Self-Recovery Winch

Thank you for purchasing a PREMIER 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

Every PREMIER 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:

˙Confirm that the winch is suitable for the operation and conditions
˙Ensure that the winch is securely mounted and the rope wound correctly.
˙Don't use unsuitable pulleys or accessories.
˙Genuine replacement parts should only be used.
˙Check the winch for smooth operation without load prior to any recovery.
˙Make sure the wire rope is wound evenly on the first layer on the drum, rewind it if not.

WARNING

1. The winch is designed as a vehicle self-recovery unit and only 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 must remain on the drum at all times to support
the rated load.
4. When choosing a winch, you need to consider the vehicles size and weight. As a
general guide, you will need a winch with a maximum load rating of at least one to
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.

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I.Safety Precautions

This winch is designed to give safe, dependable service and trouble-free operation. Please read and
understand this Instruction Manual before installing and operating your winch.

Precautions before use:

Confirm that the winch is suitable for the application before use.
Because the maximum load capacity decreases corresponding to the increase in the number of
layers, wind the rope according to the instructions in this manual.
Mount the winch securely and ensure that the rope is attached correctly.
Genuine replacement parts should only be used.
If a hook or pulley blocks are to be used, ensure that they are correct for the application, and
remember that a pulley block should be rated at least twice the capacity of the winch.

Precautions at the time of operation of the winch are listed as follows:

The operator of a winch in some cases, is required to hold qualifications
according to applicable laws and ordinances.
Only a responsible person should operate the winch.
Prior to use, carry out the daily checks without fail, and use only
after confirming the winch is functioning correctly.
A minimum of 5 wraps of rope must remain on the drum at all times! (Fig 1)
Do not use winch to move people
Keep hands clear of wire rope and fairlead opening.
Use leather gloves or a heavy rag when handling the wire rope.
The winch is not to be used as a lifting device or a hoist for vertical lifting
(Fig1)
Do not exceed maximum line pull ratings shown in these instructions. Fleet angle
Do not impose shock loads on the winch.
Pull from an angle below 15 degree when straightening up the vehicle or
Centre line of anchor
load. (Fig 2)
Run the engine during winching operations to keep battery charged. point (Fig2)
When winching a heavy load, lay a heavy
blanket or jacket over the wire Rope, near to
the hook end.
Always operate your winch in an
underwound orientation only. (Fig3)

(Fig3)

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II.Performance Data
Specifications

Model DV-6000S DV-9000ES DV-9000i DV-12 light DV-12000ES DV-15000ES

Line Pull (first layer) 2,722kg / 6,000lb 4,082kg / 9,000lb 5,443kg/12,000lb 5,443kg/12,000lb 6,803kg/15,000lb
Line Speed (first layer, no load) 8.0mpm / 26.2fpm 13.4mpm / 44fpm 8.0mpm / 26.2fpm 8.3mpm/27fpm 6.9mpm/22fpm
Line Speed (first layer, full load) 2.0mpm / 6.5fpm 2.0mpm / 6.4fpm 1.0mpm / 3.3fpm 1.2mpm/4.0fpm 0.8mpm/2.5fpm
no load 12V 60A 55A 50A 60A 60A
full load 12V 300A 350A 350A 440A 460A
Amp. Draw
no load 24V 35A 30A 30A 50A 50A
full load 24V 200A 210A 210A 290A 340A
Type Series wound
Motor 12V 2,390w / 3.2hp 3,430w / 4.6hp 3,430w / 4.6hp 4,175w/5.6hp
Output
24V 1,490w / 2.0hp 1,940w / 2.6hp 1,940w / 2.6hp 2,684w/3.6hp
Type 3 stage planetary
Gear Train
Ratio 216:1 156:1 211:1 261:1 315:1
Clutch Rotating ring-gear
Brake Automatic, full load CBS (Cone Brake Structure)
Detachable control Detachable Bridge Detachable control
Control Detachable control box
box control box control box box
Type Galvanized aircraft A 7 x 19 6 x 29-IWRC
Wire Rope Length 24.4m / 80ft 30.5m / 100ft 25m / 82ft 38m / 125ft 27m / 89ft
Size 7mm / 9/32” 8mm / 21/64” 9.5mm / 3/8” 9.5mm / 3/8” 11mm / 7/16”

