Tuf-Lugger User Manual
Contents
1. SPEG A CATIONS h gt uanpbsargank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 ARAPMB amp 706 5541 zD v l 4 47121 In the Underhand Configurations Type B the rope passes under the Wrist Sheave Wi between the Extension Arms and over the Elbow Sheave sm Panel Box Pull Down BB Horizontal Low Pull SPEC A CATIONS Pull Box Underhand hpuammbsarqank z 11 7G af tc K_pj_ bcj 0 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Review the jobsite safety reguirements WARNING FOLLOW STANDARD PROCEDURES WHEN ACCESSING VAULTS AND MANHOLES INCLUDING GAS DETECTION VENTILATION AND WORK AREA PROTECTION FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY WARNING USE EXTREME CAUTION WHEN WORKING AROUND LIVE ELECTRICAL CIRCUITS FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY CAUTION WEAR RECOGNIZED SAFETY EQUIPMENT INGLUDING HARDHAT SAFETY GLASSES LL hath SAFETY SHOES AND LEATHER WORK GLOVES FAILURE TO DO SO MAY RESULT IN a 5 PERSONAL INJURY Inspect the condition of the TUF Lugger checking for worn or damaged parts WARNING HAVE DAMAGED PARTS REPLAGED BY AN AUTHORIZED SERVICE GENTER ANY ATTEMPT TO MODIFY THE TUF LUGGER OR USE OTHER THAN REPLACEMENT PARTS WILL VOID THE WARRANTY AND MAY RESULT IN DEATH OR SERIOUS INJURY WARNING ENSURE THAT THE PROTECTIVE GAP FOR 120 VAC2. dhru ampbsargank z 11 7 _af tc K_py_bcj PowA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 ACCESSORIES Load Monitor 40000 200 29 Operation of the Load Monitor is straightforward Turn the Transport Knob counter clockwise so that the Power Pack is free to apply load againstthe Load Cell through the front mounting bracket Set the Alarm Switch to the ON position When the TUF Lugger speed selector is setin the LO position the 2000 Ib alarm is automatically disabled F8 Set the Power Switch to the ON position The pulling line tension is displayed in pounds FO To secure the TUF Lugger for transport screw the Transport Knob clockwise until resistance is felt This prevents vibration damage to the load cell ACCESSORIES hpuanmbsarqank 2 11 7 _af tc K_ pg _bcjPcwA 7 0702 Nf m 66 4 ARAPMB 6 4706 5541 zDv A 47121
3. 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Orient the new Duct Guide depending on the pulling configuration and secure with the Wrist Pin Rotate the Duct Guide and secure in position using Duct Guide Pins in whichever of the two holes in the Duct Guide that provides the best angular alignment Install the Duct Guide into the conduit For overhand configurations Type A pivot the TUF Lugger forward to insert the Duct Guide into the conduit The pulling forces will maintain the frame in this position For underhand configurations Type B pivot the TUF Lugger forward to position the Duct Guide at the mouth of the conduit Pivot the frame rearward to allow the Duct Guide to enter the conduit Install the pulling rope over the sheaves For overhand configurations Type A the rope goes over both sheaves For underhand configurations Type B the rope goes under the Wrist Sheave between the Extension Arms and over the Elbow Sheave Continue the rope clockwise around the capstan and around the deflector sheave hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Plug the TUF Lugger into a 120 V 15 Agrounded outlet or extension cord WARNING READ ALL ELECTRICAL SAFETY INSTRUCTIONS LOCATED ON THE FIRST PAGE OF THIS MANUAL BEFORE USING THE TUF LUGGER FAILURE TO DO SAY MAY RESULT IN SERIOUS INJURY OR DEATH USE ONLY A THREE PRONG
4. ULTIMATE PULLOUT FORCE OF 8 000 LB ENSURE THAT THEY ARE INSTALLED IN AGCORDANGE WITH THE INSTRUCTIONS PROVIDED BY THE INSERT MANUFACTURER FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY ACCESSORIES Place the TUF Lugger Power Pack into the Floor Mount Adapter and secure using the pins provided with the adapter THE TUF LUGGER POWER PACK WEIGHS 125 LB USE PROPER LIFTING TECHNIQUE WHEN MOVING THE POWER PACK FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Manhole Adapter 40000 300 The Manhole Adapter allows the TUF Lugger to pull cable into a manhole using guides and sheaves located in the manhole It features two independent stop plates and an independent guide plate which allow the rope to be pulled from any position in the manhole gt Manhole Range 18 36 Diameter gt The adapter requires the use of a 6 Duct Guide 0 0 Loosen the locking handles on the stop D3 Install the TUF Lugger into the plates and adjust the plates against the inside edges of the manhole Manhole Adapter 6 hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v81 4 47121 Universal Adapter 40000 500 For horizontal pulls the TUF Lugger must be positioned directly in line with the conduit For some applications t
