Bulldog Security HW8000 User manual

HW Series Hydraulic 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
.............................6
12
... 15
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

3
Before First Operation
• Purchaser/ownermustensure
thatproductisinstalledac-
cordingtotheseinstructions.
Purchaser/owner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ropeonthedrum
forcontinuousduty.
• Thewinchisratedattherst
layerofwireropeonthedrum
forS3 10%ED & 1 min/10 min
rating intermittent periodic duty.
Notcontinuousduty.
Are you ready to pull?
• NEVERoperatethiswinchwhen
undertheinuenceofdrugs,
alcoholormedication.
• ALWAYSremovejewel-
ry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other-
wise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op-
eratingwinch.Frayed,kinked
ordamagedwinchropemust
bereplacedimmediately.
Damagedcomponentsmustbe
replacedbeforeoperation.
• Periodicallycheckmounting
hardwareforpropertorqueand
tightenifnecessary.
• ALWAYSremoveanyelementor
obstaclethatmayinterferewith
safeoperationofthewinch.
• Wireropecanbreakwithout
warning.Alwayskeepasafe
distancefromthewinchand
ropewhileunderaload.
• NEVERwrapwinchrope
backontoitself.Useachoker
chainorstrap.
• ALWAYSensurehook
latchisclosedandnotsupport-
ing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ap-
propriate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un-spool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horizontally.Without
maintainingthepropereetan-
gleof±5degrees;(SeeFigure
10page14)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dam-
agewinchropeorwinch.
• ALWAYSensuretheclutchis
fullyengagedordisengaged.
• NEVERsubmergewinchin
water.
Important Safety Messages

4
Figure 1 - Winch Components
Know Your Winch
Winch Drum
Over-Center
Valve
Planetary
Gear Box
Clutch
T-Handle
Hydraulic
Motor
Roller Fairlead
(with Mounting Hardware)
Mounting Footprint
Template Hand Saver Cable Strap
Drum
Drag Bolt

5
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industrialwinchesareratedattheirrstlayercapacities.
Table 1 - Winch Capacity
HW8000 HW12000 HW15000
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 8,000lbs./
3,630kgs.
25.6ft./
7.8m.
1st 12,000lbs./
5,440kgs.
23ft./
7m.
1st
15,000lbs./
6,800kgs.
23.3ft./
7.1m.
2nd 6,669lbs./
3,025kgs.
56.1ft./
17.1m.
2nd 10,075lbs./
4,570kgs.
50.9ft./
15.5m.
2nd
12,273lbs./
5,567kgs.
51.5ft./
15.7m.
3rd 5,717lbs/
2,593kgs.
91.9ft./
28m.
3rd 8,684lbs./
3,939kgs.
82ft./
25m.
3rd
10,390lbs./
4,713kgs.
85ft./
25.9m.
4th 5,002lbs/
2,269kgs.
131ft./
40m.
4th N/A N/A 4th
9,008lbs./
4,086kgs.
123.4ft./
37.6m.
5th N/A N/A 5th N/A N/A 5th
7,950lbs./
3,606kgs.
165ft./
50.3m.
Table 2 - Winch Specifications
Powered
Winches HW8000 HW12000 HW15000
Wire rope 3/8”x131’(9.5mmx30.5m)
1,960N/m2EIPSGrade
Aminimumbreakingstrengthof
15,663lbf./69.8kN
1/2”x82’(12.7mmx25m)
1,960N/m2EIPSGrade
Aminimumbreakingstrengthof
22,552lbf./100.5kN
1/2”x165’(12.7mmx50.3m)
1,960N/m2EIPSGrade
Aminimumbreakingstrengthof
22,552lbf./100.5kN
Brake
Dragbrakeandover-centervalveprovidedfor100%braking.
Clutch (free-
spooling)
TurnclutchbyaergonomicT-handleforrapidwireropepayout.
Table 3 - Line Speed at 15.9 g/min (60 l/min)
HW8000 HW12000 HW15000
Rope
Layer
Line Speed
(FPM/MPM)
Rope
Layer
Line Speed
(FPM/MPM)
Rope
Layer
Line Speed
(FPM/MPM)
1st 49/15 1st 36/11 1st 30/9
2nd 59.7/18.2 2nd 43.3/13.2 2nd 35.8/10.9
3rd 69.8/21.2 3rd 51.2/15.6 3rd 42/12.8
4th 79.4/24.2 4th N/A 4th 48.6/14.6
5th N/A 5th N/A 5th 55/16.8
FPM = Feet Per Minute MPM = Meters Per Minute Based on Operation Pressure 2175 PSI / 150 Bar.

