DCD TUF-Lugger Lite Electric Lifting Cable Puller User Manual
Contents
1. rope can also move the load in an unpredictable or dangerous way A stretched rope can recoil and bring your hand towards the winch causing severe injuries NEVER WRAP THE ROPE AROUND YOUR HAND CAUTION ALWAYS WEAR GLOVES 3 2 2 Rope maintenance CAUTION The rope and its ends should be inspected regularly to detect wear Please refer to CI 2001 Document FIBER ROPE INSPECTION AND RETIREMENT CRITERIA from the Cordage Institute available at www ropecord com for the procedure and criteria of scrapping the rope 8 uamphbsargank 29 dreuammbsarqank 2 11 7 af tc K pij bcjPcWA 7 070 Nnt c85 J ARAPMB amp 706 5541 2 8 4 47121 You will find a chart located at the end of this manual to better help you register your observations CAUTION IF YOUR ROPE IS DIRTY WASH IT DIRTY ROPES DETERIORATE FASTER AND CAUSE PREMATURE WEAR OF THE PARTS IN CONTACT WITH THE ROPE SUCH AS THE CAPSTAN DRUM AND ROPE GUIDE 3 2 3 At the end of the rope 3 2 3 1 Recommendations Since the TUF Lugger Lite Lifting Cable Puller Electric can be used for pulling and lifting there are some guidelines to follow 3 2 3 2 1 When pulling 1 For pulling loads you have to attach the load to the end of the rope Even if a simple knot can do the job we recommend the installation of a hook with the bowline knot figure 1 on the right because it can be easily undone if you need to change2. Using the winch without the rope grabbing system allows you to release the tension and benefit from the elasticity of the rope to restart pulling and let the motor reach its maximum power To disengage the rope grabbing system open the spring loaded cam upwards and let it rest on the frame of the rope grabbing system figure 1 no 1 To re engage it lift it upward again and bring it back towards the pulling rope figure 1 no 2 3 4 3 1 Releasing the tension CAUTION ALWays WEAR GLOVES WARNING STRETCH EQUALS DANGER DANGER DO NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT 3 4 3 1 1 When pulling with the rope grabbing system engaged If the rope grabbing system is used when you stop pulling with the TUF Lugger Lite Lifting Cable Puller Electric the rope grabbing system engages therefore applies pressure on the rope and keeps it under tension To release it follow steps 1 to 6 of section 3 4 2 3 3 4 3 1 2 When pulling with the rope grabbing system disengaged If the rope grabbing system is not used when you stop pulling with the TUF Lugger Lite Lifting Cable Puller Electric you simply have to release tension gradually to lower the winch gently to the ground 3 5 If the TUF Lugger Lite Lifting Cable Puller Electric doesn t work DAN
3. WET 1 READ IV CAREFULLY PRODUCTS BEFORE USE Since 1980 TUF Lugger Lite Lifting Cable Puller Electric 41000 500 USER MANUAL Maximum pulling force single line 1800 Ib 820 kg Rated lifting capacity single line 550 Ib 250 kg dreuamprbsargank 2 11 7 _af tc K m 7 0702 nh ARNPMB amp 065541 zD val 4 447121 uamphbsargank 29 druammbsarqank 2 11 7 _af tc K pj bcjPcWA 7 070 M nhc85 U ARAPMB 6 706 5541 z 8 4 49121 Summary Introduction p 3 1 0 Safety guidelines p 3 1 1 Safety messages p 3 1 2 Labels p 4 1 2 1 Serial number and warning label p 4 1 22 Rope DANGER label p 4 1 3 Safety information p 4 2 0 Before first use p 6 2 1 Upon receiving the winch p 6 2 2 Capstan drum p 6 3 0 Winch usage p 7 3 1 Working cycle p 8 3 2 Rope p 8 3 21 Rope type 8 3 2 2 Rope maintenance p 8 3 23 At the end of the rope p 9 3 2 3 1 Recommendations p 9 3 2 3 1 1 When pulling p 9 3 2 3 1 2 lifting Rope with buried eyed splice p 9 3 3 Winch anchors p 10 3 3 1 Using the polyester sling p 10 3 3 2 Using the hitch plate winch anchor for tow balls p 10 3 3 3 Using the winch support plate with square tubing p 11 3 3 4 Using the winch support plate with Heck Pack system for European balls p 12 3 3 5 Using the tree
4. 4706 5541 2 DEN 4 49121 5 4 Exploded view and parts list 62 re Go 6 9 lt lt 62926206242 Ev Gv zv G9 68 Cv UT 87 7 23 uamphbsargank 29 dmuammbsaqank 2 11 7 af tc K pj bcjPcWA 7 070 M nhc85 U ARAPMB 6 706 5541 2 8 4 49121 PART NUMBER DESCRIPTION 1 31 0011 HCS 1 4 20 X 2 1 4 GR5 ZN i 2 10 0102 DRUM RETAINING WASHER 1 3 42110 337 SAFETY LIP FOR CAPSTAN DRUM 3 3 8 1 4 10 0043 SPACER FOR SAFETY LIP 1 5 31 0025 BHCS 1 4 20 X 3 4 SS 2 6 100106 ROPE GUIDE FOR CAPSTAN DRUM 85 MM 1 7 31 0010 HCS 1 2 13 X 6 GR5 ZN 1 35 0004 FLAT WASHER 1 2 ZN 4 9 10 0098 BUSHING FOR SAFETY HOOK 2 10 42430 020 SAFETY HOOK 3 4 TON 2 13 31 0019 HCS 3 8 24 X 1 GR5 ZN 3 14 10 0073 ADPATOR FOR HANDLE 41000 500 50Hz P 1 15 ELECTRIC BOX 16 10 0080 ELECTRIC BOX MACHINED 1 17 33 0004 K LOK 10 24 ZN 4 18 42 0020 2 POLES 240 VOLTS 50Hz CONTACTOR OR 60Hz 1 19 00116 ELECTRIC WIRE 14 AWG FOR CONTACTOR 1 20 31 0021 MACHINE SCREW 10 24 X 1 2 ZN PAN HEAD SQ DR 3 21 42 0010 STRAIN RELIEF CONNECTOR 1 2 WITH NUT W TIGHTENIG RING 1 23 42 0007 1 2 LIQUIDTIGHT STRAIN RELEF CORD CONNECTOR 4 24 10 0114 ELECTRIC CORD 14 3 AWG FROM MOTOR 1 2