5. gt gt Pulling Speed fpm Footswitch Amp Type Load Meter Conduit Guides Standard 2 3 3 1 2 4 Optional 2 1 2 5 6 Maximum Height 6 6 can be extended see accessories Pulling Forces Maximum Low High Pulling Force Speed Speed Continuous 4 000 Ib 2 000 Ib Intermittent 6 500 Ib 3 250 Ib Pulling Speeds High Speed Continuous Intermittent a bw Low Speed A CATIONS 0 1000 2000 3000 Pulling Force Ib 4000 5000 6000 7000 hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Extension Arms Le 2 D 4 WZ Elbow Sheave Wrist Sheave 2 Capstan Locking Pin Mounting Pin Load Meter Wrist Pin Power Pack Deflector Sheave Duct Duct Guide Zza Guide Pin Mounting Pin Speed Selector 2 Boom Pin Base Plate L 7 A U 1 LD 1 Ii dmuammbsarqank z 11 7 Gr af tc K_pj_bcj PowA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 The TUF Lugger can be configured to suit a variety of premise and outside plant 3 applications The following sketches detail some of the more common pulling configurations In Overhand Configurations Type A the rope passes over both sheaves A Panel Box Pull Up 0 Horizontal High Pull
6. GROUNDED EXTENSION CORD WITH THE PROPER WIRE WARNING SIZE FOR THE LENGTH OF GORD FOR LENGTHS LESS THAN 50OFT USE A 14GA CORD AS A MINIMUM LENGTHS FROM 50 100FT USE A 12 GA CORD AS A h MINIMUM FAILURE TO DO SO MAY RESULT IN OVERHEATING AND DAMAGE TO THE ELECTRIC MOTOR Selectthe pulling speed depending on the anticipated load eu une SPEED CAUTION DO NOT ATTEMPT TO CHANGE SPEEDS WITH THE MOTOR RUNNING SPEED CHANGES WHILE THE MOTOR IS RUNNING MAY RESULT IN PERMANENT DAMAGE TO THE TUF LUGGER Manually apply tension to the tail end of the rope and depress the footswitch to begin pulling STAND AT LEAST 30 TO EITHER SIDE OF THE PULLING ROPE WHILE UNDER LOAD THE PULLING ROPE MAY FAIL UNDER TENSION AND RELEASE STORED ENERGY FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY Monitor the pulling load using the meter provided Use the low speed mode if the pulling force exceeds 2000 Ib Do NOT OPERATE THE TUF LUGGER CONTINUOUSLY AT PULLING FORCES ABOVE CAUTION 2 000 LB HIGH SPEED MODE OR 4 000 LB IN LOW SPEED MODE CONTINUOUS OPERATION OF THE TUF LUGGER ABOVE THESE RATINGS MAY OVERHEAT AND DAMAGE THE MOTOR Do NOT OPERATE THE TUF LUGGER WARNING INTERMITTENTLY AT PULLING FORCES ABOVE 3 250 LB HIGH SPEED MODE OR 6 500 LB LOW SPEED MODE INTERMITTENT OPERATION OF THE TUF LUGGER ABOVE THESE RATINGS MAY RESULT IN DEATH OR SERIOUS INJURY 6 hpuammbsarqank z 11 7
7. 4 50 X 40010 600 6 6 00 5 50 X hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v81 4 447121 ACCESSORIES Extension Arms p The range of the TUF Lugger may be extended by replacing the standard Extension Arms with longer sections of 2 steel rigid conduit or 2 Sch40 steel pipe This will allow higher box pulls and deeper vault pulls B1 Loosen the two bolts in the Outboard B2 Loosen the two bolts in the Inboard Arm Arm Fitting and remove the Fitting Fitting and remove the Extension Arms B 3 Cut two identical lengths of 2 steel rigid conduit or 2 Sch40 steel pipe WARNING USE ONLY 2 STEEL RIGID CONDUIT OR 2 SCH40 STEEL PIPE FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY WARNING DO NOT EXCEED A MAXIMUM LENGTH OF 14 FEET FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY B4 Re assemble the new Extension Arms to the Inboard and Outboard ArmFittings ACCESSORIES hpuammbsarqank z 11 7G af tc K_ph_ bcj 0 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Floor Mount Adapter 40000 400 B TUF Lugger Power Pack may be removed from the frame and secured to a concrete floor using the Floor Mount Adapter Align the Floor Mount Adapter with the direction of pull and secure to the floor with 4 x 5 8 concrete inserts USE ONLY CONCRETE INSERTS WITH AN
