Bulldog Security DC Series Manual de usuario

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.

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specied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.

Table Of Contents

Safety Page

ImportantSafetyMessages......................................................3

KnowYourWinch..............................................................4

5

.............................7

... 16

FeaturesandRatings...........................................................

Instructions

InstallationInstructions .............................

OperationInstructions ..........................................................

Maintenance ................................ ...............................

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indicatesahazardous

situationthat,ifnotavoided,

couldresultindeathorserious

injury.

NOTICEindicatesahazardous

situationthat,ifnotavoided,

couldresultinpropertydamage

CAUTIONindicatesahazardous

situationthat,ifnotavoided

couldresultinminoror

moderateinjury.

Throughout this manual WARNING, CAUTION, NOTICE and the SAFETY ALERT SYMBOL will be used.

WARNING CAUTION NOTICE

Before First Operation

• Purchaser/ownermustensurethat

productisinstalledaccordingto

theseinstructions.Purchaser/own-

ermustnotalterormodifyproduct.

• Understandyourwinchand

itsinstructions.

• Neverexceedmaximumrated

capacity.Refertostamped

markingsordecalsonproductto

obtainratedcapacity.

• Thewinchisratedatthefirstlayer

ofwireropeonthedrumforinter-

mittent-periodicduty.

Are you ready to pull?

• NEVERoperatethiswinchwhen

undertheinuenceofdrugs,alco-

holormedication.

• ALWAYSremovejewelry

andweareyeprotection.

• Useleatherglovesorahand

savercablestrapwhenhandling

thewirerope.

• NEVERletwinchropeslipthrough

yourhands.

• Nevertouchawinchropeorhook

whensomeoneelseisatthe

controls.

• NEVERtouchwinchropeorhook

whileundertensionorunderload.

• ALWAYSstandclearofwinchrope

andloadandkeepothersaway

whilewinching.

• Donotusethe

winchasaliftingdeviceorahoist

forverticallift.

• Operatorandbystandersshould

neverpositionanypartofbody

underanyportionofthisproductor

theloadbeingsupported.

• Donotallowchildrentoplayon

oraroundthisproductortheload

beingsupported.

• Keep

clearofwinch,rope,hook,and

fairleadwhileoperating.

• Thewinchisnottobe

usedtolift,supportorotherwise

transportpersonnel.

• ALWAYSbeawareof

possiblehotsurfacesatwinch

motor,drumorropeduringorafter

winchuse.

• ALWAYSensuretheoperatorand

bystandersareawareofthestabili-

tyofthevehicleand/orload.

Is your winch ready to pull?

• ALWAYSinspectwinchrope,hook,

andslingsbeforeoperatingwinch.

Frayed,kinkedordamagedwinch

ropemustbereplacedimmediate-

ly.Damagedcomponentsmustbe

replacedbeforeoperation.

• Periodicallycheckmountinghard-

wareforpropertorqueandtighten

ifnecessary.

• ALWAYSremoveanyelementor

obstaclethatmayinterferewith

safeoperationofthewinch.

• ALWAYSbecertaintheanchoryou

selectwillwithstandtheloadand

thestraporchainwillnotslip.

• Wireropecanbreakwithoutwarn-

ing.Alwayskeepasafedistance

fromthewinchandropewhile

underaload.

• ALWAYSkeepwiredpendant

controlleadandpowercordclear

ofthedrum,rope,andrigging.

Inspectforcracks,pinches,

frayedwiresorlooseconnections.

Damagedcomponentsmustbe

replacedbeforeoperation.

• NEVERwrapwinchrope

backontoitself.Useachoker

chainorstrap.

• ALWAYSensurehooklatch

isclosedandnotsupportingload.

• NEVERapplyloadtohook

tiporlatch.Applyloadonlytothe

centerofhook.

• NEVERuseahookwhosethroat

openinghasincreased,orwhose

tipisbentortwisted.

• ALWAYSuseahookwithalatch.

• Neverusewinchropefortowing.

• NEVERuseexcessiveefforttofree

spoolwinchrope.

• ALWAYStaketimetouseappropri-

ateriggingtechniquesforawinch

pull.

During the pull

• NEVERexceedwinchorwinch

roperatedcapacity.Doubleline

usingasnatchblocktoreduce

winchload.

• Donotshockloadthewinch.

• Neveruseawinchtosecureaload.

• ALWAYSunspoolasmuchwinch

ropeaspossiblewhenrigging.

Doublelineorpickdistantanchor

point.

• Neverengageordisengagethe

clutchwhenthewinchisunder

loadorthedrumismoving.

• Pullfromanangleoflessthan5

degreeslaterallyand15degrees

horizontly.Withoutmaintainingthe

propereetangleof+/-5degrees;

(SeeFigure18page15)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.