Performance

Layer Model DV-6000S DV-9000ES DV-9000i DV-12 light DV-12000ES DV-15000ES

Line Pull 5,443 / 5,443 / 6,804 /
2,722 / 6,000 4,082 / 9,000 4,082 / 9,000
1st kg / lb 12,000 12,000 15,000
Layer Total Rope on
3.8 / 12.5 6.1 / 20.0 6.1 / 20.0 5.4 / 17.7 6.6 /21.5 5.7 / 18.6
the Drum m/ft
Line Pull 4,319 / 4,563 / 5,569 /
2,266 / 4,995 3,316 / 7,310 3,316 / 7,310
2nd kg / lb 9,522 10,060 12,277
Layer Total Rope on
8.4 / 27.5 13.6 / 44.7 13.6 / 44.7 12.2 / 40.0 14.4 / 47.2 12.6 / 41.4
the Drum m/ft
Line Pull 3,580 / 4,713 /
1,941 / 4,279 2,792 / 6,154 2,792 / 6,154 3,928 / 8,659
3rd kg / lb 7,893 10,391
Layer Total Rope on
13.7 / 45.0 22.6 / 74.0 22.6 / 74.0 20.5 / 67.3 23.5 / 77.0 20.8 / 68.3
the Drum m/ft
Line Pull 3,056 /
1,697 / 3,742 2,410 / 5,314 2,410 / 5,314 3,448 / 7,601 4,086 / 9,007
4th kg / lb 6,737
Layer Total Rope on
19.8 / 65.1 30.5 /100 30.5 /100 25.0 / 82.0 33.8 / 110.9 27.1 / 89
the Drum m/ft
Line Pull
1,508 / 3,325 3,072 / 6,774
5th kg / lb
Layer Total Rope on
24.4 / 80 38.1 / 125
the Drum m/ft

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Main Components

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5
How the winch is rated.

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.

III.Installation
Before using the winch, make sure all electrical components have no corrosion or damage; the
environment should be clean and dry. 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
DV- 6000S/9000ES/12 light DV- 9000i
mounting channel to prevent from 12000ES/15000ES
damaging winch or vehicle.
3. It is also recommended that the roller fairlead must be fitted to prevent excessive wear of the
wire rope.
4. Tighten all mounting nuts on motor and roller fairlead securely.
Battery cable connection
Battery cable specification:
Model DV-6000S DV-9000ES / DV-12 light DV-9000i DV-12000ES DV-15000ES

Control Type Detachable control box Bridge control box Detachable control box

Red cable: 4AWG X 1.83m/72” Red cable: 2AWG X 1.83m/72” Red cable: 2AWG X 1.83m/72”
Volt 12V or 24V
Black cable: 4AWG X 1.8m/70” Black cable: 2AWG X 1.8m/70” Black cable: 2AWG X 1.8m/70”

1. Attach the black cable (earth) firmly to the chassis of the vehicle or to the negative – battery
terminal.
2. Attach the red cable to the circuit breaker, connect the other end to the positive + battery
terminal.
3. The circuit breaker must be fitted.

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 DV-6000S DV-9000i

DV- 9000ES / DV-12 light

DV-12000ES/15000ES

Switch Connection
1. A hand-held remote switch withψ2.0mm X 3c X
3m/ψ1/12” X 3c X 10’ cord supplied
2. Open the dust-proof cover of the winch, then
insert the switch plug into the socket (fig4).

IV. Operation
Precautions (Fig4)

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 defect.
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 clutch lever is in the “Engaged” position during and after use.
Remove the pendant 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 winch operations (winch speeds & direction).
To avoid insufficient power when winching a load, the vehicle should be running and in
neutral.
Keep the pendant cord clear of the winch cable at all times.
If noise or vibration occurs when running, stop the winch immediately and return it for repair.
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Cable-in/ Cable-out Operation
1). To determine “Cable - Out”, depress ↑ button (fig.5)
2). To determine “Cable - In” depress ↓ button (fig.6)
To stop winching, release the button

Cable-Out Cable-In

(Fig5) (Fig6)

Free Wheel (Clutch) Function

The clutch allows rapid unspooling of the wire rope for hooking onto a load or anchor points and is
operated by a clutch lever.
The clutch lever must be in the “Engaged” position before winching.
1). To disengage the clutch lift the clutch lever up and turn it at 900 clockwise rotation to the
“Disengaged” position, wire rope can now be free spooled off the drum.
2). To engage the clutch lift the clutch lever up and turn it at 90 0 counter-clockwise rotation to the
“Engaged” position.
3). If a clutch lever can’t be properly locked in the “Engaged” position, rotate the drum to make the
clutch couple to the gear train.
4). Wear leather gloves and use a handsaver bar when guiding the wire rope off the drum