5. 4 Figure 1 no 4 Release the tension applied to the rubber handle this will re engage the rope grabbing system You can now let go the pulling rope and grab it further 5 Repeat steps 1 to 4 until the load is at desired position or completely lowered 6 Once at desired position let the rubber handle go this will re engage the system if needed 3 4 2 4 Sending the rope back down After lifting objects you may want to send the rope back down Since there is no reverse on the winch and friction is in cause simply disengage the rope grabbing system remove the rope from the capstan drum to eliminate friction and let the rope back down If the rope does not come down you may have to attach a small rope to it prior to lifting in order to pull it back down 3 4 3 Pulling To pull a load follow the steps found in section 3 4 1 However when pulling a load on the ground that does not risk falling or rolling back you may want to disengage the rope grabbing system If you do not and the load get stuck you may have trouble getting some slack since the rope will already be stretched to its maximum and the rope grabbing system will be very hard to disengage uamphbsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 M nhc85 U ARAPMB amp 706 5541 2 DVBI 4 49121 WARNING IF THERE IS ANY RISK THE LOAD MAY FALL OR ROLL BACK DO NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM
6. purchaser The original purchaser is defined as the party or entity which purchases the winch and or accessories from an authorized DCD Design amp Manufacturing Ltd retailer as shown by the original invoice The warranty ownership is transferable provided the end user has a copy of the original purchaser s invoice This warranty does not apply to wear parts defined as being in contact with the rope while winching The TUF Lugger Lite Lifting Cable Puller Electric is covered as follow Winch components o Private use Two 2 year warranty service by DCD Design amp Manufacturing Ltd and or its retailers o Commercial use One 1 year warranty service by DCD Design amp Manufacturing Ltd and or its retailers Motor The Baldor motor is warranted by Baldor and the duration varies according to country and usage All Baldor service centers can repair the winch motor under warranty Hang on to your proof of purchase invoice with serial number It will be used to establish the beginning of the warranty period DCD Design amp Manufacturing Ltd will replace or repair at its option any defective product All other TUF Lugger Lite accessories are covered by a complete one 1 year warranty Please refer to the DCD Design amp Manufacturing Ltd warranty policies on www dcddesign com if you have any questions 22 uamphbsargank 29 2 11 7 af tc K pij bcjPcWA 7 070 M J ARAPMB
7. A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE CAUTION MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 3 3 5 Using the pole mount with anchor strap 42200 040 The pole mount is intended to use with either the winch support plate 42200 010 or the vertical pull winch support 42200 050 Therefore you must first install the pole mount To do this follow these steps 1 Figure 1 Place the pole mount at the base of the tree or pole Insert the sling s hook into the anchor point on the left then feed the sling s end through the ratchet system 2 Figure 2 Slide the whole set up upward to the desired height and remove the supplied wrench 3 Figure 3 Tighten the sling with the wrench while making sure the rubber pads are properly positioned The pads should offer maximum contact surface with the tree or pole Uampibsargank 2 2 11 7 af tc K pi bcjPoWA 7 070 M nhc85 ARAPMB amp 706 5541 2 Dv l 4 49121 3 3 5 1 With the winch support plate 42200 010 After the installation of the tree pole mount section 3 3 5 follow these steps 1 Figure 1 Insert the winch support plate onto the square tubing of the pole mount 42200 040 and fasten it down with the hitch pin and R pin Note Its lateral movement can be adjusted by positioning the bolts into the square holes 2 Figure 2 A
8. LIFTING IT IS RECOMMENDED TO HAVE A 10 TO 1 SAFETY FACTOR FOR ALL ACCESSORIES 5 Uampibsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 85 J ARAPMB 706 5541 2 DVBI 4 47121 DANGER IT IS STRICTLY FORBIDDEN TO LIFT LOADS WITH A WEIGHT GREATER THAN TO THE RATED LIFTING CAPACITY 550 LB 250 KG TO LIFT LOADS THAT IMPAIR THE OPERATOR S VISIBILITY OR THAT COULD COLLIDE WITH OTHER MOVING LOADS OR WITH ADJACENT STRUCTURES USE THE WINCH TO LIFT PEOPLE ALLOW PEOPLE TO PASS UNDER A SUSPENDED LOAD LIFT LOADS THAT ARE POORLY SLINGED LEAVE SUSPENDED LOADS UNATTENDED ALLOW OTHER PEOPLE TO USE THE WINCH 2 0 Before first use 2 1 Upon receiving the winch Inspect the box to detect any apparent damage If there is damage or missing parts inform the carrier immediately 2 2 Capstan drum Your TUF Lugger Lite Lifting Cable Puller Electric is equipped with the 3 3 8 85 mm diameter capstan drum and the 5 127 mm diameter safety lip If you wish to change the drum for the 2 1 4 57 mm drum sold separately you will also need to purchase and install the 4 5 8 117 mm diameter safety lip To do so follow these simple steps The tools required to change the drum are e A 5 32 4 mm hex wrench included with your winch 7 16 11 mm wrench or adjustable wrench not included 1 Figure 1 Remove the two bolts holding the rope guid
