This document is a user manual for the COME.UP WINCH ATV/UTV-3000 and ATV/UTV-4000 models. It provides comprehensive information on the winch's function, technical specifications, installation, operation, maintenance, and troubleshooting.
Function Description
The COME.UP ATV/UTV winch is designed for self-recovery and utility applications on All-Terrain Vehicles (ATVs) and Utility Task Vehicles (UTVs). Its primary function is to pull loads using a wire rope, enabling vehicles to extricate themselves from difficult situations or to move objects. The winch operates on a 12VDC power supply, typically from the vehicle's battery. It features a freespool function, allowing the wire rope to be pulled out manually without engaging the motor, which is useful for quick deployment. The winch is controlled via a remote control and a trigger switch (for ATV-3000 only), offering flexibility in operation. The design incorporates a roller fairlead to guide the wire rope smoothly and reduce wear.
Important Technical Specifications
The manual details specifications for both the ATV-3000 and ATV-4000 models, highlighting differences in their capacities and performance.
Line Pull and Rope Capacity:
- ATV-3000:
- First Layer Line Pull: 1,360 kg / 3,000 lb
- First Layer Line Speed: 7.6 mpm / 24.9 fpm (no load)
- Rope Capacity (1st layer): 1,363 kg / 3,000 lb
- Rope Capacity (5th layer): 830 lb
- Wire Rope Length: 15.2 m / 50 ft
- Wire Rope Size: 4.8 mm / 3/16 in
- Drum Size: 55mm x 75mm
- ATV-4000:
- First Layer Line Pull: 1,814 kg / 4,000 lb
- First Layer Line Speed: 6.0 mpm / 19.7 fpm (no load)
- Rope Capacity (1st layer): 1,814 kg / 4,000 lb
- Rope Capacity (5th layer): 830 lb
- Wire Rope Length: 15.2 m / 50 ft
- Wire Rope Size: 5.5 mm / 7/32 in
- Drum Size: 55mm x 119mm
General Specifications (Common to both unless specified):
- Motor: Permanent magnet, 12V, 800 W / 1.0 hp
- Gear Train: 3 stage planetary
- Gear Ratio: 145:1 (ATV-3000), 184:1 (ATV-4000)
- Freespool: Sliding shaft gear
- Brake: Dynamic and mechanical
- Control: Remote switch & trigger switch (ATV-3000 only), Remote switch (ATV-4000 only)
- Wire Rope: A7 x 19 aircraft galvanized
Line Speed and Amp Draw (at 12V):
The manual provides detailed tables for line speed and amp draw at various load levels for both models. For example, at a 2,000 lb load:
- ATV-3000: Line speed of 3.7 mpm (12.1 fpm) with an amp draw of 140A.
- ATV-4000: Line speed of 9.5 mpm (31.2 fpm) with an amp draw of 120A.
Usage Features
The winch is designed for user-friendly operation with several key features:
- Remote Control: Both models come with a remote control for operating the winch from a safe distance, enhancing user safety.
- Trigger Switch (ATV-3000 only): The ATV-3000 model includes a handlebar-mounted trigger switch, allowing for convenient operation directly from the ATV's handlebars without removing hands from the grip.
- Freespool Function: This feature allows the user to quickly pull out the wire rope manually by disengaging the gear train, saving battery power and time when deploying the rope. The freespool shifter is located on the end of the winch.
- Cable In/Out Operation: The manual clearly outlines how to operate the winch to pull the cable in ("In" position) or release it ("Out" position) using the trigger level or remote control.
- Mounting Flexibility: The manual provides instructions for mounting the winch, roller fairlead, solenoid, and remote socket, suggesting proper mounting locations to ensure optimal performance and safety. It specifies different mounting plates for ATV-3000 and UTV-4000.
- Safety Precautions: The manual emphasizes critical safety warnings, including checking the winch and environment before use, ensuring proper cable routing, avoiding overloading, and never wrapping the wire rope around any object other than the load or anchor point. It also warns against operating the winch with less than 30 seconds of intermittent duty rating to prevent motor damage.
Maintenance Features
Regular maintenance is crucial for the longevity and safe operation of the winch. The manual outlines a comprehensive maintenance schedule and procedures:
- Lubrication: All moving parts in the winch should be periodically lubricated to ensure smooth operation and prevent wear. Re-lubrication is necessary after repair or disassembly.
- Wire Rope Replacement: Detailed instructions are provided for replacing the wire rope, including disengaging the freespool, spooling the old rope, installing the new rope, and tightening the roller fairlead. It is critical to use aircraft grade wire ropes of the correct size.
- Maintenance Schedule: A classification of check table is provided, detailing daily, monthly, and three-monthly checks. This includes:
- Daily Checks: Complete winch operation, mounting bolts & alignment, working, remote control, wearing in contact points.
- Monthly Checks: Broken strands, decrease in rope diameter, deforming or corrosion and fastening condition of end.
- Three-Monthly Checks: Freespool, motor, staining/damage, wearing of lining, brake, performance, gear train.
- Troubleshooting: A dedicated section helps users diagnose and resolve common issues. It lists various symptoms (e.g., winch will not operate, motor runs in one direction, drum will not freespool, no brake) and their possible causes and remedies. For example, if the winch will not operate, possible causes include cut circuit or loosing, weak battery, damaged over load protector, loose connection, damaged solenoid, or defective remote control. Remedies include checking battery cable, replacing battery, replacing overload protector, checking all wirings, replacing solenoid, or checking winch operation with an auxiliary switch.
- Replacement Parts List: The manual includes exploded diagrams and corresponding parts lists for both ATV-3000 and UTV-4000 models, making it easy to identify and order specific components for repair or replacement. This ensures that users can maintain their winch with genuine parts.
- Limited Warranty: The product comes with a 1-year warranty on electrical components and a warranty for all parts and components, with the exception of the wire rope, motor, and electric parts, against defects in materials and workmanship under normal use. The warranty is non-transferable and does not cover failures resulting from improper installation, operation, or modification.
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