8. LOAD MONITOR RECEPTACLE IS INSTALLED WHEN THE RECEPTACLE IS NOT IN USE FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY SERVICE PERIODICALLY LUBRICATE THE DRIVE GHAINS WITH LIGHT MACHINE OIL Examine the condition of the pulling rope Check for contamination with mud sand or dirt Check for rust discoloration Check for broken or worn strands WARNING USE A PULLING ROPE WITH A MAXIMUM RATED GAPAGITY THAT MEETS OR EXGEEDS THE TUF LUGGER MAXIMUM PULLING FORCE OF 6 500 LB FAILURE TO DO Sp MAY RESULT IN DEATH OR SERIOUS INJURY WARNING DOWNGRADE OR DISGARD PULLING ROPE THAT HAS BEEN SUBJECT TO OVERLOAD OR PHYSICAL DEGRADATION FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 4 Roll the TUF Lugger into the desired operating location Uncoil the footswitch cord and power cord 5 Grasp the spare Locking Pin and tilt the Remove the Locking Pin and rotate the TUF Lugger rearwards until it rests on Extension Arm assembly to the desired the base plate position Continue to rotate past the desired position until the next set of pin holes aligns Replace the Locking Pin Select a Duct Guide suitable for the size of conduit being used 8 Remove the existing Duct Guide by removing the Guide Pins and Wrist Pin 9 hpuammbsarqank z 11 7G af tc K_pj_ bcj 0 7
9. OPERATING INSTRUCTION MANUAL TUF Lugger PRODUCTS dhru ampbsargank z 11 7 _af tc K_py_bcj PCWA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 IMPORTANT SAFETY INSTRUCTIONS READ ALL INSTRUCTIONS BEFORE USING THE TUF Lugger WARNING To REDUCE THE RISK OF FIRE ELECTRIC SHOCK OR INJURY mw The TUF Lugger is an electrical device Use only as described in this manual M Connect to a properly grounded outlet only See Grounding Instructions Aw Do not use with damaged cord or plug Aw Do not leave the TUF Lugger when plugged in Unplug from outlet when not in use and before servicing A Do not handle plug or Power Pack with wet hands Do not unplug by pulling on cord To unplug grasp the plug not the cord Do not pull or carry by cord use cord as a handle close a door on cord or pull cord around sharp edges or corners Do not run over cord Keep cord away from heated surfaces Aw Donot remove or modify the 15 Amp 125 VAC plug A Donotuse in wet or damp locations Do not expose to rain Store indoors Aw Do not use in the presence of flammable liquids or gases GROUNDING INSTRUCTIONS This appliance must be grounded If it should malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the risk of electric shock This appliance is equipped with a cord having an equipment grounding conductor and grounding plug The plug must be inserted into an
10. _af tc K_ph_ bcj 0 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 1 Rotate the Duct Guide into the position Rotate the TUF Lugger Extension Arms shown into the position shown Place the spare locking pin in the elbow plate Place your foot on the front axle Grasp the locking pin and pull forwards to pivot the TUF Lugger into the transport position Wrap the footswitch cord and power Steer the TUF Lugger by pushing cord around the cutouts in the base down on the spare locking pin raising plate Stow the footswitch on the frame the rear wheels and rotating about the front wheels dhru ampbsargank z 11 7 _af tc K_py_bcj PowA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 There are several accessories available for the TUF Lugger to enhance its capabilities 10 hpuammbsarqank z 11 7G af tc K_pj_ bcj PowA 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Duct Guides 40010 XXX 1 The TUF Lugger comes standard with Duct Guides to suit 2 3 3 1 2 and 4 conduit Guides are also available as optional accessories to suit 2 1 2 5 and 6 conduit Part Conduit Number Size op dei Sid Opt 40010 200 2 1 91 1 67 X 40010 250 2 1 2 2 38 2 07 X 40010 300 3 2 88 2 50 X 40010 350 3 1 2 3 54 3 11 X 40010 400 4 3 93 3 43 X 40010 500 5 5 00
11. appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances WARNING Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician or service person if you are in doubt as to whether the outlet is properly grounded Do not modify the plug provided with the appliance if it will not fit the outlet have a proper outlet installed by a qualified electrician This appliance is for use on a nominal 120 volt circuit and has a grounding attachment plug that 11 looks like the plug illustrated in the adjacent sketch Make sure that the appliance is connected to an outlet having the same configuration as the plug No adaptor should be used with this appliance aye OUTLET BOX GROUNDING PIN SAVE THESE INSTRUCTIONS d hpuammbsarqank z 11 7 _af tc K_pj_ bcj PowA 7 0702 Nf nh 66 J ARAPMB amp 706 5541 z D v l 4 47121 SPECIFICATIONS 1 OPERATION 5 TRANSPORT 9 ACCESSORIES Duct Guides Extension Arms Floor Mount Adapter Manhole Adapter Universal Adapter Load Monitor TABLE OF CONTENTS aya 3 3 d hpuanmbsarqank z 11 76 af tc K _bcjPcwA 7 0702 Nf m 66 4 ARAPMB amp 4706 5541 z D v81 A 47121 The TUF Lugger is a two speed capstan winch intended for pulling rope or polyester M pull tape The winch power pack is mounted in a wheeled pulling frame gt