9. PAGE AS IT WILL CREATE FRICTION AND WILL REDUCE LIFTING CAPACITY GO UNDER THE ROPE ENTRY PULLEY FIGURE 1 NEXT PAGE IN THIS CASE THE ROPE ENTRY PULLEY OF THE WINCH WILL NOT BE USED WARNING portant AFTER PULLING FOR A FEW SECONDS RELEASE THE TENSION OFF THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING OF THE TREE POLE MOUNT AGAIN uamphbsargank 29 druammbsarqank 2 11 7 _af tc K pj bcjPcWA 7 070 M nhc85 U ARAPMB 6 706 5541 z 8 4 47121 3 4 Moving a load WARNING USING COMMON SENSE WHILE MOVING A LOAD IS THE KEY TO A SECURE WINCH USAGE The great variety of situations encountered when winching prevents us from providing specific instructions however you need to consider the following points WARNING CHECK WINCH POSITION ROPE CONDITION SOLIDITY OF THE ANCHOR POINT KNOTS CARABINERS OR SHACKLES IN ORDER TO PREVENT INJURIES OR MATERIAL DAMAGE WARNING INSTALL THE ROPE IN SUCH A WAY THAT IT DOES RUB AGAINST OTHER OBJECTS OR THROUGH AN OBSTRUCTION A GENERALLY IF THE ROPE TOUCHES AN OBJECT YOUR INSTALLATION IS INCORRECT WARNING NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM THE ROPE GRABBING SYSTEM THE ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING WARNING LOOK AT YOUR SET UP TO MAKE SURE THAT THE WINCH ANCHORS AND THE ROPE ENTRY PULL
10. The implementation of safety measures to prevent loads from falling 1 1 Safety messages Your safety and the safety of others are very important You will find important safety messages in this manual READ THEM CAREFULLY These security messages are warning you of potential injuries to either you or others Every safety message is preceded by a warning symbol A and one of the following terms DANGER WARNING or CAUTION uamphbsargank 2 2 11 7 af tc K pij bcjPcWA 7 070 M amp J ARAPMB amp 706 5541 2 Dv l 4 49121 These indicator words mean instructions these instructions 1 2 Labels 1 2 1 Serial number and warning label The serial number and warning label is positioned on the right side of the winch housing Read the meaning of all four icons figure 1 to the right Read this instruction manual and Baldor engine user s manual prior to using the winch 2 Only use low stretch rope Minimum diameter 1 2 12 m Maximum diameter 1 2 13 mm 3 Never place your hands near the moving parts while the engine is running 4 Never use the winch for lifting people 1 2 2 Rope DANGER label The rope DANGER label is positioned on the top of the winch housing The meaning of the icon in figure 1 to the right is 1 It is IMPERATIVE to use ONLY DCD Design amp Manufacturing Ltd double braided polyester rope 1 2 12 13 mm with buried eyed splice
11. and a minimal breaking strength of 6945 Ib 3150 kg 1 3 Safety information A DANGER You WILL be MORTALLY or SEVERELY INJURED if you do not follow these WARNING vou COULD be MORTALLY or SEVERELY INJURED if you do not follow CAUTION vou COULD be INJURED if you do not follow these instructions DCD Design amp 180 5520 McMillan Way Richmond BC Canada 888 7944 4445 wwwrdcddesoncom Puling force Rated lifting capacity Winching speed Serial number Year manufactured WARNING DO NOT LET CHILDREN USE THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA WARNING NEVER LET SOMEONE WITHOUT TRAINING USE THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC MAKE SURE THE USER KNOWS ABOUT THE SAFETY AND USAGE PROCEDURES AND HAS READ THIS MANUAL AND THE BALDOR MOTOR LEAFLET THE OPERATOR SHOULD BE ABLE TO OPERATE A LIFTING DEVICE 4 uamphbsargank z dreuampbsargank 2 11 7 af tc K pj bcjPcWA 7 070 M nhc85 ARAPMB amp 706 5541 2 8 4 49121 AND BE AWARE OF ALL ASPECTS OF SUCH OPERATIONS HE SHOULD ALSO BE AWARE OF LOCAL REGULATION WARNING INFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE PROCEDURES WARNING FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY GUIDELINES BEFORE WORKING WITH THIS
