Bulldog Security DC9.0 User manual

DC Series Utility Winches
Owners Manual

CEQUENT™PERFORMANCE PRODUCTS, INC.
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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
Legal Warnings ................................................................ 17
Instructions
Installation Instructions .......................................................... 6
Operation Instructions .......................................................... 11
Maintenance .................................................................. 14
Troubleshooting / Checklist ...................................................... 16
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.

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Before First Operation
• Purchaser/owner must ensure that
product is installed according to
these instructions. Purchaser/owner
must not alter or modify product.
• Understand your winch and its
instructions.
•
•
Never exceed maximum rated ca-
pacity. Refer to stamped markings or
decals on product to obtain rated ca-
pacity.
The winch is rated at the first layer of
wire/synthetic rope on the drum for
intermittent-periodic duty.
Are you ready to pull?
• Your
winch can develop tremendous
pull forces and if used unsafely or
improperly could result in property
damage, serious injury or death.
Ultimately, safe operation of this
device rests with you, the operator.
• NEVER operate this winch when
under the inuence of drugs, alcohol
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 stability
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 use winch rope for towing.
• NEVER use excessive effort to free
spool winch rope.
• ALWAYS take time to use appropriate
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. Dou-
ble 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
horizontally. Short pulls of up to 45
degrees laterally are acceptable;
however without maintaining the
proper eet angle of +/- 5 degrees;
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

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Know Your Winch
Figure 1 - Winch Components
Winch Drum
Contactor
Control Box
Planetary
Gear Box
Clutch
Handle
Motor
Pendant Remote
Control Socket
Pendant Remote ControlRoller Fairlead
(with Mounting Hardware)
Battery Lead Hand Saver
Cable Strap Winch Mounting Hardware Hook

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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 2 - Winch Capacity
WARNING - Do not exceed rated capacity shown in this table.
DC9.0 DC12.0
Rope
Layer
Capacity Length of Rope
on Drum
Rope
Layer
Capacity Length of Rope
on Drum
1st 9,000 lbs. / 4,082 kgs. 20.0 ft. / 6.1 m. 1st 12,000 lbs. / 5,443 kgs. 16.1 ft. / 4.9 m.
2nd 7,350 lbs. / 3,334 kgs. 44.3 ft. / 13.5 m. 2nd 9,563 lbs. / 4,338 kgs. 36.4 ft. / 11.1 m.
3rd 6,200 lbs. / 2,812 kgs. 72.2 ft. / 22.0 m. 3rd 7,948 lbs. / 3,605 kgs. 60.0 ft. / 18.3 m.
4th 5,400 lbs. / 2,449 kgs. 95.1 ft./ 29.0 m. 4th 6,800 lbs. / 3,084 kgs. 83.7 ft. / 25.5 m.
Table 1 - Winch Specifications
Powered Winches DC9.0 DC12.0
Rated Line Pull 9000 lbs. / 4082 kgs. 12000 lbs. / 5443 kgs.
Motor: Series Wound 12V : Input: 4.63 kW / 5.8 hp;
Output: 2.1 kW / 2.8 hp
12V : Input: 5.4 kW / 7.2.hp;
Output: 2.7 kW / 3.6.hp
Gear Reduction Ratio 230:1 230:1
Wire Type -
Max. Cable Diameter
21/64” x 95’ / Ø8.3 mm × 29 m
A7 x 19 Aircraft Cable
13/32” x 83.7’ / Ø10.2 mm × 25.5 m
A7 x 19 Aircraft Cable
Drum Size - Dia.× L 2.48” × 8.8” / Ø63 mm × 223 mm 2.48”× 8.8” / Ø63 mm× 223 mm
Mounting Bolt Pattern 10” × 4.5” / 254 mm × 114.3 mm; 4-M10 10” × 4.5” / 254 mm×114.3 mm; 4-M10
Overall Dimensions -
L×W×H
21.3” × 6.5” × 9.9” /
540 mm × 166 mm × 251 mm
23.2” × 6.5” × 9.9” /
589 mm × 166 mm × 251 mm
Net Weight 82.1 lbs. / 37.2 kgs. 96.6 lbs. / 43.8 kgs.
Clutch (free-spooling) Turn handle
Control Handheld pendant switch
Table 3 - Line Speed And Amp Draw
DC9.0 DC12.0
Line Pull (lbs./
kgs.)
Line Speed
(FPM/MPM)
Current
(A)
Line Pull (lbs./
kgs.)
Line Speed
(FPM/MPM)
Current
(A)
0 19.7 / 6.0 80 0 22.3 / 6.8 100
3000 / 1361 12.5 / 3.8 170 4000 / 1814 13.1 / 4.0 220
6000 / 2722 9.8 / 3.0 260 8000 / 3629 9.8 / 3.0 330
9000 / 4082 6.6 / 2.0 360 12000 / 5443 5.9 / 1.8 450
FPM = Feet Per Minute MPM = Meters Per Minute

