Bulldog Security DC6000 User manual

DC Series Electric 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.

2
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
FeaturesandRatings...........................................................5
Instructions
.............................7
19
... 23
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 CAUTION NOTICE
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.

3
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rstlayer
ofwire/syntheticropeonthedrum
forintermittent-periodicduty.
• Alwaysoperateyourwinchin
accordancewiththemounting
congurationontable5page9.
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/syntheticropecanbreak
withoutwarning.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hookbackonrope.
• 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.
• Trytopullfromanangleofless
than5degreeslaterallyand15
degreeshorizontly.Shortpulls
ofupto45degreeslaterallyare
acceptable;howeverwithout
maintainingthepropereetangle
of+/-5degrees;(SeeFigure35on
page21)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wireropenearthe
hookend.
• 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.
• 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

4
Figure 1 - Winch Components
Know Your Winch
Winch Drum
Contactor
Control Box
Planetary
Gear Box
Clutch
T-Handle
Motor
Pendant Remote
Control Socket
Pendant Remote ControlRoller Fairlead
(with Mounting Hardware)
2 Gauge
Battery Lead Hose Clamps
Mounting Footprint
Template Hand Saver Cable Strap Winch Mounting Hardware

Features and Ratings
Load Rating
Loadandspeedvariesaccordingtohowmuchwire/synthetic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
DC6000 DC9000 DC12000L
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 6,000lbs./
2,722kgs.
12.5ft./
3.8m.
1st 9,000lbs./
4,083kgs.
17.7ft./
5.4m.
1st
12,000lbs./
5,443kgs.
17.7ft./
5.4m.
2nd 4,995lbs./
2,266kgs.
27.5ft./
8.4m.
2nd 7,310lbs./
3,316kgs.
40ft./
12.2m.
2nd 9,522lbs./
4,319kgs.
40ft./
12.2m.
3rd 4,279lbs./
1,941kgs.
45ft./
13.7m.
3rd 6,154lbs./
2,792kgs.
67.3ft./
20.5m.
3rd 7,893lbs./
3,580kgs.
67.3ft./
20.5m.
4th 3,742lbs./
1,698kgs.
65.1ft./
19.8m.
4th 5,314lbs./
2,410kgs.
82ft./
25m.
4th 6,737lbs./
3,055kgs.
82ft./
25m.
5th 3,325lbs./
1,509kgs.
80ft./
24.4m.
5th N/A N/A 5th N/A N/A
DC12000 DC15000 DC18000
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 12,000lbs./
5,443kgs.
21.5ft./
6.6m.
1st 15,000lbs./
6,804kgs.
18.6ft./
5.7m.
1st 18,000
lbs./
8,165kgs.
15.4ft./
4.7m.
2nd 10,060lbs./
4,563kgs.
47.2ft./
14.4m.
2nd 12,277lbs./
5,569kgs.
41.4ft./
12.6m.
2nd 14.431
lbs./
6,546kgs.
34.4ft./
10.5m.
3rd 8,659lbs./
3,928kgs.
77ft./
23.5m.
3rd 10,391lbs./
4,713kgs.
68.3ft./
20.8m.
3rd 12,028
lbs./
5,455kgs.
57.4ft./
17.5m.
4th 7,601lbs./
3,448kgs.
110.9ft./
33.8m.
4th 9,007lbs./
4,086kgs.
89ft./
27m.
4th 10,311
lbs./
4,677kgs.
82ft./
25m.
5th 6,774lbs./
3,073kgs.
125ft./
58m.
5th N/A N/A 5th N/A N/A
5