6
Mounting Hardware Requirements
Eight(8)WinchMountingBoltsandtwo(2)FairleadMountingBolts,Nuts,andWashersarerequired.Refer
toTable4onpage9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 page 9 to
prevent vibration during operation.
ALWAYS use a grade 8 class 12.9 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 HYDRAULIC 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 hydraulic lines.
1. Before Installation
WARNING
Installation Instructions
1.1 Inspect Parts
Hand Saver Cable Strap
Clutch T-Handle
Instruction/Owners Manual
Winch Assembly
Roller Fairlead
Mounting Footprint Template
Mounting Hardware
Drum Drag Bolt
1.2 Select Mount Location
ALWAYS choose a mounting location that is sufficiently strong to withstand the maximum
pulling capacity of your winch.
Templates are not to scale.
WARNING
HW8000 & HW12000 DIMENSIONS
WARNING
Figure 2 - Template

7
Installation Instructions
HW15000 DIMENSIONS
HW8000 & HW12000 FOOTPRINT
HW15000 FOOTPRINT
Figure 3 - Template

8
Installation Instructions
1.2.1 Winch and Fairlead Mounting
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
1.Makesurethewinchisalignedcorrectly
2.Setwinchinmountinglocation.Conrmrequiredboltlength.
3.InstallboltsandtightentotorquespeciedinTable4onPage9.
1.3 Install the Winch
Figure 4

9
1.3.1 Install the Winch Fairlead
Installation Instructions
Table 4 - Mounting Torque Requirements
Powered
Winches HW8000 HW12000 HW15000
Winch
Mounting
Bolt Size
1/2”–13pitch
8.8grade
8 Required
1/2”–13pitch
8.8grade
8 Required
9/16”–12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
M12x
1.75pitch
8.8grade
2 Required
Winch
Mounting
Bolt Torque
119ft./lbs.
161N-m
119ft./lbs.
161N-m
169ft./lbs.
229N-m
Fairlead
Mounting
Bolt Torque
20ft./lbs.
28N-m
20ft./lbs.
28N-m
65ft./lbs.
88N-m
1. Disconnectpowertothehydraulicpumpordisconnectthehydrauliclinestothewinch.
2. PlacethecabletensionerontothewinchasshowninFig5.
3. Installthefourbuttonheadcapscrewsandtorqueto20ft.-lbs.
4. Installthelockwashersandnutsontothefourbuttonheadcapscrewswhichprotrudefromthe
backofthemountingplate.Torqueto20ft.-lbs.
1.4 Cable Tensioner Installation
Figure 5 - HW8000, HW12000, & HW15000 Cable Tensioner
Cable Tensioner
Button Head Cap Screw
Install cable tensioner prior to Installing rope.
NOTICE

10
Installation Instructions
Figure 7 - HW8000, HW12000, & HW15000 Installation Diagram
Uponcompletionofinstallation,checkwinchforproperoperation.
1.6 System Check
Advantage:Professionalwinchsystem
for“working”applications,costeffective,
extremelypowerful,reliable,lightweight,
andvariablelinespeedforhighworkrate.
ALWAYS complete the winch installation and hook attachment before hooking up the
hydraulic pump.
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 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.
1.5 Install the Rope
WARNING
Roller Fairlead
Theuseof4waysrollerfairleadcanreducethecontactingfrictionbecausethefairleadrollerscontact
withthewirerope.Butthefairleaddoesnotinsurethewireropewillwindontothedruminanorderly
manner.Thepropereetanglewithin±5°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rope.
Cable Tensioner
Thepurposeofcabletensionerdeviceistokeepthewirerope
tightonthedrumwhilethewinchisinfreespoolmodeorwhile
thereisnoloadonthewirerope.
Figure 6