12. his is not possible as the TUF Lugger is physically restricted by a manhole or sidewall H This problem can be overcome with the Universal Adapter It is a second set of extension arms with a joint that can bend and rotate It is installed between the standard Extension Arms and the Duct Guide The Universal Adapter allows the TUF Lugger frame to be set at an angle to the line of pull 0 0 hpuammbsarqank z 11 7G af tc K_pj_ bcj 0 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Universal Adapter 40000 500 16 Adjust the angle of the extension arms on the TUF Lugger For Overhand Pulls Type A the outboard end of the arms should be below the height of the conduit For Underhand Pulls Type 8 the outboard end should be above the height of the conduit Install the Duct Guide onto the sheave end of the Universal Adapter For Overhand Pulls Type A the slot in the plate should be up For Underhand Pulls Type B the slot in the plate should be down ACCESSORIES Overhand Pulls Type A Underhand Pulls Type B dhru ampbsargank z 11 7 _af tc K_py_bcj PowA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 Universal Adapter 40000 500 17 E3 Insert the Duct Guide into the end of the conduit Loosen the nut on the adjustment plate and rotate the Universal Adapter so that it will align with the Extension Arms In
13. stall the Universal Adapter onto the TUF Lugger Extension Arms and secure in place using the Wrist Pin and Duct Guide Pins Tighten the nut on the adjustment plate THE ADDED WEIGHT OF THE CAUTION UNIVERSAL ADAPTER WILL MAKE THE ASSEMBLY UNSTABLE UNTIL ALL OF THE PINS ARE INSTALLED EXERCISE CAUTION FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY Install the pull rope It may pass between the TUF Lugger Extension Arms but must not pass between the Universal Adapter Arms When correctly installed the rope will run parallel to the Universal Adapter Arms ACCESSORIES ENSURE THAT THE ROPE DOES NOT WARNING PASS BETWEEN THE ARMS OF THE UNIVERSAL ADAPTER FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY hpuammbsarqank z 11 7G af tc K_pj_ bcj 0 7 0702 Nf nh c86 J ARAPMB amp 706 5541 z D v l 4 47121 Load Monitor 40000 200 18 The Load Monitor system uses a load cell to measure the reaction force on the Power Pack and convert it to a line tension reading It consists of a load cell digital readout and audible alarm It receives its power from the TUF Lugger via an auxiliary power cord The Load Monitor can only be used with the TUF Lugger frame Load Cell gt Line Tension Range 0 6500 Ib gt Audible Alarms 2000 Ib 4000 Ib gt Alarm Override Switch gt Analog Output 0 10 VDC Alarm Switch pigia Display Power Switch Aux Power Cord Installa
14. tion of the Load Monitor requires a screwdriver and two 3 4 wrenches Once installed the Load Monitor can be left in place permanently ACCESSORI ES Fl Remove the front Mounting Pin and Remove the screws that secure the Load raise the Power Pack Install the load Monitor cover Remove the cover and cell into the frame cross member attach the Load Monitor to the top of the Secure in place with nut and lock nut TUF Lugger Power Pack using the Replace the Mounting Pin Screws provided Replace the cover dheuammbsarqank z 11 7 _af tc K_py_bcj PowA 7 0702 Nf nh c86 AR APMB 6 206 5541 z D v81 4 447121 Install the Transport Knob into the Power Pack mounting bracket Ensure that the Knob does not restrict the movement of the bracket against the load cell Secure the load cell wire to the underside of the TUF Lugger frame by using the half clips and screws provided screwing them into the pre drilled holes Load Monitor 0 19 Unplug the TUF Lugger Power Pack Remove the protective cap on the auxiliary power receptacle Connect the Load Monitor cord to the receptacle ENSURE THAT THE TUF LUGGER POWER PACK Is UNPLUGGED BEFORE MAKING THIS CONNECTION FAILURE TO DO SO MAY RESULT IN DEATH OR SERIOUS INJURY Secure the load cell wire to the side of the TUF Lugger frame by removing the three rear chain cover screws and reinserting them with the half clips provided and routing the wire as
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