch
Damaged motor or carbon brush.
Poor or lost connections to motor
Broken wiring or bad connections
Motor runs in one
Damaged or stuck DC solenoid
direction.
Switch inoperative
Clutch does not disengage
Drum will not Damaged 1st shaft
Damaged brake cam and disc
clutch.
Damaged output shaft
The gear train is mechanically binding
up
Damaged brake cam and disc
Damaged gear box
No brake
Broken retaining ring
Oil leakage into brake cavity
Damaged or inoperative spiral spring
Worn brake disc or loose brake
Brake distance is spacer
too long
Oil leakage into brake cavity
Too much brake disc powder in the
brake hub
Brake will be
Over tensioned spiral spring
locked
Stuck between brake disc and gear
box
Hit by certain exterior force
Damaged gear train
Damaged gear
Over load operation
box
Long period of operation
Motor runs
Damaged motor
extremely hot
Damaged or inoperative brake

Remedy
Check battery lead
Recharge or replace battery, 650CCA
Replace circuit breaker
Reconnect tightly
Replace DC solenoid
Replace switch
Replace motor or carbon brush
Replace wiring or tighten it
Reconnect or replace wiring
Replace DC solenoid
Replace switch
Replace clutch
Replace 1st shaft
Replace brake cam and disc
Replace output shaft
Check to insure the winch is mounted on
a flat, rigid surface
Replace brake cam and disc
Replace gear box
Replace retaining ring
Repair and clean oil leakage
Replace and position spiral spring
Replace brake disc or adjust brake spacer
according to brake adjustment procedures
Repair and clean oil leakage
Clean brake hub
Adjust tension on spiral spring
Replace with new brake assembly
Replace the damaged components
Replace the damaged components
Stop the winch operation and reduce the
load
Allow to cool
Replace or repair motor
Replace or repair brake

---

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