6
Features and Ratings
Table 3 - Line Speed And Amp Draw
DC6000 DC9000 DC12000L
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 26.2/8 60 NoLoad 44/13.4 55 NoLoad 26.2/8 50
2,000/
907.2
17/5.2 150 2,000/
907.2
15/4.6 110 4,000/
1,814.4
9.8/3 120
4,000/
1,814.4
10.2/3.1 240 4,000/
1,814.4
11/3.4 200 8,000/
3,628.8
5/1.5 230
6,000/
2,721.6
6.5/2 300 6,000/
2,721.6
9/2.7 230 10,000/
4,536
4/1.2 290
N/A N/A N/A 9,000/
4,082.3
6.4/2 350 12,000/
5,443.1
3.3/1 350
DC12000 DC15000 DC18000
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 27/8.3 60 NoLoad 22/6.9 60 NoLoad 28.2/8.6 40
4,000/
1,814.4
8.6/2.6 200 4,000/
1,814.4
5.4/1.6 180 8,000/
3,628.8
12/3.6 140
8,000/
3,628.8
5.8/1.7 310 8,000/
3,628.8
3.8/1.2 280 12,000/
5,443.1
9.3/2.8 210
10,000/
4,536
4.4/1.4 370 12,000/
5,443.1
2.9/0.9 385 15,000/
6,803.9
7.5/2.3 260
12,000/
5,443.1
4/1.2 440 15,000/
6,803.9
2.5/0.8 460 18,000/
8,164.7
3.3/1 320
Table 2 - Winch Specifications
Powered
Winches DC6000 DC9000 DC12000L DC12000 DC15000 DC18000
Wire rope 5/16”x80’
A7x19
Aircraft
Cable
3/8”x82’
A7x19
Aircraft
Cable
3/8”x82’
A7x19
Aircraft
Cable
3/8”x125’
A7x19
Aircraft
Cable
7/16”x90’
6x29-IWRC
1/2”x82’
6x29-IWRC
Brake Patentedconebrakeholdsfullload
Clutch (free-
spooling) LiftandTurn“T”handle
Control Handheldpendantswitch
FPM = Feet Per Minute MPM = Meters Per Minute

7
Mounting Hardware Requirements
Four(4)orEight(8)WinchMountingBoltsandtwo(2)FairleadMountingBolts,Nuts,andWashersare
required.RefertoTable4belowforboltquantity,sizes,andrequiredtorque.Mountingsystemwill
dictateboltlength.
ALWAYS torque mounting bolts to the values specified for your winch in Table 4 to prevent vibration
during operation.
ALWAYS use class 8.8 metric (grade 5) 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.
Table 4 - Mounting Torque Requirements
Powered
Winches DC6000 DC9000 DC12000L DC12000 DC15000 DC18000
Winch
Mounting
Bolt Size
M10x
1.5pitch
8.8grade
4 Required
M10x
1.5pitch
8.8grade
4 Required
M10x
1.5pitch
8.8grade
4 Required
M12x
1.75pitch
8.8grade
8 Required
M12x
1.75pitch
8.8grade
8 Required
M12x
1.75pitch
8.8grade
8 Required
Fairlead
Mounting
Bolt Size
M8x
1.5pitch
8.8grade
2 Required
M8x
1.5pitch
8.8grade
2 Required
M8x
1.5pitch
8.8grade
2 Required
M12x
1.75pitch
8.8grade
2 Required
M12x
1.75pitch
8.8grade
2 Required
M12x
1.75pitch
8.8grade
2 Required
Winch &
Fairlead
Mounting
Bolt Torque
40ft./lbs. 40ft./lbs. 40ft./lbs. 65ft./lbs. 65ft./lbs. 65ft./lbs.
BEFORE INSTALLING AND USING YOUR POWERED WINCH, READ AND
FOLLOW ALL MOUNTING INSTRUCTIONS AND SAFETY MESSAGES.
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 T-Handle
Instruction/Owners Manual
Winch Assembly
Contactor Control Box
Pendant Remote Control
Pendant Remote Control Socket
Roller Fairlead
2 Gauge Battery Lead
Mounting Footprint Template
Mounting Hardware
Hose Clamps
WARNING

8
1.2.1 Mounting Configurations
Thepay-outdirectionforwirerope/syntheticropeandthecorrectmethodsformountingthewinch
varyaccordingtothedifferentwinchmodels(seepage9).Whenmountingthewinchfootforward,
windtheropefromthetoporbottomofthedrumtowardsthedirectionofthemountingbaseplate.
SeeFigure5,page9.Whenmountingthewinchfootdown,windtheropefromthebottomofthe
drum.SeeFigure6,page9.
1.2.2 Winch and fairlead mounting considerations
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.Makesurethemotor,drumandgearboxhousingarealignedcorrectly.
3.Thefairleaddoesnotmountdirectlytothewinch.
4.Thewire/syntheticropeshallbewoundinaccordancewithTable5,page9.
ALWAYS position fairlead with warning readily visible on top.
WARNING
Templates are not to scale.
Remember that all winches do not mount in the same orientation.
Dashed rectangle represents the cable access hole for foot forward mounting.
DC6000
Minimum
Mounting Surface
DC9000 & DC12000L
Minimum Mounting Surface
DC12000, DC15000 &
DC18000 Minimum
Mounting Surface
Installation Instructions
Figure 2 - Mounting Hole Templates and minimum surface areas

