Summary of Contents for Bulldog Security HW8000
- Page 1 HW Series Hydraulic Winches Instruction Manual To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand and follow the warnings and instructions in this manual. Keep for future reference.
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Page 2: Table Of Contents
Read, Understand, Follow and Save These Instructions • Read, understand and follow all of these instructions and warnings before installing and using this product. • Install and use this product only as specified in these instructions. • Improper installation or use of this product may result in property damage, serious injury, and/or death. • Never allow installation or use of this product by anyone without providing them with these instruc- tions. • You must read, understand and follow all instructions and warnings for any product(s) to which this product is used in conjunction with or installed. • Save these instructions with the product for use as a reference for any future installation and use of the product. Throughout this manual WARNING, CAUTION, NOTICE and the SAFETY ALERT SYMBOL will be used. The safety alert symbol alerts you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING CAUTION NOTICE... -
Page 3: Important Safety Messages
Important Safety Messages Before First Operation of body under any portion of • NEVER use a hook whose this product or the load being throat opening has increased, • Purchaser/owner must ensure supported. or whose tip is bent or twisted. that product is installed ac- • Do not allow children to play on • ALWAYS use a hook with a cording to these instructions. or around this product or the latch. Purchaser/owner must not alter load being supported. • Never use winch rope for or modify product. towing. • NEVER use excessive effort to • Keep • Understand your winch free spool winch rope. clear of winch, rope, hook, and and its instructions. • ALWAYS take time to use ap- fairlead while operating. -
Page 4: Know Your Winch
Know Your Winch Figure 1 - Winch Components Clutch T-Handle Winch Drum Over-Center Valve Drum Drag Bolt Planetary Hydraulic Gear Box Motor Roller Fairlead (with Mounting Hardware) Mounting Footprint Hand Saver Template Cable Strap... -
Page 5: Features And Ratings
Features and Ratings Load Rating Load and speed varies 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, all industrial winches are rated at their first layer capacities. Table 1 - Winch Capacity HW8000 HW12000 HW15000 Rope Capacity Length of Rope Capacity Length of Rope Capacity Length of Layer Rope on Layer Rope on Layer Rope on Drum Drum Drum 8,000 lbs. /... -
Page 6: Installation Instructions
ALWAYS confirm required bolt length to ensure proper thread engagement. 1.2 Select Mount Location WARNING ALWAYS choose a mounting location that is sufficiently strong to withstand the maximum pulling capacity of your winch. Templates are not to scale. Figure 2 - Template HW8000 & HW12000 DIMENSIONS... - Page 7 Installation Instructions Figure 3 - Template HW8000 & HW12000 FOOTPRINT HW15000 DIMENSIONS HW15000 FOOTPRINT...
- Page 8 Installation Instructions 1.2.1 Winch and fairlead Mounting WARNING ALWAYS position fairlead with warning readily visible on top. 1. Your mounting surface must be equal to or greater than the footprint of the winch frame. 2. Make sure the motor, drum and gearbox housing are aligned correctly. 1.3 Install the Winch 1. Make sure the winch is aligned correctly 2. Set winch in mounting location. Confirm required bolt length. 3. Install bolts and tighten to torque specified in Table 4 on Page 9. Figure 4...
- Page 9 28 N-m 88 N-m Bolt Torque 1.4 Cable Tensioner Installation NOTICE Install cable tensioner prior to Installing rope. 1. Disconnect power to the hydraulic pump or disconnect the hydraulic lines to the winch. 2. Place the cable tensioner onto the winch as shown in Fig 5. 3. Install the four button head cap screws and torque to 20 ft.-lbs. 4. Install the lock washers and nuts onto the four button head cap screws which protrude from the back of the mounting plate. Torque to 20 ft.-lbs. Figure 5 - HW8000, HW12000, & HW15000 Cable Tensioner Cable Tensioner Button Head Cap Screw...
- Page 10 This is required for the automatic brake to function properly. Roller fairlead The use of 4 ways roller fairlead can reduce the contacting friction because the fairlead rollers contact with the wire rope. But the fairlead does not insure the wire rope will wind onto the drum in an orderly manner. The proper fleet angle within ±5° must be maintained for the wire 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 rope. Figure 6 Cable Tensioner The purpose of cable tensioner device is to keep the wire rope tight on the drum while the winch is in free spool mode or while there is no load on the wire rope. 1.6 System Check Upon completion of installation, check winch for proper operation. Figure 7 - HW8000, HW12000, & HW15000 Installation Diagram Advantage: Professional winch system for “working” applications, cost effective, extremely powerful, reliable, light weight, and variable line speed for high work rate.