12. pj bcjPcWA 7 070 M nhc85 U ARAPMB amp 065541 2 8 4 49121 o Rope Low stretch double braided polyester not included Unlimited rope length Minimum diameter 1 2 12 mm Maximum diameter 1 2 13 mm e 41000 500 Motor o Motor AC Electric Baldor TEFC 115 230 VAC 1 ph 3 4 HP o Unit weight dry 53 Ib 24 kg o Dimensions overall Length 19 48 cm Width 15 38 cm Height 14 36 cm 5 7 Periodical tests Some local regulations require that equipment used for lifting be tested regularly Check with local authorities and contact your authorized dealer for DCD Design amp Manufacturing Ltd for testing procedures 5 8 Manufacturer The TUF Lugger Lite Lifting Cable Puller Electric is manufactured for DCD Design amp Manufacturing Ltd 180 6620 McMillan Way Richmond BC V6W 1J7 CANADA Phone 1 604 232 4445 Toll free Canada amp USA 1 888 794 8357 Fax 1 604 232 4446 Email sales dcddesign com Web site www dcddesign com 27 uamphbsargank 2 dreuammbsarqank 2 11 7 af tc K pij bcjPcWA 7 070 Nnt c85 J ARAPMB 906 5541 2 DEN 4 49121 Schedule Examining the rope As specified in section 3 2 2 the rope and its termination should be inspected daily to its full length to detect wear This page allows you to collect information It is indicative and may be reproduced and used for daily verification of your rope Winching Rope DIAMETER TERMINATION LENGH
13. pole mount with anchor strap p 12 3 3 5 1 With the winch support plate p 13 3 3 5 2 With the vertical pull winch support p 14 3 4 Moving a load p 15 3 4 1 Installing the rope on the PCT1800 Winch p 17 3 42 Lifting p 18 3 4 2 1 Load lifting chart p 18 3 4 2 2 Lifting operation p 18 3 4 2 8 Lowering a load p 19 3 4 2 4 Sending the rope back down p 20 3 43 Pulling p 20 3 4 3 1 Releasing the tension p 21 3 4211 When pulling with the rope grabbing system engaged p 21 3 4 3 1 2 When pulling with the rope grabbing system disengaged p 21 3 5 If the TUF Lugger Lite Lifting Cable Puller Electric doesn t work p 21 lenance p 22 4 1 Cleaning p 22 4 2 Lubrication p 22 4 3 AC Electric motor p 22 4 4 Storage p 23 5 0 Complementary information p 23 5 1 Accessories p 23 5 2 Serial number localization p 23 5 3 Warranty p 23 5 4 CE Declaration of conformity p 24 5 5 Electrical diagrams p 27 5 6 Technical data p 28 5 7 Periodical tests p 29 5 8 Manufacturer p 29 4 0 Maii Schedule 1 Examining the rope p 30 uamphbsargank 29 druammbsarqank 2 11 7 _af tc K pj bcjPcWA 7 070 Nnt c85 J ARAPMB 6 706 5541 2 DEN 4 49121 Introduction DCD Design amp Manufacturing Ltd wishes to thank you for purchasing a TUF Lugger Lite Lifting Cable Puller Electric This manual was written to help you make th
14. 0014 PULL PIN 1 4 20 1 56 70 0007 ROPE GRABBING SYSTEM ATTACHMENT 57 42110 225 SAFETY LIP FOR CAPSTAN DRUM 2 1 4 1 58 42100 225 CAPSTAN DRUM 2 1 4 1 60 10 0100 ROPE GUIDE FOR CAPSTAN 2 1 4 1 31 0015 HCS 3 8 X 1 1 4 GR5 ZN 2 42 0023 WIRE CONNECTOR 8 TO 12 3 10 0072 SUPPORT PLATE FOR ELECTRIC BOX 41000 500 50Hz 1 10 0071 SUPPORT PLATE FOR ELECTRIC BOX 41000 500 60Hz 10 0077 EYE CONNECTOR 12 GA YELLOW 1 10 0082 WIRE CONNECTOR 14 GA BLUE 2 10 0113 ON OFF CABLE FOR 1800 1 5 5 Electrical diagrams CONTACTOR WIRING DIAGRAM WHITE TO PUG CONTACTOR WIRING DIAGRAM m a Uampibsargank 29 2 11 7 af tc K pij bcjPcWA 7 070 M amp J ARAPMB amp 706 5541 2 Dv l 4 49121 MOTOR WIRING DIAGRAM 220V 50HZ 1 PHASE PULL SWITCH WIRING DIAGRAM 5 6 Technical data e 41000 500 o Gear box Aluminum alloy o Capstan drum 3 3 8 85 mm o Maximum pulling force single line 3 3 8 drum 1800 Ib 820 kg 2 1 4 drum 2200 Ib 1000 kg o Rated pulling force 3 3 8 drum 1000 Ib 455 kg 2 1 4 drum 1220 Ib 555 kg o Rated lifting capacity 555 Ib 250 kg 3 3 8 drum 550 Ib 250 kg 2 1 4 drum 550 Ib 250 kg o Speed 3 3 8 drum 35 ft min 10 5 m min 2 1 4 drum 23 ft min 7 m min o Duty cycle 25 15 min per hour is recommended o LP Rating 54 uampbsargank 29 druammbsarqank 2 11 7 tc K
15. 5 10 0115 ELECTRIC CORD 14 3 AWG FOR SWITCH 2 26 INCLUDED WITH 42 0022 KEY FOR ELECTRIC MOTOR SHAFT 1 26 42 0019 ELECTRIC PLUG CEE 7 7 250V 16AMP GROUNDED 1 27 42 0022 BALDOR ELECTRIC MOTOR 50Hz 220V 3 4 1 28 44 0019 VINYL GRIP 1 29 10 0094 WINCH HANDLE 1 30 33 0005 NYLON LOCKNUT 1 2 13 Zn 1 31 10 0067 COUPLING SHAFT FOR ELECTRIC MOTOR 1 32 43 0005 KEY FOR INPUT PINION 1 31 0020 MACHINE SCREW 10 24 X 1 3 4 ZN PAN HEAD SQ DR 2 34 10 0081 LIMIT SWITCH 1 38 10 0086 INPUT PINION 1 35 0006 FLAT WASHER 1 4 ZN 2 40 31 0023 BUTTON HEAD CAP SCREW 1 4 28 x 1 2 Gr5 Zn 1 41 10 0069 GUARD PLATE PCT1800 50Hz 1 41 10 0068 GUARD PLATE PCT1800 60Hz 42 32 0002 HEX FLANGE SERRATED BOLT M61 X 12 MM ZP 4 43 32 0003 SHCS M5 0 80 X 16 5 44 100111 ON OFF CABLE END HOLDER 1 45_ 10 0112 ON OFF CABLE HOUSING FOR 1800 1 46_ 43 0013 KEY FOR CAPSTAN DRUMS 57 MM amp 85 1 46 10 0103 ROPE KEEPER 1 47 10 0101 ROPE ENTRY PULLEY 1 48 10 0119 SHOULDER BOLT 5 8 X 1 1 2 ZN 2 R Uampibsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 M 85 amp 706 5541 2 DVBI 4 47121 49 42100 337 CAPSTAN DRUM 3 3 8 1 50 44 0001 UNIVERSAL SERIAL NUMBER amp WARNING LABEL 1 52 44 0022 ROPE DANGER LABEL 1 53 70 0006 ROPE GRABBING SYSTEM 1 54 31 0083 SHCS 5 16 18 X 1 3 4 SS 1 55 39