9
Table 5 - Mounting Position Specifications
Electric Winch
Model
Mounting Position Repositioning
Foot Down Foot Forward Foot Down Foot Forward
DC6000 x x 90˚
DC9000 x x 40˚ 90˚
DC12000L x 40˚ 90˚
DC12000 & DC15000 x x 36˚ 90˚
DC18000 x 36˚ 90˚
Under-windonlyonwinches
mountedinafootdown
orientation.
Figure 5 - Foot Forward Mounting Position
Windtheropefromthetoporbottomofthedrum
towardsthedirectionofthemountingbaseplate
forfootforwardmountingwinches.
Over-windorunderwoundon
winchesmountedinafoot
forwardorientation.
Figure 6 - Foot Down Mounting Position
Windtheropearoundthebottomofthedrumfor
footdownmountingcongurations.
Roller
Fairlead
Hawse
Fairlead
Under-Wound
CORRECT
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/synthetic rope and
mounting surface.
The mounting surface must be equal to or greater than the footprint of the winch frame.
WARNING
OnlythemountingorientationsinTable5arepermissableforsafewinchingoperation.Allothersare
improperandinappropriateandwillvoidyourwarranty.
Installation Instructions
Figure 3 - Over Wound Figure 4 - Under Wound

10
1. Setangednutsintopocketsofwinchfeet.
2. Makesurethemotor,drumandgearboxhousingarealignedcorrectly
3. Setwinchinmountinglocation.Conrmrequiredboltlength.
4. InstallboltsandtightentotorquespeciedinTable4,Page7.
The fairlead does not mount directly to the winch.
1.4 Install the Winch
1.4.1 Install the Winch Fairlead
Installation Instructions
Figure 7 - Installation
NOTICE

11
Installation Instructions
1.5 Motor Repositioning
Tochangethemotormountingorientation
usean11mmwrenchandremovethe2
screws.Holdthemotorandpullbackabout
a1/4”androtatethemotorby90degree
incrementstotherequiredposition.Reinstall
thetwoscrewsandtorqueto10ft.-lbs.See
Figure8.
Figure 8 - Motor Position Rotated By 90°
1.5.1 Clutch Repositioning
ChangethepositionoftheFree-SpoolT-handle
accordingtothefollowingsteps.Loosenand
releasetheboltsonthebrakerearcover.Rotate
thegearboxbyproperangleincrements.See
Figure9.Re-assemblythegearboxandrear
brakecover.Torquescrewsto5ft.-lbs.
Remove these
screws to
rotate motor
Figure 9 - T-Handle Cluth Postion & Rotation
DC9000 & DC12000L Models
Rotate by 40˚ Increments DC12000, DC15000, DC18000 Models
Rotate by 36˚ Increments
Remove these
screws to
rotate clutch
Remove these
screws to
rotate clutch
Clutch
Handle
Clutch
Handle
Itmaybenecessarytorotatethemotororclutch.Thiswilldependonthemountingpositionor
variablesthatrestrictaccesstothemotorconnectionsortheclutchhandle.

12
ALWAYS complete the winch installation and hook attachment before installing the wiring.
ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces
chances of “binding”, which can damage the rope.
A minimum of five (5) wraps of steel wire rope and a minimum of ten (10) wraps of synthetic
rope around the drum is necessary to support the rated load.
ALWAYS spool the winch rope onto the drum in the direction specified by the drum rotation
labels on the winch and/or in the documentation. This is required for the automatic brake to
function properly.
1.6 Install the Rope
WARNING
Installation Instructions
Usearollerfairlead(showninFigure10)when
usingwire ropeineitherafootforwardorfoot
downapplication.
UseaHawsefairlead(showninFigure11)when
usingsynthetic rope ineitherafootforwardor
footdownapplication.
Roller
Fairlead Hawse
Fairlead
Roller Fairlead
Theuseofa4wayrollerfairleadcanreducethecontactingfrictionwiththewirerope.Thefairlead
doesnotensurethewireropewillwindontothedruminanorderlymanner.Thepropereetangle
within15°mustbemaintainedforthewireropetowindontothedruminanorderlymanner.Ifthe
propereetangleisnotmaintained,itcanresultindamagetothewinchandwire/syntheticrope.
Figure35onpage21.
Hawse Fairlead
TheuseofaHawseFairleadcanreducethecontactingfrictionwiththesyntheticrope.Analuminum
hawsefairleadisrecommendedbecauseithasnosharpedgesandresistsweardamagemoreeffec-
tivelythanarollerfairlead.Thefairleaddoesnotensurethesyntheticropewillwindontothedrumin
anorderlymanner.Ifthepropereetangleisnotmaintained,itcanresultindamagetothewinchand
syntheticrope.Figure35onpage21.
Figure 10 - Roller Fairlead - Foot Forward Figure 11 - Hawse Fairlead - Foot Down
Figure 12 - Control Box Attachment Method 1 Figure 13 - Control Box Attachment Method 2
1.7 Install Control Box And Wiring
Supplied
Hose
Clamps
Supplied
Bolts