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Mounting Hardware Requirements
Four (4) 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 DC9.0 DC12.0
Winch Mounting Bolt Size M10 x 1.5 pitch, 8.8 grade, 4 Required M10 x1.5 pitch, 8.8 grade, 4 Required
Fairlead Mounting Bolt Size M10 x 1.5 pitch, 8.8 grade, 2 Required M10 x 1.5 pitch, 8.8 grade, 2 Required
Winch & Fairlead Mounting
Bolt Torque
40 ft./lbs. 40 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 Handle
Instruction/Owners Manual
Winch Assembly
Pendant Remote Control
Pendant Remote Control Socket
Roller Fairlead
Battery Lead
Mounting Hardware
Hook
WARNING
1.2.1 Winch and Fairlead Mounting Considerations
1.2 Select Mount Location
ALWAYS choose a mounting location that is sufficiently strong to withstand the maximum
pulling 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.
ALWAYS position fairlead with warning readily visible on top.
WARNING

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Installation Instructions
Figure 2 - Mounting Hole Pattern and minimum surface areas
11.57
6.144.50
10.00
.41 x 4
DC9.0 & DC12.0 - Bottom View
Bolt Pattern & Minimum Mounting Surface - Pattern Is Not To Scale
IN
OUT
Figure 3 - Mounting Position
Roller
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
3. The fairlead does not mount directly to the winch.
4. The wire/synthetic rope shall be under wound. Figure 4.

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Installation Instructions
1. Set hex nuts into pockets of winch feet. See Figure 5.
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 5.
5. Wind the rope around the bottom of the drum.
1.4 Install the Winch
Figure 5 - InstallationFigure 4 - Under Wound
Under-wind
only.
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 an under wound orientation.
1.5 Install the Rope
WARNING
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 pulling angle
must be maintained for the wire rope to wind onto the drum in an orderly manner. If the proper pulling
angle is not maintained, it can result in damage to the winch and wire rope. Figure 14 on page 13.
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 pulling angle is not maintained, it can result in damage to the winch
and synthetic rope. Figure 14 on page 13.
Hex Nut
Mounting
Plate
Split Lock
Washer
Hex Head Bolt

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Installation Instructions
Use a Hawse fairlead when using synthetic rope.
Hawse
Fairlead
Figure 7 - Hawse Fairlead
Roller
Fairlead
Use a Roller fairlead with wire rope.rope.
Figure 6 - Roller Fairlead
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.
1.6.2 Battery Recommendations & Lead Size
WARNING
1.6.1 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.
1.6 Wiring
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.
1.6.3 Battery Cable Routing

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Installation Instructions
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
insulation wear or abrasion.
5. FIRST attach red (positive) battery cable, then black (negative) battery cable. Install boots as
appropriate to protect connections.
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.
WARNING
Figure 8 - DC9.0 / DC12.0 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 DC.
1.6.4 System Check
Blue wire (connect motor "A")
Yellow wire (connect motor "F1")
Red wire (connect Motor "F2")
Red long wire assembly (connect battery positive +)
Black long wire assembly – Battery black
connect the ground terminal on the the motor
Black wire assembly (connect motor’s
ground terminal and battery negative -)
Motor
Motor’s grounding terminal

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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
winching 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
additional layers of wire. It can take up to 1,000 lbs. to properly stretch large diameter cable. This can
be accomplished 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.