16. BING SYSTEM WARNING NEVER SHOCKLOAD THE SYSTEM WARNING BEWARE OF ROPE SNARLS WHILE LOWERING IF ROPE GETS TANGLED PULL ON ROPE WHICH WILL START THE MOTOR UNTIL CLEARED CAUTION NOT TOUCH THE CAPSTAN DRUM IMMEDIATELY AFTER OPERATION AS IT WILL GET HOT AND BURN BARE SKIN When you stop lifting with the TUF Lugger Lite Lifting Cable Puller Electric the rope grabbing system engages therefore holds a load in position and keeps the rope under tension To release it follow these steps 1 Figure 1 no 1 Pull horizontally and gently on the pulling rope to engage the motor this will release the tension applied by the rope grabbing system on the pulling rope 2 Figure 1 no 2 Pull gently on the rubber handle of the rope attached to the rope grabbing system this will disengage the system uamphbsargank 2 2 11 7 af tc K pij bcjPcWA 7 070 N nh c85 J ARAPMB amp 706 5541 2 DVBI 4 47121 WARNING NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM IN CASE OF EMERGENCY SIMPLY LET THE RUBBER HANDLE GO THE SYSTEM WILL RE ENGAGE WARNING NEVER LET THE PULLING ROPE SLIDE SUDDENLY IF A LOAD IS SUSPENDED 3 Figure 1 no 3 Slowly payout the pulling rope push it towards the winch if necessary this may occur if you have four wraps of rope on the drum and a light load while keeping the rope grabbing system slightly open
17. EY ARE ALIGNED WITH THE ROPE WARNING WHILE WINCHING POSITION YOURSELF AWAY FROM THE WINCH IN ORDER TO SEE BOTH THE WINCH AND THE LOAD PULL HORIZONTALLY ON THE ROPE THE TENSION YOU EXERT ON THE ROPE WILL KEEP THE WINCH LEVELED A DANGER DO NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT WARNING CAREFULLY WATCH THE CAPSTAN DRUM DURING THE OPERATION AND MAKE SURE THE ROPE DOES NOT CROSS OVER ON IT IF IT HAPPENS RELEASE THE TENSION ON THE ROPE AND STOP THE ENGINE WHILE UNDOING THE CROSS OVER WARNING NOT PULL A LOAD DIRECTLY TOWARD THE WINCH IN A DOWNWARD SLOPE SINCE IT COULD SLIDE WITHOUT YOU BEING ABLE TO STOP IT IN THAT SITUATION USE A PULLEY AT THE BOTTOM OF THE HILL AND POSITION THE WINCH OUTSIDE OF THE LOAD S PATH uamphbsargank 2 2 11 7 af tc K pij bcjPcWA 7 070 M amp J ARAPMB amp 706 5541 2 DEN 4 49121 3 4 1 Installing the rope on the TUF Luqger Lite Lifting Cable Puller Electric WARNING never Pur your HANDS ON THE CAPSTAN DRUM OR THE ROPE ENTRY PULLEY WHEN THE WINCH IS RUNNING 1 Figure 1 Open the rope grabbing system no 1 and lock in place with spring pin no 2 2 Figure 2 Run the rope OVER the rope keeper and the rope entry pulley no 1 and UNDER the drum except when using the vertical pu
18. GER PRIOR TO INSPECTING OR REPAIRING THE WINCH BE SURE TO DISCONNECT FROM POWER SOURCE If the winch does not work check the power source Make sure the voltage and or the frequency used is correct Disconnect the wire from the electrical outlet and remove the lid of the control 20 uampbsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 M nh c85 J ARAPMB amp 706 5541 z Dv l 4 49121 box Make sure there no unconnected wires poorly connected relays or loosened screws If the unit still does not work contact DCD Design amp Manufacturing Ltd 4 0 Maintenance When the unit is outside make sure to thoroughly cover the engine and controls against the weather or ground water When the winch is running make sure it is free of obstructions Periodic inspections must be made for damage or cuts to the various components which may require replacement 4 1 Cleaning Once your job is done you should clean and dry your winch CAUTION INSPECT THE WINCH HOOKS ROPE GRABBING SYSTEM ROPE AND POLYESTER SLING TO DETECT ANY DAMAGE OR SIGNS OF WEAR BEFORE AND AFTER EACH USE Periodically remove the capstan drum section 2 2 and clean around the shaft figure 1 Accumulated debris can damage the shaft seal Apply a bit of oil on the shaft to prevent corrosion 4 2 Lubrication The rope entry pulley figure 1 no 1 must turn freely Lubricate it regularly w
19. HE JOB TO BE DONE IN THIS CASE LIFTING IT IS RECOMMENDED TO HAVE A 10 TO 1 SAFETY FACTOR FOR ALL ACCESSORIES Refer to the chart in section 3 4 2 1 for the correct number of wraps of rope to use uamphbsargank 29 dmuammbsarqank 2 11 7 af tc K pj bcjPcWA 7 070 M nhc85 U ARAPMB amp 706 5541 2 8 4 49121 3 4 2 3 Lowering a load CAUTION ALWAYS WEAR GLOVES WARNING YOUR TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC IS EQUIPPED WITH A ROPE GRABBING SYSTEM THIS SYSTEM IS NOT DESIGNED TO STOP FAST MOVING LOADS DAMAGE CAN OCCUR TO THE ROPE AND OR THE ROPE GRABBING SYSTEM WHEN SHOCK LOADED AND POSSIBLY LEAD TO CATASTROPHIC FAILURE DANGER DO WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING NEXT TO YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT DANGER THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC 15 NOT DESIGNED FOR LOWERING HEAVY LOADS OVER LONG DISTANCES FRICTION OF THE ROPE ON THE CAPSTAN DRUM WILL GENERATE HEAT THAT COULD DETERIORATE OR EVEN MELT THE ROPE YOU MAY WANT TO RUN SOME TESTS IN ORDER TO EXPERIMENT YOU CAN ALSO USE PULLEY BLOCKS ON THE LOAD TO REDUCE FRICTION ON THE DRUM CAUTION AFTER EACH LOWERING OPERATION IT IS IMPERATIVE TO CHECK ROPE CONDITION WARNING NEVER GO OVER THE RATED LIFTING CAPACITY 550 LB 250 KG SINGLE LINE WARNING NEVER BYPASS THE ROPE GRAB