- Page 11 Installation Instructions 1.6 System Check (Continued) Hydraulic Fluid • The hydraulic fluid should be a high grade, petroleum based fluid, with rust, oxidation and wear resistance. Fluid cleanliness and operating viscosity are critical to winch reliability, efficiency and service lift. Hydraulic Pump • To maintain the maximum performance, the hydraulic pump must supply the maximum flow of hydraulic fluid at the hydraulic pressure stated in specification. Hydraulic Control Valve • The control valve must have a four-way spring return to neutral feature, which provides for open flow from the pressure ports of the winch to the reservoir in neutral position of the control (motor spool). Hydraulic Pressure Relief • The hydraulic system requires a pressure relief valve set at the operating pressured. • Failure to use the correct pressure and flow may result in damage to the winch, property or personal injury. Hydraulic Reservoir • The hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over-heating of the hydraulic fluid. • Must be fitted with an oil filler device comprising strainer and filter and a dip stick. The capacity of the tank should be at least 60 liters. Over-Center Valve / Counterbalance Valve •...
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Page 12: Operation Instructions
Operation Instructions WARNING ALWAYS use supplied hand saver cable strap whenever spooling winch rope in or out, during installation or operation to avoid injury to hands and fingers. 2.1 Spooling in under Load WARNING NEVER exceed winch’s rated line pull. Power-in the winch rope evenly and tightly on the drum. This prevents the outer winch wraps from sinking into the inner wraps, binding and damaging the winch rope. - Page 13 Operation Instructions 2.4 Clutch Operation WARNING NEVER engage or disengage clutch if winch is under load, winch rope is in tension or drum is moving. To prevent damage, ALWAYS fully engage or fully disengage the clutch lever. The clutch lever, located on the winch housing opposite the motor, controls the clutch position. When the clutch is engaged, the gear train is coupled to the winch drum and power can be transferred from the winch motor. CAUTION NEVER engage the clutch while the drum is rotating.
- Page 14 Operation Instructions 2.5 Winching Principles Figure 10 - Fleet Angle 2.5.1 Calculating fleet angle To obtain the best wire/synthetic rope service, the direction of pull will be on a horizontal within ±15 degrees and perpendicular to the centerline of the winch drum within ±5 degrees. However without maintaining the proper fleet angle; the rope will pile onto one side of the rope drum and possibly do damage to the rope or winch. Re-spool your winch as required. Roller Fairlead 2.5.2 Recovery damper Figure 11 - Recovery Damper A recovery damper is a safety device designed to help reduce the possibility of injury or property damage in the event of a wire rope failure. Place in the middle third of a live rope. Figure 11. 2.5.3 Snatch Block Figure 12 - 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.
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Page 15: Maintenance
Maintenance 3.1 Wire Rope Replacement 1. Disengage the clutch T-handle. 2. Un-spool the entire rope, and remove it from the drum. 3. Place the replacement rope through the roller fairlead opening, pass under the drum and insert it into the hole on the drum core. Tighten the set-screw downwards to secure the wire rope. 4. A minimum of five (5) wraps of wire rope around the drum is necessary to support the rated load. Figure 13 - Wire Rope Replacement Lift and Engaged turn to disengage • Check the wire rope. Before winching, make sure the rope Figure 14 - Mixed Winding is wound on the drum evenly. If there is mixed winding, it is essential to rewind it evenly. • Be careful to keep the rope under tension. Never guide a wire rope onto the drum with your hand, use a hand saver cable strap. - Page 16 Maintenance 3.3 Lubrication All moving parts in the winch are permanently lubricated at the time of assembly. Under normal con- ditions factory lubrication will suffice. If re-lubrication of gear box is necessary after repair or disas- sembly use Shell EP2 or equivalent grease. Regularly lubricate Clutch T-handle with light oil. Never lubricate the brake system.
- Page 17 Troubleshooting Table 5 - Troubleshooting Symptom Possible Cause Remedy Remove and disassembly motor Motor may be damaged and examine all parts and replace any that are worn or damaged Check oil supply line connections No oil supply to winch and hoses System not delivering full pressure Confirm pump is running to a high- to winch...
- Page 18 Checklist Table 6 - Checklist Before After Every First EVERY 90 Days Operation Read, understand and follow the warnings and instructions in this manual. Check all fasteners and verify they are at the proper torque. Replace fasteners as needed. If damaged, discontinue use and replace rope immediately.
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