13
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.Thebatteryleadshallbe2gauge
with72”inlengthatmost,otherwiseaconsiderablevoltagedropwilloccur.
Figure 14 - Torque Specification
WARNING
14 N-m
124 in-lbs.
Installation Instructions
1.7.1 Install the Wiring
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14.
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chafeorcutthroughtheinsu-
lation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.
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.
1.7.2 Battery Recommendations & Lead Size
1.7.3 Battery Cable Routing
WARNING

14
Figure 16 - DC6000 Wiring Diagram
Figure 15 - DC9000, DC12000L, DC12000, DC15000, & DC18000 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.
1.7.4 System Check
Installation Instructions
1.7.5 Sealed Reversing Contactor Installation
1. Disconnectthepowerfromyourwinchpriortoperforminganymaintenanceorotherwiseservicing
yourwinch.
2. Removethecontrolboxfromitsmounts.
3. Removethescrewsfromeithersideofthecontrolboxandremovethecover.
4. Takeapictureofthecontactorandthewireplacement.Disconnectthewiresfromthecontactor.
5. Removethecontactorfromthecontrolbox.
6. Replacethecontactor.
7. Replacethewirestothecontactor.Usethewiringdiagramsoryourphotoasareference.
8. Reattachthecontrolboxcover.
9. Remountthecontrolbox.
10.Reconnectpowertoyourwinch.
WARNING

15
1.8 Know Your Wireless Remote
Installation Instructions
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.
WARNING
1.Transmissionrange:15~27m(50~90ft)
2.Receiveroperationvoltage:8~24V
3.Receiverfusecurrentrating:7.5A
4.Protection:IP-66
5.Operatingtemperaturerange:-20°C~+70°C
6.LEDindication:Greenlightforpoweron;Redlight
foroperating;Blinkinggreenforlowbatterylife;
Blinkingredlightforpoorsignalreceived
1.8.1 Wireless Remote and Transmitter Specifications
Wireless
Receiver
Switch Cord W/3Pin plugs
Ø8 X 1500 mm
Wireless
Transmitter
Lithium Battery:
3V CR2032
Transmitter
Strap
LED Indication
1.7.5 Sealed Reversing Contactor Installation Continued
• Sealedreversingcontactordesignedtocontrol
directcurrentmotorsasusedonwinches,cranes,
vehicles,etc.
• IP66ratingperIEC60529(suitableforsubmersible
purpose)
• Silveralloycontactmaterial.
• Mono-blockconstructionsiscompactinsizeand
lightweight
Performance Data
Thermal current rating (100%): 75 Amperes
Intermittent current rating:
 5%Duty  ...................
300Amperes
 30%Duty  ..................
140Amperes
 50%Duty  ..................
110Amperes
 70%Duty  ..................
85Amperes
Typical fault currents can be ruptured
(5ms time con-stant) ............
400Aat48VDCx
Typical voltage drops across contacts
 Per100Amperes .............40mV
MechanicalLife
..............
>5X1000000
Maximum pull-in voltage (coil at 20°C)
IntermittentlyRatedTypes......60%V
ContinuouslyRatedTypes 
.....
66%V
TypicalDrop-OutVoltage 
......
10—20%V
Figure 17 - Sealed Reverse Contactor
Figure 18 - Connection Diagram
Figure 19 - Wireless Remote Components
Figure 20 - Wireless Remote

