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