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Summary of Contents for Bulldog Security DC Series
- Page 1 DC Series Utility 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 fairlead while operating. tip is bent or twisted. • ALWAYS use a hook with a latch. • Purchaser/owner must ensure that • Never use winch rope for towing. • The winch is not to be product is installed according to • NEVER use excessive effort to free used to lift, support or otherwise these instructions. Purchaser/own- spool winch rope. transport personnel. er must not alter or modify product. • ALWAYS take time to use appropri- ate rigging techniques for a winch • ALWAYS be aware of • Understand your winch and pull. possible hot surfaces at winch its instructions. During the pull motor, drum or rope during or after • Never exceed maximum rated winch use. -
Page 4: Know Your Winch
Know Your Winch Figure 1 - Winch Components Winch Drum Clutch Lever Roller Pendant Remote Fairlead Control Socket Pendant Remote Control Circuit Breaker (Varies Per Model) Hand Saver Winch Mounting Cable Strap Hardware... -
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 utility duty winches are rated at their first layer capacities. Table 1 - Winch Capacity DC2500 DC3500 DC4500 Rope Capacity Length of Rope Capacity Length of Rope Capacity Length of Layer Rope on Layer Rope on Layer Rope on Drum Drum Drum 10.2 ft./ 8.9 ft./ 7.9 ft./... - Page 6 Features and Ratings Table 3 - Line Speed And Amp Draw DC2500 DC3500 DC4500 1st Layer Line Speed 1st Layer Line Speed 1st Layer Line Speed Line Pull (FPM/ Draw Line Pull (FPM/ Draw Line Pull (FPM/ Draw (lbs./kgs.) MPM) (lbs./kgs.) MPM) (lbs./kgs.)
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Page 7: Installation Instructions
Installation Instructions BefORe InSTALLIng AnD USIng yOUR POWeReD WInCH, ReAD AnD fOLLOW ALL MOUnTIng InSTRUCTIOnS AnD SAfeTy MeSSAgeS. 1. Mounting WARNING To prevent accidental activation of the winch and serious injury, complete the winch installation and attach the hook before installing the wiring. 1. - Page 8 Installation Instructions 1.3 Determine Mount Position WARNING 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 surface. 1.4 Install the Winch 1.
- Page 9 Installation Instructions 1.5 Install the Wiring WARNING BEFORE installing the winch, make sure all electrical parts are corrosion free. ALWAYS place the supplied terminal boots on wires and terminals as directed by the installation instructions. NEVER lean over battery while making connections. NEVER route electrical cables over battery terminals.
- Page 10 Installation Instructions Figure 5 - Torque Specification 14 n-m 124 in-lbs. 1.5.3 System Check Upon completion of installation, check winch for proper operation. The voltage drop for the winch motor must not exceed 10% of the nominal voltage of 12/24 DC. Figure 6 - DC2500, DC3500 & DC4500 Wiring Diagram...
- Page 11 Installation Instructions 1.6 Know your Wireless Remote WARNING Never lose sight of the winch or jack while using the wireless remote. Never touch the winch or jack while the remote is in someone else’s hands. Figure 7 - Wireless Remote Components Wireless Switch Cord W/3Pin plugs Wireless...
- Page 12 Installation Instructions 1.6.3 Wireless Remote and Transmitter Installation 1. Install Battery Figure 11 - Battery Replacement a. R emove the three screws from the wireless transmitter. b. S eparate the top section, insert the battery positive (+) side up and replace the top section. c. Replace the three screws. Lithium Battery: CR2032 (3V) 2. Test a. Press the Power Button for 5 seconds until the Green light comes on. b. Press the In/Down or Out/Up button. The Red indicator light will come on. Figure 12 - Operations Power Button LED Indicator Cable IN Cable OUT...
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Page 13: 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 14 Operation Instructions 2.5 for first Time operation 2.5.1 Handheld Pendant Control Figure 14 - Connect Remote Industrial grade and waterproof remote. DC2500, DC3500 and DC4500 winches includes LED overheating indicator. 2.5.2 Connect the remote control Always keep the remote control wire clear of the winch, wire rope and roller fairlead. Figure 14. WARNING DO NOT leave the pendant control plugged into the winch when not in use. This may result in a dangerous condition and/or battery drain.
- Page 15 Operation Instructions 2.7 Winching Principles 2.7.1 Calculating fleet Angle Figure 18 - Fleet Angle CAUTION To obtain the best wire rope service, the direction of pull will be on a horizontal within ±15 degrees and perpendicular to the cen- terline of the winch drum within ±5 degrees. Short pulls of up to 45 degrees laterally are acceptable; 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. Figure 18 Roller Fairlead 2.7.2 Recovery Damper Figure 19 - Recovery Damper WARNING 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 19. 2.7.3 Snatch Block An important aid to successful winching is the Figure 20 - Snatch Block use of snatch block, which can be used to...
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Page 16: Maintenance
Operation Instructions WARNING Do not use the winch as a lifting device or a hoist for vertical lifting. CAUTION The Power-Out function should be used for relieving tension on the rope, not for extended distances. The Power-Out function drives the winch motor against the brake which is similar to driving your vehicle with the parking brake engaged. Do not use the Power-Out function for lowering a load -- winches are not designed to be used as hoists. Use the free-spool function to pay out wire rope. If you Power-Out over 25 feet, let the winch cool for 15 minutes. Maintenance 3.1 Install/Replace the Rope WARNING ALWAYS complete the winch installation and hook attachment before installing the wiring. - Page 17 Maintenance Figure 22 - Mixed Winding • Check the wire rope. Before winching, make sure the rope 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. 3.2 Lubrication All moving parts in the winch are permanently lubricated at the time of assembly. Under normal condi- tions factory lubrication will suffice. If re-lubrication of gear box is necessary after repair or disassem- bly use Shell EP2 or equivalent grease. Regularly lubricate Clutch Lever with light oil. Never lubricate the brake system.
- Page 18 Troubleshooting Table 6 - Troubleshooting Symptom Possible Cause Remedy Cut circuit Check battery lead Weak battery Recharge or replace battery, 650CCA Damaged circuit breaker Replace circuit breaker Bad connection of wiring Reconnect tightly Winch will not operate Damaged DC solenoid Replace DC solenoid Cut circuit on switch Replace switch...
- Page 19 Checklist Table 7 - Checklist Classification of Check Checking Checking Item Periodical method reference Daily Monthly Yearly Mounting bolts & Bolt tension & Existence of Installation alignment wear abnormalities Reasonable Working Manual actuation Remote control Wearing in Free of wear Visual contact points or damage...
- Page 20 Checklist Table 8 - 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. Check that the wiring is correct and the connections are tight Check that there are no bare or exposed wires, terminals, or damage to the cables.
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