20. T MANUFACTURER FIBRES COMMISSIONING DATE CONSTRUCTION Daily verification DATE INSPECTION OR INCIDENT NOTES AND TECHNICIANS SIGNATURE 12 13 14 15 16 28 uamphbsargnk 24 dheuampbsargank 2 11 7 a tc K pi bcjPcWA 7 070 N nhc JARAPMB amp 9065541 2 D val 4 47121 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 29
21. WINCH WARNING MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT INTO THE WINCH MOBILE PARTS WARNING USE ONLY 1 2 12 13 MM DIAMETER DOUBLE BRAID DCD DESIGN amp MANUFACTURING LTD POLYESTER ROPE WITH THIS WINCH WARNING ALWAYS USE THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC HORIZONTALLY USING A PULLEY OR THE VERTICAL PULL WINCH SUPPORT TO REDIRECT THE ROPE VERTICALLY CAUTION REPLACE ANY SAFETY LABELS THAT ARE DAMAGED ILLEGIBLE OR MISSING WARNING NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM THE ROPE GRABBING SYSTEM THE ROPE ENTRY PULLEY OR NEAR THE ROPE GUIDE WHEN THE MOTOR IS CONNECTED TO POWER SOURCE WARNING ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA DANGER NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR CONTROL WARNING NEVER TRY TO MOVE FIXED OR OBSTRUCTED LOADS WARNING AVOID EXCESSIVE INCHING E G GIVING SHORT PULSES TO THE MOTOR WARNING ALWAYS INITIATE MOVEMENTS OF THE LOAD WITH THE LOWEST AVAILABLE SPEED THE ROPE SHALL BE TIGHTENED AND SHALL NOT BE IN THE SLACK CONDITION WHEN THE LOAD MOVEMENT BEGINS WARNING SIDE PULL OF LOAD IS NOT ALLOWED WITH THIS WINCH WARNING KEEP IN MIND THAT YOUR SET UP IS ONLY AS RESISTANT AS THE WEAKEST LINK THIS IS WHY IT IS VERY IMPORTANT TO USE THE ADEQUATE ACCESSORIES IN ACCORDANCE WITH THE JOB TO BE DONE IN THIS CASE
22. e and then remove the rope guide 2 Figure 2 Remove the hex bolt holding the safety lip and drum using the 7 16 11 mm wrench Then remove the washer the safety lip and the spacer bushing uamphbsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 85 J ARAPMB amp 706 5541 2 DEN 4 49121 3 Figure 3 Remove the drum from the shaft If necessary you may push it forward with two screwdrivers Make sure that the shaft key stays in place 4 Figure 4 Insert the 2 1 4 57 mm drum on the winch shaft Insert the washer the 4 5 8 117 mm safety lip and the spacer bushing on the hex bolt and insert this assembly in the hole of the shaft Then tighten the hex bolt with the 7 16 11 mm wrench 5 Figure 5 Insert the new rope guide in position and tighten it using the two 2 bolts IMPORTANT Make sure that the rope guide is not in contact with the capstan drum 3 0 Winch usage WARNING MOST WINCHING SITUATIONS PRESENT POTENTIAL DANGERS The winch must be plugged into a grounded plug The use of an extension cord can cause a loss of power at full capacity As listed on the product label figure 1 make sure the voltage and current type respected Units 115V 60hz require 20 amps while the units 220V 50hz require 10 amps uamphbsargank 29 druammbsarqank 2 11 7 af tc K pj bc
23. e best use of your new winch and to use it in the most secure way READ IT CAREFULLY BEFORE USING THE WINCH For any problems or questions please contact DCD Design amp Manufacturing Ltd directly 1 0 Safety guidelines The TUF Lugger Lite Lifting Cable Puller Electric is designed for lifting objects at angles up to vertical It is fitted with a rope grabbing system that can maintain the load in position and provide stop and go operation THE ROPE GRABBING SYSTEM IS NOT DESIGNED TO STOP A FAST MOVING LOAD OR TO LIFT PEOPLE The use of a lifting device implies serious risks of injuries property damage or even death DO NOT UNDERESTIMATE ITS POTENTIAL DANGER WARNING WHEN LIFTING NEVER GO OVER THE RATED LIFTING CAPACITY 550 Ib 250 kg SINGLE LINE WARNING WHEN LIFTING NEVER BYPASS THE ROPE GRABBING SYSTEM WARNING NEVER SHOCKLOAD THE SYSTEM WARNING NEVER OPERATE THE WINCH WITHOUT PROPER TRAINING AND SUPERVISION REMEMBER THE FIRST CAUSE OF ACCIDENT IS HUMAN ERROR MAKE SURE EVERY PERSON HAS RECEIVED THE APPROPRIATE TRAINING FOR THE JOB CAUTION THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGE CAUSED BY NEGLECTING TO FOLLOW THE GUIDELINES AND BY NEGLECTING TO FOLLOW SAFETY REGULATIONS In particular the USER has the obligation to verify a If the electrical receptacle is equipped with a ground compatible with the connector b If the electrical system is adequate c
24. g The winch will align itself automatically with the load CAUTION USE THE HITCH PLATE ONLY WITH CATEGORY II BALL HITCH 3300 LB 1500 KG OR HIGHER MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 3 3 3 Using the winch support plate 42200 010 with 2 square tubing 42200 020 1 Figure 1 no 1 Slide the square tubing 42200 020 into the vehicle s receiver and secure it with both the hitch pin and the R pin 2 Figure 1 no 2 Slide the winch support plate 42200 010 onto the square tubing and secure it with both the hitch pin and the R pin Note Its lateral movement can be adjusted by positioning the bolts into the square holes 3 Figure 2 Attach the winch anchor hooks to the eye bolts 4 Figure 2 Wrap the rope around the drum and start winching The winch will align itself automatically with the load p Fes 267 uamphbsargank 2 2 11 7 af tc K pi bcjPcWA 7 070 M nhc85 U ARAPMB 706 5541 2 DVBI 4 49121 CAUTION IF YOU NEED TO PULL DOWNWARD YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE CAUTION MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK PN CAUTION IF YOU NEED TO PULL DOWNWARD YOU WILL NEED TO INSTALL EITHER A PULLEY OR
