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