• Whenwinchingaheavyload,lay

arecoverydamperoraheavy

blanketoverthemiddlethirdofthe

wirerope.

• ALWAYSavoidsidepullswhich

canpileupwinchropeatoneend

ofthedrum.Thiscandamage

winchropeorwinch.

• ALWAYSensuretheclutchis

fullyengagedordisengaged.

Thetypeofdutyisintermittent-

periodicdutyS3andtheloadtime

neverexceeds2minutes.

• NEVERsubmergewinchinwater.

After Use

• Disconnectthehandheldpendant

fromthewinchwhennotinuse.

• ALWAYSstorethependantcontrol

inaprotected,clean,dryarea.

Important Safety Messages

Figure 1 - Winch Components

Know Your Winch

Winch

Drum

Pendant Remote

Control Socket

Pendant Remote Control

Roller

Fairlead

Hand Saver

Cable Strap Winch Mounting

Hardware

Clutch

Lever

Circuit Breaker

(Varies Per Model)

Features and Ratings

Load Rating

Loadandspeedvariesaccordingtohowmuchwireropeisonthedrum.Therst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rstlayercapacities.

Table 1 - Winch Capacity

DC2500 DC3500 DC4500

Rope

Layer

Capacity Length of

Rope on

Drum

Rope

Layer

Capacity Length of

Rope on

Drum

Rope

Layer

Capacity Length of

Rope on

Drum

1st 2,500lbs./

1,134kgs.

10.2ft./

3.1m.

1st 3,500lbs./

1,588kgs.

8.9ft./

2.7m.

1st

4,500lbs./

2,041kgs.

7.9ft./

2.4m.

2nd 2,149lbs./

975kgs.

22ft./

6.7m.

2nd 2,954lbs./

1,340kgs.

19.6ft./

6m.

2nd 3,722lbs./

1,688kgs.

17.4ft./

5.3m.

3rd 1,885lbs./

855kgs.

35.5ft./

10.8m.

3rd 2,555lbs./

1,159kgs.

31.8ft./

9.7m.

3rd 3,174lbs./

1,440kgs.

28.6ft./

8.7m.

4th 1,678lbs./

761kgs.

50ft./

15.2m.

4th 2,251lbs./

1,021kgs.

45.7ft./

13.9m.

4th 2,766lbs./

1,255kgs.

41.4ft./

12.6m.

5th N/A N/A 5th 2,012lbs./

913kgs.

50ft./

15.2m.

5th 2,451lbs./

1,112kgs.

50ft./

15.2m.

Table 2 - Winch Speciﬁcations

Powered

Winches DC2500 DC3500 DC4500

Wire rope 3/16”x50’

A7x19

Aircraft

Cable

7/32”x50’

A7x19

Aircraft

Cable

1/4”x50’

A7x19

Aircraft

Cable

Brake Mechanicalanddynamicbrakesholdfullload

Clutch (free-

spooling) Free-spoollever

Control Handheldpendantswitch

Features and Ratings

Table 3 - Line Speed And Amp Draw

DC2500 DC3500 DC4500

1st Layer

Line Pull

(lbs./kgs.)

Line Speed

(FPM/

MPM)

Amp

Draw

1st Layer

Line Pull

(lbs./kgs.)

Line Speed

(FPM/

MPM)

Amp

Draw

1st Layer

Line Pull

(lbs./kgs.)

Line Speed

(FPM/

MPM)

Amp

Draw

NoLoad 16.4/5 30 NoLoad 21.3/6.5 25 NoLoad 21.3/6.5 25

1,000/

454

11/3.5 80 1,000/

454

16.4/5 110 1,000/

454

16.4/5 110

2,000/

907

7.5/2.3 150 2,000/

907

11.8/3.6 200 2,000/

907

11.8/3.6 210

2,500/

1,134

4.2/1.3 200 2,500/

1,134

10.5/3.2 230 2,500/

1,134

10.5/3.2 240

N/A N/A N/A 3,000/

1,361

8.2/2.5 260 3,000/

1,361

8.2/2.5 270

N/A N/A N/A 3,500/

1,588

5.9/1.8 300 3,500/

1,588

5.9/1.8 290

N/A N/A N/A N/A N/A N/A 4,000/

1,814

4.6/1.4 310

N/A N/A N/A N/A N/A N/A 4,500/

2,041

1.3/0.4 330

FPM = Feet Per Minute MPM = Meters Per Minute

Mounting Hardware Requirements

ALWAYS torque mounting bolts to the values speciﬁed for your winch in Table 4 page 8 to prevent

vibration during operation.

ALWAYS use Grade 5 / 8.8 Metric or better hardware.

NEVER weld mounting bolts.