25. inimal number of wraps required on the capstan drum in order to move the load Below is a chart showing the number of turns to do on the drum in accordance with the weight of the load This chart is designed to help figure out the number of wraps you need to lift a load and also allow its lowering The friction on the capstan drum is relative to the size of the drum installed the number of wraps and the load weight therefore too many wraps may prevent a load to lower WARNING iuPORTANT NOTE IF THE MOTOR STALLS WHILE LIFTING A LOAD YOU HAVE EXCEEDED THE RATED LIFTING CAPACITY THEREFORE YOU MUST LOWER THE LOAD TO RELEASE THE TENSION ON THE ROPE AND INSTALL A BLOCK AND TACKLE DEVICE TO INCREASE THE LIFTING CAPACITY BEFORE RESTARTING TO PULL DO NOT START UNDER TENSION OR YOU MAY DAMAGE THE MOTOR Number of Welght turns on the Pounds Kilograms drum From To From To 1 4 WARNING Never make only one turn WARNING 2 210 176 Ib 1kg 80 kg 3 177 Ib 374 lb 81 kg 170 kg 4 375 Ib 550 Ib 171 kg 250 kg 3 4 2 2 ig operation CAUTION AL WAYS WEAR GLOVES To lift a load you will need to decide which anchoring accessories you will use Refer to section 3 3 to decide WARNING KEEP IN MIND THAT YOUR SET UP IS ONLY AS RESISTANT AS THE WEAKEST LINK THIS IS WHY IT IS VERY IMPORTANT TO USE THE ADEQUATE ACCESSORIES IN ACCORDANCE WITH T
26. ith light oil Dirt and grime lodged between the pulley and the shaft may prevent it from turning freely If required disassemble it to clean the shaft Use an 8 mm hex key The gearbox is lubricated at the factory and SHOULD NOT require additional lubrication or maintenance If there is appearance of a leak check oil level by placing the winch on a level surface and remove the oil plug figure 1 no 2 Lean it toward you some oil should leak out of the hole If needed you can add type gear box oil 4 3 AC Electric motor Follow the instructions found in the fact sheet of the Baldor electric motor to maintain it properly 21 Uampibsargank 2 dreuampbsarqank 2 11 7 af tc K pi bcjPcWA 7 070 N nh c85 J ARAPMB amp 706 5541 2 8 4 49121 4 4 Storage Always store your TUF Lugger Lite Lifting Cable Puller Electric seated on its guard plate and in a dry environment 5 0 Complementary information 5 1 Accessories A complete line of accessories is available Simply visit www tufluggerlite com 5 2 Serial number localization The winch serial number is indicated on the serial number and warning label located on the right side of the winch housing and is also engraved on the cover of the winch to the left of the capstan drum 5 3 Warranty DCD Design amp Manufacturing Ltd products are warranted against defects in materials and workmanship while owned by the original
27. itself with the load The friction of the sling against the anchor point could prevent correct alignment If that is the case release the tension on the rope and position the sling on the anchor point so that the tension is equally distributed on both winch anchor hooks DON T DO THIS WHEN YOU ANCHOR THE WINCH MAKE SURE THAT YOU DO NOT DO A COMPLETE WRAP AROUND THE ANCHOR POINT FIGURE 2 BELOW THIS SET UP WILL PREVENT PROPER ALIGNMENT OF THE WINCH WITH THE LOAD AND WILL PUT UNEVEN TENSION ON THE WINCH ANCHOR HOOKS CAUTION AVOID INSTALLING THE SLING ON SHARP EDGES THAT MIGHT DAMAGE IT WHETHER YOU ARE USING A POST A TREE OR A STUMP ALWAYS INSTALL THE SLING NEAR THE ANCHOR S BASE A CAUTION USING A STUMP AS AN ANCHOR POINT MEANS PAYING SPECIAL ATTENTION IN ORDER TO PREVENT THE SLING FROM SLIPPING OVER IT WARNING MAKE SURE THE ANCHOR POINT IS STRONG ENOUGH TO RESIST THE PULL WITHOUT BREAKING OR BEING DAMAGED 3 3 2 Using the towing ball adapter 42200 030 for tow balls up to 2 50 mm diameter uamphbsargank 2 2 11 7 af tc K pij bcjPcWA 7 070 M amp J ARAPMB amp 706 5541 z DEN 4 49121 1 Figure 1 Push the safety hooks in the rectangular openings of the hitch plate The rubber plate must be under the winch 2 Figure 2 Slide the plate on the ball hitch and pull the winch forward 3 Figure 3 Wrap the rope around the drum and start winchin