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2.5.1 Connect the Remote Control
Always keep the Industrial grade and waterproof
remote control wire clear of the winch, wire/syn-
thetic rope and roller/hawse fairlead. Figure 9.
Figure 9 - 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
rotating.
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
Turn the handle 180° counter-clockwise rotation
to the “Disengaged” position, rope can now
free-spool off the drum. Figure 11.
2.6.2 Engage Clutch For Winching
To engage, turn the clutch handle 180° clockwise
to the “Engaged” position. Never engage the
clutch while the drum is rotating.
Figure 12.
Figure 11 - Disengage Clutch
Figure 12 - Engage Clutch
Figure 10 - Remote Control Operation
Operation Instructions
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 10.
CAUTION
Cable-Out Cable-In
Disengaged
Engaged

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2.7 Winching Principles
2.7.2 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/synthetic rope
failure. A blanket or heavy jacket are acceptable
substitutes for the damper. Place 5-6 feet from
hook. Figure 15.
2.7.3 Snatch Block
For pulls over 70% rated line pull, we recom-
mend the use of the snatch block/pulley block to
double line the wire/synthetic rope. Figure 16.
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.
A winch double lined with a snatch block creates
a mechanical leverage cutting the effort required
by nearly half.
The use of one snatch block shows an indirect
pull where the vehicle is limited due to unsuitable
ground or obstruction. The pull on the load is
the actual line pull of the winch. If more than one
snatch block is used, they must be located at
least 40" (100 cm) apart. Figure 16.
Figure 16 - Snatch Block
Snatch
Block
Operation Instructions
2.7.1 Pulling Angle
Locate a suitable anchor such as a strong tree
trunk or boulder. Always use a sling as an anchor
point.
DO NOT attach the clevis hook back onto the
cable as this could cause damage to the cable.
Figure 13.
CAUTION
Figure 13 - Suitable Anchor
Figure 14 - Pulling Angle
Figure 15 - Dampen Wire Rope
DO NOT winch from an acute angle as the
wire rope will pile up on one side of the drum
causing damage to wire/synthetic rope and the
winch. Figure 14.
CAUTION
Short pulls from an angle can be used to straight-
en the vehicle. Long pulls should be done with
the wire rope at a 90° angle to the winch/vehicle.
Wrong
Rope Hooked
To Itself
Right
Sling
Wrong
Right
LOAD
LOAD
ANCHOR POINT
ANCHOR POINT

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2.8 Tips For Prolonging The Life Of Synthetic Rope
• Check the rope for damage or wear before each use.
• Abrasion can damage or weaken your synthetic rope, protect your rope from rubbing against sharp objects.
• An aluminum hawse fairlead is recommended because it has no sharp edges and resists damage
more easily than a roller fairlead.
• Keep your synthetic rope clean and dry. To clean it, spool out the rope, rinse it with a hose, and let it
dry completely before re-spooling.
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/synthetic
rope. If you power out over 25 feet, let the winch cool for 15 minutes.
Do not use the winch as a lifting device or a hoist for vertical lifting.
WARNING
The “Power-Out” function should be used for relieving tension on the rope,
not for extended distances.
CAUTION
Operation Instructions
3.1 Wire Rope Replacement
1. Disengage the clutch 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 per Figure 17 and
insert it into the hole on the drum core. Tighten the set-screw downwards to secure the wire rope.
4. A minimum of ve (5) wraps of wire rope and ten (10) wraps of synthetic rope around the drum is neces-
sary to support the rated load.
5. Respool under lead. Stretching the wire rope. See Page 7.
Figure 17 - Wire Rope Replacement
Disengaged
Engaged
Maintenance
ALWAYS pre-stretch rope and re-spool under load before use. Tightly wound rope reduces
chances of “binding”, which can damage the rope.
WARNING