ALWAYS choose the proper bolt length for your application.

ALWAYS conﬁrm required bolt length to ensure proper thread engagement.

BEFORE INSTALLING AND USING YOUR POWERED WINCH, READ AND

FOLLOW ALL MOUNTING INSTRUCTIONS AND SAFETY MESSAGES.

1. Mounting

To prevent accidental activation of the winch and serious injury, complete the winch installation

and attach the hook before installing the wiring.

1. Before Installation

WARNING

Installation Instructions

1.1 Inspect Parts

Hand Saver Cable Strap

Clutch Lever

Instruction/Owners Manual

Winch Assembly

Drum Cover

Pendant Remote Control

Pendant Remote Control Socket

Roller Fairlead

6 Gauge Battery Lead

Hardware

1.2.1 Winch Mounting

1.2 Select Mount Location

ALWAYS choose a mounting location that is sufﬁciently strong to withstand the maximum pull-

ing capacity of your winch.

WARNING

1. Yourmountingsurfacemustbeequaltoorgreaterthanthefootprintofthewinchframe.

2. Thewireropeshallbeunderwoundasseenbelow.

WARNING

Figure 2

Installation Instructions

1.3 Determine Mount Position

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.

WARNING

1. Makesurethewinchisalignedcorrectly

2. Setwinchinmountinglocation.Conrmrequiredboltlength.

3. Installbolts,nuts,andlockwashersandtightentotorquespeciedinTable4below.

1.4 Install the Winch

Table 4 - Mounting Torque Requirements

Powered

Winches DC2500 DC3500 DC4500

Winch

Mounting

Bolt Size

M10x

1.5pitch

8.8grade

2 Required

M10x

1.5pitch

8.8grade

2 Required

M10x

1.5pitch

8.8grade

2 Required

Winch

Mounting

Bolt Torque

40ft./lbs. 40ft./lbs. 40ft./lbs.

7.48"/190mm

5.59"/142mm

3.66"/93mm

2–ø.433"/

2–ø11mm

FOOTPRINT

Figure 4Figure 3

Installation Instructions

WARNING

1.5 Install the Wiring

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.

ALWAYS consult Electrical Connections section for proper wiring details.

Run the charging system during winching operations to keep battery charged.

NEVER route electrical cables across sharp edges.

NEVER route electrical cables near parts that get hot.

NEVER route electrical cables through or near moving parts.

AVOID pinch and wear/abrasion points when installing all electrical cables.

ALWAYS insulate and protect all exposed wiring and electrical terminals.

Afullychargedbatteryandgoodconnectionsareessentialfortheproperoperationofyourwinch.The

minimumrequirementforthebatteryis650coldcrankingamps.

1.5.1 Battery Recommendations & Lead Size

Table 5 - Wire Gauge Speciﬁcations

Model DC2500 DC3500 DC4500

Control Type Solenoid/Indirect

Volt 12V 6AWG×5’(1.5m) 6AWG×5’(1.5m) 6AWG×5’(1.5m)

1. Plantheroutingpath.

2. Looselysecurepowercablesalongpath.

3. Conrmpowercablesareprotectedfromsharpedges,heatandmovingparts.Considerchassis

exandvibrationwhichmightdamagecable.

4. Carefullyinspectelectricalcablerouting.Ziptieandsecureelectricalcables.Ziptiesshouldbe

snug,butnotcuttingintowireinsulation.Useelectricaltape,piecesofrubberhoseorelectrical

conduittoprotectelectricalcablesandwireharnesswhereneededtoavoidelectricalcableinsula-

tionwearorabrasion.

5. FIRSTattachred(positive)batterycable,thenblack(negative)batterycable.Installbootsasappro-

priatetoprotectconnections.Torquebatteryterminalfastenersto124in/lbs(14N-m).SeeFigure5,

page10.

ALWAYS route battery cables along a path that allows the cables to be secured with zip ties.

Loose or unsecured power cables can cause serious injury or death.

Routebatteryconnectioncablesinareasthatwillnotcausethemtowearorcutthroughtheinsulation

causingapotentialshortcircuit.Thewinchpowerwiremustberoutedtothebattery.Adirectbattery

connectionofthepower(red)andground(black)cablesisrequired.

1.5.2 Battery Cable Routing

WARNING

Figure 5 - Torque Speciﬁcation

14 N-m

124 in-lbs.

Installation Instructions

Figure 6 - DC2500, DC3500 & DC4500 Wiring Diagram

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.

1.5.3 System Check

Otros manuales para DC Series

Este manual sirve para los siguientes modelos

Tabla de contenidos

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Bulldog Security DC Series Manual de usuario

Bulldog Security

Bulldog Security DC Series Manual de usuario

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