11
Hydraulic Fluid
• Thehydraulicuidshouldbeahighgrade,petroleumbaseduid,withrust,oxidationandwear
resistance.Fluidcleanlinessandoperatingviscosityarecriticaltowinchreliability,efciencyand
servicelift.
Hydraulic Pump
• Tomaintainthemaximumperformance,thehydraulicpumpmustsupplythemaximumowof
hydraulicuidatthehydraulicpressurestatedinspecication.
Hydraulic Control Valve
• Thecontrolvalvemusthaveafour-wayspringreturntoneutralfeature,whichprovidesforopen
owfromthepressureportsofthewinchtothereservoirinneutralpositionofthecontrol(motor
spool).
Hydraulic Pressure Relief
• Thehydraulicsystemrequiresapressurereliefvalvesetattheoperatingpressured.
• Failuretousethecorrectpressureandowmayresultindamagetothewinch,propertyorpersonal
injury.
Hydraulic Reservoir
• Thehydraulicreservoirhassufcientcapacitytoprovidegoodheatdissipationinordertoprevent
over-heatingofthehydraulicuid.
• Mustbettedwithanoilllerdevicecomprisingstrainerandlterandadipstick.Thecapacityof
thetankshouldbeatleast60liters.
Over-Center Valve / Counterbalance Valve
• Givesmoothlycontrolledwinchoutwhenunderloadandtoprovidefulldynamicbraking.Itmustbe
installedtoholdfullload.
• ThePortAofover-centervalvemeanstheinletportofoilfromreservoirandthePortBmeaningthe
returnportofoiltoreservoir.
• Over-centervalveisastandardaccessoryfortheHWserieswinch.
Hydraulic Hoses
• Thefollowinghydraulichosesarerecommendedformaximumefciencyofthehydraulicwinch.
Thebiggernominalborehose,thebetterwinchperformance.
• Allhoselengthsarekepttoaminimumbecausepressureandowlossisincreasedashoselength
increases.
• Pressureandreturnlinesinexcessof3.5meter(11.5feetv)shouldbecompensatedwithanin-
creaseinnominalboresize.Motordrainlinepipeshallberatedat1/4”BSPN.B.
Inletline .......................11/4”–11/2”nominalbore(N.B.)fromreservoirtopump
Returnline .....................1”(N.B.)fromcontroltoreservoir
Pressurehoses..................1/2”(N.B.)fromcontrolvalvetoover-centervalve
Installation Instructions
1.6 System Check (Continued)

12
2.1 Spooling in Under Load
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
2.2 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 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
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.
WARNING
ALWAYS use supplied hand saver cable strap whenever spooling winch rope in or out, during
installation or operation to avoid injury to hands and fingers.
WARNING
Operation Instructions
2.3 Safe Working Conditions
NEVER work around the winch rope while under load.
NEVER step over a winch rope while under load.
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.

13
2.4 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.
Operation Instructions
2.4.2 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8.
2.4.3 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9.
Figure 8 - Disengage Clutch
Figure 9 - Engage Clutch
Disengaged
To engage,
lift and turn
2.4.1 Drum Drag Bolt
Thedragissetbythefactory.Intime,thedragmayneedadjusting.Adjustthedragtocontrolfree-
wheelingofthewinchdrum.Tomaintainatightdrum(resistsdrumrotation)turnthenylonboltby
quarterturnincrements.Thedrumshouldbetightenoughtoresistrotationandlooseenoughtoallow
cabletobefreewheeledoffofthedrumforuse.Tightenthejamnutto6ft./lbs.
CAUTION
NEVER engage the clutch while the drum is rotating.

14
2.5.2 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ropefailure.Placeinthemiddlethirdofaliverope.
Figure11.
2.5.3 Snatch Block
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lever-
age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12.
Figure 11 - Recovery Damper
Figure 12 - Snatch Block
Snatch
Block
Operation Instructions
ThePower-Outfunctiondrivesthewinchmotoragainstthebrakewhichissimilartodrivingyour
vehiclewiththeparkingbrakeengaged.DonotusethePower-Outfunctionforloweringaload--
winchesarenotdesignedtobeusedashoists.Usethefree-spoolfunctiontopayoutwirerope.
IfyouPower-Outover25feet,letthewinchcoolfor15minutes.
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
2.5.1 Calculating Fleet Angle
Toobtainthebestwire/syntheticropeservice,thedirectionof
pullwillbeonahorizontalwithin±15degreesandperpendicular
tothecenterlineofthewinchdrumwithin±5degrees.However
withoutmaintainingthepropereetangle;theropewillpileonto
onesideoftheropedrumandpossiblydodamagetotherope
orwinch.Re-spoolyourwinchasrequired.
2.5 Winching Principles Figure 10 - Fleet Angle
Roller
Fairlead