16
Installation Instructions
1. Install Battery
a.Removethethreescrewsfromthewireless
transmitter.
b.Separate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.
LED Indicator
Cable OUT
Power Button
Cable IN
Cable IN Cable OUT
1. Connect The Wiring
ConnecttheSwitchcordW/3or6Pin
plugstothesocketonthecontrolpack.
ConnecttheRedwiretothepositive(+)
terminalofthebattery.
ConnecttheBlackwiretothenegative(-)
terminalofthebattery.
1.8.2 Wireless Remote and Transmitter Installation
2. Mount the Receiver
Thereceivershouldbemountedinaclearand
drylocation.
Mountonaatsurfacewithatleast2fasteners
(notincluded)throughthe7mmmountingholes
oneachsideofthereceiver.Minimumofone
mountingfastenereachside
1.8.3 Wireless Remote and Transmitter Installation
Figure 22 - Mounting
Figure 21 - Connections
Black
RedFuse
Figure 23 - Battery Replacement
Figure 24 - Operations

17
3. Stop
a.Thesystemwillautomaticallyshutdownthe
transmitterifnotactivatedfor5minutes.
b.PressandholdthePowerButtonfor5sec-
ondstoshutdownthetransmitter.
LED
Indicator
Programming
Button
4. Reset
a.PressandholdtheProgrammingButtonfor5secondsuntiltheRedindicatorilluminates.
b.PressthePowerButtononthetransmitterfor5secondsuntiltheGreenindicatorlightsup.
c.PresstheInorOutbuttononthetransmitteruntiltheRedindicatorlighton
thereceiverturnsoff.
d.Resetisnowcompleted.Pleasenoteonlyoneremotetransmittercanberesetforeachreceiver.
5. Notes
a.Thewirelessremotecontrolandwiredremotecanbeexchangedforactivatingthewinchorjack.
b.BlinkingGreenLEDlightshowsthetransmitterbatteryislow,thebatteryshouldbereplaced
immediately.
c.Pleasenoteonlyoneremotecanberesetforeachreceiver.
d.BlinkingRedLEDforpoorsignal.
1.9 Cable Tensioner
1. Disconnectpowertoyourwinch
2. Removethewireropefromthewinch.
DisengagetheclutchT-handle.
Un-spooltheentirerope,andremoveitfrom
thedrum.
3. Removethewinchfromit’smount.
4. Loosenandremoveallofthetierodbolts
fromonesideofthewinch.
5. Pulleachofthetwohalvesofthewinchabout
oneortwoinchesapartfromthedrum.Fig.26.
6. Looselyinstalltheboltsandsquarenutsinto
themountingplate.Fig27.
7. Pushthewinchsidesbacktogetherwhile
guidingthesquarenutsintothepocketson
theinsideoftheframesides.Fig.28.
8. Replacethetierodbolts.
9. Usinganadjustablewrenchtoholdtheat
spotsonthetierod;torquethetierodbolts
accordingtoTable6,page18.
10.Torquethecabletensionermountingplate
boltsaccordingtoTable6,page18.Fig30.
11.Placethecabletensionerontothewinchas
shown.Fig30.
12.Installthefourbuttonheadcapscrewsand
torqueto20ft.-lbs.Fig30.
Installation Instructions
Figure 26 - Disassemble Winch Halves
Figure 27 - Mounting Plate
Figure 28 - Assemble Winch Halves
Cable Tensioner
Mounting Plate Holes
1.8.3 Wireless Remote and Transmitter Installation Continued
Figure 25 - Resting

18
Installation Instructions
Table 6 - Cable Tensioner Mounting Torque Requirements
Powered
Winches DC6000 DC9000 DC12000L DC12000 DC15000 DC18000
Tie Rod
Bolt Size &
Torque
M8x
1.5pitch
8.8grade
20 ft./lbs.
M8x
1.5pitch
8.8grade
20 ft./lbs.
M8x
1.5pitch
8.8grade
20 ft./lbs.
M10x
1.5pitch
8.8grade
20 ft./lbs.
M10x
1.5pitch
8.8grade
20 ft./lbs.
M10x
1.5pitch
8.8grade
20 ft./lbs.
Cable
Tensioner
Mouniting
Plate Bolt
Size & Torque
N/A N/A N/A M12x
1.75pitch
8.8grade
65 ft./lbs.
M12x
1.75pitch
8.8grade
65 ft./lbs.
M12x
1.75pitch
8.8grade
65 ft./lbs.
Cable
Tensioner
Mouniting
Bolt Size &
Torque
N/A N/A N/A M8x
1.5pitch
ButtonHead
CapScrews,
Nuts,andLock
Washers
8.8grade
20 ft./lbs.
M8x
1.5pitch
ButtonHead
CapScrews,
Nuts,andLock
Washers
8.8grade
20 ft./lbs.
M8x
1.5pitch
ButtonHead
CapScrews,
Nuts,andLock
Washers
8.8grade
20 ft./lbs.
1.9 Cable Tensioner Continued
Figure 29 - Tensioner Mounting Plate Figure 30 - Install Button Head Screws
Torque the cable tensioner
mounting plate bolts
according to Table 6
Install the four button head
cap screws and torque to
20 ft.-lbs
13.Installthelockwashersandnutsontothefourbuttonheadcapscrewswhichprotrudefromthe
backofthecabletensionermountingplate.Torqueto20ft.-lbs.
14.ReinstallthewinchandtorquethewinchmountingboltsaccordingtoTable4,page7.
15.Reinstallthewirerope.
16.Reconnectpowertoyourwinch.