(Engaged) (Disengaged)

8
Recovery Procedures
Followings are some safety tips to get out
of trouble during a recovery.

1).When using a winch to rescue another car,

the safest and most efficient direction is
to pull in the same direction, which the
car was moving when it became stuck.
2).When a car is stuck on a slope, the safest
way to pull the car is up the slope
3).Using a snatch block will increase the
capacity, but the speed will decrease
accordingly.
4).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
5).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.

LIFTING
Although Premier DV-9000/DV-9000i have been designed primarily for winching operations , it’s
possible to use the product for hoisting.
Premier Self-Recovery Winches can be used for lifting if you follow these suggestions.
Remove freespool function or make sure freespool is fully engaged before using.
Divide your winches’ rated load by 5. Take this number and reduce it by 10% for the
second and each additional layer of wire rope to be pulled up onto the drum. The
result of this calculation will be the load that you can lift. Don’t forget friction is one
of the important factors.
Operators and all others need to stand well clear of the lifting area.
Never lift people of lift loads over people.
Check local building and machinery codes to be sure you are in compliance before
using your winches.
Please note the winches’ duty rating is S3 (intermittent-periodic).
Do not keep winching in / out if the motor is overheated , or motor will be burnt-out.

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V. Maintenance

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 is necessary after
repair or disassembly use a marine type grease.

Cable Replacement
 Never use a rope of a different size or material.
 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 clutch (Fig7)

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. (Fig8)
4). Tighten the screw downwards to secure the wire rope (Fig8).
5). Secure a clevis hook to the wire rope by using a clevis pin and cotter pin.

(Engaged) (Disengaged)
(Fig 7) (Fig 8)

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 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
Item Checking method Checking reference
Daily
One Three
month month

 Installation Mounting bolts & alignment. Bolt tension & wear. Existence of abnormalities

 Working Manual Reasonable actuation

Switch

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

 Broken strands Visual, measuring (monthly) Less than 10%

7% of nominal diameter
  Decrease in rope diameter Visual, measuring (monthly)
max
Wire rope

 Deforming or corrosion Visual Existence of abnormalities

 Fastening condition of end Visual Existence of abnormalities

 Clutch Wear in spring Visual evidence of wear Free of wear or damage.

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

 Wearing of lining Visual evidence of wear Free of wear or damage.

Brake

 Performance Visual Reasonable actuation

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

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VI.Trouble Shooting

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

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 wiring Reconnect tightly

Winch will not operate
Damaged contactor Replace contactor

Cut circuit on switch Replace switch

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

Poor or lost connections to motor Replace wiring or tighten it

Broken wiring or bad connections Reconnect or replace wiring

Motor runs in one
Damaged or stuck contactor Replace contactor
direction.
Switch inoperative Replace switch

Clutch does not disengage Replace clutch

Damaged 1st shaft Replace 1st shaft

Drum will not clutch.
Damaged brake cam and disc Replace brake cam and disc

Damaged output shaft Replace output shaft

Check to insure the winch is mounted on a flat, rigid
The gear train is mechanically binding up
surface
Damaged brake cam and disc Replace brake cam and disc

No brake Damaged gear box Replace gear box

Broken retaining ring Replace retaining ring

Oil leakage into brake cavity Repair and clean oil leakage

Damaged or inoperative spiral spring Replace and position spiral spring

Replace brake disc or adjust brake spacer according to
Brake distance is too Worn brake disc or loose brake spacer
brake adjustment procedures
long
Oil leakage into brake cavity Repair and clean oil leakage

Too much brake disc powder in the brake hub Clean brake hub

Brake will be locked Over tensioned spiral spring Adjust tension on spiral spring

Stuck between brake disc and gear box Replace with new brake assembly

Hit by certain exterior force Replace the damaged components

Damaged gear box Damaged gear train Replace the damaged components

Over load operation Stop the winch operation and reduce the load

Long period of operation Allow to cool

Motor runs extremely
Damaged motor Replace or repair motor
hot
Damaged or inoperative brake Replace or repair brake

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VII.Replacement Parts List For DV-6000S