28. jPcWA 7 070 M nhc85 U ARAPMB 6 706 5541 2 8 4 49121 3 1 Working cycle This TUF Lugger Lite Lifting Cable Puller Electric is designed for intermittent use The engine manufacturer recommends an engine duty cycle of 25 So to get a maximum lifetime out of the engine it should only be used for fifteen 15 minutes period every hour This data varies depending on the loads pulled or lifted Light loads can be lifted or pulled continuously without affecting the life of the engine Continuous pulls are however less damageable for the motor than frequents stop and go 3 2 Rope WARNING STAY OUT OF THE WINCH LINE S PATH 3 2 1 Rope type WARNING USE ONLY LOW STRETCH 1 2 12 13 MM DIAMETER DCD DESIGN amp MANUFACTURING LTD DOUBLE BRAIDED POLYESTER ROPE WITH A MINIMAL BREAKING POINT OF 6945 LB 3150 KG WITH THIS WINCH PLEASE CONTACT US FOR OTHER ROPE TYPE S SUITABILITY WARNING DO NOT USE 3 STRAND POLYPROPYLENE YELLOW ROPE e Polypropylene and polyethylene ropes are dangerous for winching because of their great elasticity and low melt point e Make sure the rope is not damaged and that it offers an adequate resistance to pull the load WARNING STRETCH EQUALS DANGER stretched rope can recoil and cause serious burns as the rope leaves your hand All ropes stretch a longer one more than a shorter one The more you pull the more it stretches
29. ll winch support see section 3 3 5 2 Then wrap the rope around the drum 3 or 4 turns no 2 Figure 3 Insert the rope into rope grabbing system device by pulling the spring loaded cam lever upwards no 1 This will give enough room to insert the rope 4 Figure 4 Make sure the rope goes over the stainless steel knob no 1 Then push the spring loaded cam back against the rope which will automatically hold a load if the rope end is let go no 2 Figure 5 As you pull the rope no 1 the motor will engage and load will move IMPORTANT It is necessary to pull the rope HORIZONTALLY to get the load started To stop load movement stop pulling on rope no 2 Stand about 3 1 m from the winch and pull gently and horizontally on the rope to get the slack until you feel the tension rising on the rope 7 Look at your set up to make sure that the winch anchor and the rope entry pulley are aligned with the rope 8 Check that the rope does not rub against objects along the path Pull on the rope the power will go up and the winching will start 3 5 6 9 uamphbsargank 29 druammbsarqank 2 11 7 af tc K pj bcjPcWA 7 070 M nhc85 U ARAPMB 6 706 5541 2 8 4 47121 3 4 2 Lifting 3 4 2 1 Load lifting chart WARNING BEFORE ATTEMPTING TO LIFT A LOAD IT IS IMPERATIVE TO EVALUATE ITS APPROXIMATE WEIGHT When lifting a load you may figure the m
30. the hook Moreover it retains about 7096 of the rope s capacity while most knots will reduce it by more than 50 Even better the double bowline knot figure 2 below will keep about 75 of your rope s capacity 3 2 3 1 2 When lifting Rope with buried eyed splice For lifting again you have to attach the load to the end of the rope Even if you believe that a bowline knot could do the job itis STRONGLY RECOMMENDED to use the DCD Design amp Manufacturing Ltd rope with buried eyed splice The installation of a hook with a strong enough safety factor carabiner or shackle to the rope will help prevent any problems that might occur in case of knot failure uamphbsargank zddweuampibsargank 2 11 7 af tc K pij bcjPcWA 7 070 M amp J ARAPMB amp 706 5541 2 DEN 4 49121 NOTE Please check with local authority for safety regulation in your area 3 3 Winch anchors The winch is anchored to a fixed point using the included polyester sling or with optional anchoring devices and the rope end is tied to the object you want to move The load is moving towards the winch when you pull the rope 3 3 1 Using the polyester sling included with the winch Go around the anchor point with the sling Insert each end of the sling in one of the safety hooks located on the winch figure 1 below Position the winch in line with the load When the winch is under tension it will try to align
31. ttach the winch anchor hooks to the eye bolts of the winch support plate 3 Figure 3 Wrap the rope around the drum and start winching The winch will align itself automatically with the load A CAUTION IF YOU NEED TO PULL DOWNWARD YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DAMAGE TO THE WINCH SUPPORT PLATE WARNING AFTER PULLING FOR A FEW SECONDS WITH THE TREE POLE MOUNT RELEASE THE TENSION OFF THE TUF LUGGER LITE LIFTING CABLE PULLER ELECTRIC CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING AGAIN 3 3 5 2 With the vertical pull winch support 42200 050 After the installation of the pole mount section 3 3 5 follow these steps 1 Figure 1 Insert the vertical pull winch support onto the square tubing of the pole mount 42200 040 align the holes and insert the pulley 2 Figure 2 Tighten the nut with your fingers until it touches the support Then reinforce it with the pin 3 Figure 3 Attach the winch anchor hooks to the eye bolts of the vertical pull winch support uamphbsargank 29 dreuammbsarqank 2 11 7 af tc K pi bcjPcWA 7 070 M 85 amp 706 5541 2 8 4 49121 4 Figure 4 Wrap the rope around the drum and align the vertical support pulley with the rope axe and start to pull WARNING important DON T GO OVER THE ROPE ENTRY PULLEY OF THE WINCH WITH THE ROPE FIGURE 2 NEXT
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