19
Operation Instructions
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.
NEVER touch winch rope or hook while someone else is at the control switch or during winch-
ing operation.
WARNING
Donotshockloadthewinchwhenspooling.Avoidshockloadswhenspoolingbypulsingthecontrol
switchtotakeupwinchropeslack.Shockloadscanmomentarilyfarexceedthewinchandroperatings.
DO NOT power the hook into the fairlead. This could cause damage to the fairlead.
NOTICE
2.4 Safe Working Conditions
2.3 Stretching the Wire Rope
ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces
chances of “binding”, which can damage the rope.
NEVER operate winch with less than five (5) wraps of wire rope and ten (10) wraps of synthetic
rope around the drum. Rope could come loose from the drum, as the rope attachment to the
drum is not designed to hold a load.
Thegoalofstretchingyourwireropeistowrapittightlyonthewinchdrumsothatitcansupportad-
ditionallayersofwire.Itcantakeupto1,000lbs.toproperlystretchlargediametercable.Thiscanbe
accomplisehdwithavehiclesuppliedasdeadweighttostretchtherope.Thisisanexercisethatwill
makeyourwireropelastlonger,avoidtanglesandensureatightlywrappedwinch.Usecaretoevenly
wrapeachlayertopreventdamagetotherope.
2.2 Overloading / Overheating
Thiswinchisratedforintermittentduty.Whenthemotorapproachesstallspeed,veryrapidheat
buildupoccurswhichmaycausemotordamage.Double-lineriggingwillreducetheamperagedraw,
andreduceheatbuildupinthemotor.Thisallowslongercontinualuse.
WARNING
NEVER work around the winch rope while under load.
NEVER step over a winch rope while under load.
ALWAYS use caution when working with electricity and remember to verify that no exposed
electrical connections exist before energizing your winch circuit.
WARNING
WARNING
TheoperatorshouldALWAYSoperatethewinchfromasafepositionwhenpullingaload.Thesafe
areasare:Perpendiculartothewinchrope.
Thesafepositionwillhelppreventthewireropefromstrikingtheoperatorifthewireropefailswhen
underload.
Fullyextendthependantcontrolcordtooperatewinchwheneverpossible.Theoperatormusttryto
maintainatleast8ft.(2.44m)fromthewinchwhileoperating.

20
2.5.1 Handheld Pendant Control
Industrialgradeandwaterproofremote.
DC12000,DC15000andDC18000winches
includesLEDoverheatingindicator.
2.5.2 Connect the remote control
Alwayskeeptheremotecontrolwireclearof
thewinch,wire/syntheticropeandroller/hawse
fairlead.Figure31.
Figure 31 - Connect Remote
2.5 For First Time operation
2.6 Clutch Operation
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.
WARNING
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.
2.6.1 Disengage Clutch For
Free-Spooling
LifttheclutchT-handleupandturnitat90°
counter-clockwiserotationtothe“Disengaged”
position,ropecannowfree-spooloffthedrum.
Figure33.
2.6.2 Engage Clutch For Winching
Toengage,lifttheclutchT-handleupandturnit
90°clockwisetothe“Engaged”position.Never
engagetheclutchwhilethedrumisrotating.
Figure34.
Figure 33 - Disengage Clutch
Figure 34 - Engage Clutch
Disengaged
To engage,
lift and turn
Cable-Out
Figure 32 - Cable Button
Cable-In
Operation Instructions
CAUTION
NEVER engage the clutch while the drum is
rotating.
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.
1.PressandholdtheCableInButtonforrope
windinginoperation.
2.PressandholdtheCableOutButtonforrope
windingoutoperation.
3.Tostopwinching,releasetheCableInorCable
OutButtons.Figure32.
CAUTION