15
Maintenance
3.1 Wire Rope Replacement
1. DisengagetheclutchT-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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aroundthedrumisnecessarytosupporttheratedload.
Figure 13 - Wire Rope Replacement
Engaged Lift and
turn to
disengage
•Check the wire rope. Beforewinching,makesuretherope
iswoundonthedrumevenly.Ifthereismixedwinding,itis
essentialtorewinditevenly.
• Becarefultokeeptheropeundertension.Neverguidea
wireropeontothedrumwithyourhand,useahandsaver
cablestrap.
3.2 Brake Adjustment
Undernormaluse,thebrakemechanismshouldnotrequireanyadjustment.Ifthebrakefailstohold
aload,thebrakediscmaybewornandrequireadjustmentorreplacement.Whenthebrakewearsto
thepointthattheloadbeginstoslip,thebrakecanbeadjustedasfollows:
1. Loosentheboltonthebrakecoverandtakeouttheretainingrings
2. Insertspacers/washerstomaintainthebrakespacerbetweentobe2.2±0.25mm
3. Makesuretheclutchbaseplateisrotatedcounter-clockwiseby150–180degree
Figure 15 - Brake Adjustment
Figure 14 - Mixed Winding

16
Maintenance
3.3 Lubrication
Allmovingpartsinthewincharepermanentlylubricatedatthetimeofassembly.Undernormalcon-
ditionsfactorylubricationwillsufce.Ifre-lubricationofgearboxisnecessaryafterrepairordisas-
semblyuseShellEP2orequivalentgrease.RegularlylubricateClutchT-handlewithlightoil.Never
lubricatethebrakesystem.

17
Troubleshooting
Table 5 - Troubleshooting
Symptom Possible Cause Remedy
Winch will not
pull load
Motor may be damaged Remove and disassembly motor and examine all parts and replace
any that are worn or damaged
No oil supply to winch Check oil supply line connections
and hoses
System not delivering full pressure
to winch Confirm pump is running to a high- er setting
Winch is Overload Reduce load to within rated
capacity
The pressure is not adequate to
power the load, or the back pres-
sure is too high
Check the pressure on each side of
the hydraulic motor
Winch is mechanically binding up
Loosen, but not remove, the bolts
that are attaching the tie bar and
support racks. Rotate the drum,
making sure that it turns freely
without sticking. Tighten the bolts.
The brake is not releasing This requires disassembly of the brake assembly. Remove and
replace the brake assembly.
Winch will not
pay out
Poor locking of 2nd stage ring gear Clean any burs left on the ring gear
The gear train is mechanically
bundling up
This requires disassembly of the
brake assembly. Remove and
replace the brake assembly.
Winch is mechanically binding up Same as above
Damaged clutch T-handle linkage Replace or remove the clutch
assembly
Oil leakage
Damaged drum seals Replace drum seal
Damaged drum flanges Replace drum
Front seal in the hydraulic motor
shaft has failed Replace or repair the motor
Excessive noise Low oil level Refill oil
Oil flow too high Check oil flow rate
Fail in immediate
stop after power
off
Fail in installing or damaged over-
center valve Check over-center valve
Wrong oil flow direction of port A &
B on the over-center valve Check over-center valve
Damaged brake assembly Replace or repair brake assembly
Drum noise
Insecure mounting Check mounting
Low oil flow Check flow rate
Low relief Check relief valve setting

18
Checklist
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
If damaged, discontinue use and replace
rope immediately. XXX
Keep winch, rope, and switch control free
from contaminants. Use a clean rag or towel
to remove any dirt and debris. X
To prevent SERIOUS INJURY, DEATH and PROPERTY DAMAGE, you should read, understand
and follow the warnings and instructions in this manual.
WARNING