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Maintenance
3.2 Synthetic Rope Replacement
1. Disengage the clutch handle, remove the existing rope and replace the hawse fairlead if necessary.
2. Un-spool the rope from the drum. Remove the set-screw from the drum.
3. Cut the end of the new rope at 45° and apply 2-3 wraps of electrical tape to hold the cut strands in
place. This will ease assembly.
4. Remove Rope.
5. Thread rope through a hawse fairlead and under the drum per Figure 18, insert the rope through the
hole on the drum with 6” – 8” to spare.
6. Place rope across the drum and tape the end down to hold it in place. See Figure 18. Lightly tighten
the set-screw to squeeze the rope, do not over tighten.
7. A minimum of ten (10) wraps of rope around the drum is necessary to support the rated load.
Figure 18 - Synthetic Rope Replacement
• Check the wire/synthetic 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/synthetic rope onto the drum with your hand, use a
hand saver cable strap.
Figure 19 - Mixed Winding
Tape
3.3 Lubrication
Do not attempt to disassemble the gear box. Repairs should be done by the manufacturer or an
authorized repair center. The gearbox has been lubricated using a high temperature lithium grease and
is sealed at the factory. No internal lubrication is required. Regularly lubricate clutch handle with light
oil. Never lubricate the brake system.
3.4 How To Order Replacement Parts
Use only Cequent Performance Products’ parts or parts of equal quality for repair. Replacement parts
are available through Cequent Performance Products’ Tech Service Department. Please specify
product model number.

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Troubleshooting / Checklist
Table 5 - Troubleshooting
Symptom Possible Cause Suggested Action
Motor does not
turn on
Switch Assembly not connected properly Insert Switch Assembly all the way into the
connector.
Loose battery cable connections Tighten nuts on all cable connections.
Defective Switch Assembly Replace Switch Assembly.
Defective motor Check for voltage at armature port with Switch pressed. If voltage is present, replace
motor.
Water has entered motor Allow to drain and dry. Run in short bursts
without load until completely dry.
Motor runs but cable
drum does not turn Clutch not engaged Turn clutch to the “In” position. If problem
persists, a qualified technician needs to
check and repair.
Motor runs slowly or
without normal power Insufficient current or voltage
Battery weak recharge. Run winch with
vehicle motor running.
Loose or corroded battery cable connec-
tions. Clean, tighten, or replace.
Motor overheating Winch running time too long Allow winch to cool down periodically.
Motor runs in one
direction only Defective Switch Assembly
Loose or corroded battery cable or motor
cable connections. Clean and tighten.
Repair or replace switch assembly.
Table 6 - Checklist
Before First
Operation After EVERY Use Every 90 Days
Read, understand and follow the warnings and instructions in
this manual. X
Check all fasteners and verify they are at the proper torque.
Replace fasteners as needed. X X
Check that the wiring is correct and the connections are tight. X X
Check there are no bare or exposed wires, terminals, or dam-
age to the cables (chafing/cutting).
Repair or replace wires as needed. X X
If damaged, discontinue use and replace rope immediately. X X X
Keep winch, rope, and switch control free from contaminants.
Use a clean rag or towel to remove any dirt and debris. X

CEQUENT™PERFORMANCE PRODUCTS, INC.
17
To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand
and follow the warnings and instructions in this manual.
WARNING
Mark Warning
This is a Class B product, in a domestic environment, this product may cause radio interference, in which case
the user may be required to take adequate measures.
Standard compliance of EC Directives
The EC directive includes the following individual directives:
Machinery Directive 2006/42/EC
It applies to independently functional machinery or the interlinking machines to form entire systems. The
complete machine and plant must always fulfill the directive.
Electromagnetic Compatibility Directive (EMC) 2004/108/EC
It applies to most electrical and electronic apparatus, that is, finished products and systems that include
electrical and electronic equipment to ensure that the electromagnetic disturbance generated by apparatus
does not exceed a level allowing radio and telecommunications equipment and other apparatus to operate as
intended, and that apparatus has an adequate level of intrinsic immunity to electromagnetic disturbance to
enable it to operate as intended.
Legal Warnings