13
Item No. Description Qty
Motor 12V
1 1
Motor 24V
2 Tie bar kit 2
3 Motor support rack 1
4 Motor coupling 1
5 Drum bushing 1
6 Drum kit 1
7 Drum bushing B 1
8 Gearbox support rack 1
9 Wire rope w/hook 1
10 1st shaft 1
11 Grounding lead 1
12 3rd ring gear kit 1
13 2nd stage carrier 1
14 1st stage carrier 1
15 Retaining ring 1
16 1st & 2nd ring gear 1
17 1st pinion kit 1
18 Clutch kit 1
19 Gear box kit 1
20 Cone brake disc kit 1
21 Brake clutch base 1
22 Brake cover kit 1
23 Roller fairlead WA-0508 1
24 Mounting hardware 1
25 Remote control WA-0310 1
26 Handsaver strap 1
Detachable control box 12V
27 1
Detachable control box 24V
27-1 Remote socket kit 1
Detachable control pack 12V
27-2 1
Detachable control pack 24V
28 Handle kit 1

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VIII.Replacement Parts List For DV-9000ES / DV-12 light

15
Item No. Description Qty
Motor 12V
1 1
Motor 24V
2 Tie bar kit 2
3 Motor support rack 1
4 Motor coupling 1
5 Drum bushing 2
6 Drum kit 1
7 Gearbox support rack 1
8 Grounding lead 1
9 Wire rope w/hook 1
10 1st shaft 1
11 3rd ring gear kit 1
12 3rd stage carrier 1
13 3rd bushing 1
14 2nd stage carrier 1
15 1st stage carrier 1
16 1st & 2 nd ring gear 1
17 1st pinion kit 1
18 Clutch kit 1
19 Gear box kit 1
20 Cone brake disc kit 1
21 Brake cover kit 1
22 Roller fairlead 1
23 Mounting hardware 1
24 Remote control 1
25 Handsaver strap 1
Detachable control box 12V
26 1
Detachable control box 24V
26-1 Remote socket kit 1
26-2 Detachable control pack 12V 1
27 Brake clutch base 1

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IX.Replacement Parts List For DV-9000i

17
Item No. Description Qty
Motor 12V
1 1
Motor 24V
2 Bolt, washer kit 4
3 Motor support rack 1
4 Motor coupling 1
5 Drum bushing 2
6 Drum kit 1
7 Gearbox support rack 1
8 Grounding lead 1
9 Wire rope w/hook 1
10 1st shaft 1
11 3rd ring gear kit 1
12 3rd stage carrier 1
13 3rd bushing 1
14 2nd stage carrier 1
15 1st stage carrier 1
16 1st & 2nd ring gear 1
17 1st pinion kit 1
18 Clutch kit 1
19 Gear box kit 1
20 Cone brake disc kit 1
21 Brake cover kit 1
22 Roller fairlead 1
23 Mounting hardware 1
24 Remote control 1
25 Handsaver strap 1
Integrated solenoid pack 12V
26 1
Integrated solenoid pack 24V
26-1 Remote socket kit 1
26-2 Solenoid right cover kit 1
26-3 Upper Solenoid box 1
Solenoid pack 12V
26-4 1
Solenoid pack 24V
26-5 Solenoid left cover kit 1
26-6 Rubber gland 1
26-7 Tie bar 3
27 Brake clutch base 1

18
X.Replacement parts List For DV-12000ES/15000ES

19
Item No. Description Qty
Motor 12V
1 1
Motor 24V
2 Tie bar kit 3
3 Motor support rack 1
4 Motor coupling 1
5 Drum bushing 2
6 Drum kit 1
7 Gearbox support rack 1
8 Grounding lead 1
9 Wire rope w/hook 1
10 1st shaft 1
11 3rd ring gear kit 1
12 3rd stage carrier 1
13 2nd stage carrier 1
14 1st stage carrier 1
15 Retaining ring 1
16 1st & 2nd ring gear 1
17 1st pinion 1
18 Clutch kit 1
19 Gear box kit 1
20 Brake base 1
21 Cone brake disc kit 1
22 Brake cover kit 1
23 Roller fairlead 1
24 Mounting hardware 1
25 Remote control 1
26 Handsaver strap 1
Detachable control box 12V
27 1
Detachable control box 24V
27-1 Remote socket kit 1
Detachable control pack 12V
27-2 1
Detachable control pack 24V
28 Brake clutch base 1

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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 Premier 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, motor and electric parts 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 Premier 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.

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