TUF-Lugger Lite user manual
Contents
1. READ Nhe CAREFULLY PRODUCTS BEFORE USE Sence 1980 TUF Lugger Lite Lifting Cable Puller Gas 41000 400 USER MANUAL Maximum pulling force single line 1000 Ib 450 kg Rated lifting capacity single line 555 Ib 250 kg d hruammbsargank 2 11 7 _af tc K_ ph _ bcj PcwA 7 070 N m c HP ARAPMB amp 4 06 6541 z D v l D 44 7121 uanpbsargank z hruampbsargank z 11 7 _af tc K_py_bcj PcwA 7 070 Ninhc s HARAPMB amp 706 5541 z Dv l 4 47121 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 2 2 Sound power level label p 4 1 2 3 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 Is the engine ready to work p 6 2 2 1 Engine oil p 6 2 2 2 Gas petrol p 6 2 2 3 Engine start up p 6 2 2 4 Capstan drum p 7 2 2 5 Spark arrestor p 8 3 0 Winch usage p 9 3 1 Rope p 9 3 1 1 Rope type p 9 31 2 Rope maintenance p 9 3 2 At the end of the rope p 10 3 2 1 Recommendations p 10 3 2 1 1 Pulling p 10 3 2 1 2 Lifting Rope with buried eyed splice p 10 3 3 Winch anchor p 10 3 3 1 Using the polyester sling p 11 3 3 2 Using the towing ball adapter p 11 3 3 3 Using the winch support plate with 2 square tubing p 12 3 3 42. For any problems or questions please contact us directly 1 0 Safety guidelines The TUF Lugger Lite 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 4 WARNING WHEN LIFTING NEVER GO OVER THE RATED LIFTING CAPACITY 555 Ib 250 kg SINGLE LINE 4 WARNING WHEN LIFTING NEVER BYPASS THE ROPE GRABBING SYSTEM 4 WARNING NEVER SHOCKLOAD THE SYSTEM 4 WARNING NEVER OPERATE 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 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 These indicator words mean DANGER You WILL be MORTALLY or SEVERELY INJURED if you do not follow these instructions 4 WARNING You COULD be MORTALLY or SEVERELY INJURED if you do not follow
3. Using the pole mount with anchor strap p 13 3 3 4 1 With the winch support plate p 14 3 3 4 2 With the vertical pull winch support p 15 3 4 Moving aload p 15 3 4 1 Installing the rope on the TUF Lugger Lite p 16 3 4 2 Lifting p 17 3 4 2 1 Load lifting charts p 17 3 4 2 2 Lifting operation p 18 3 4 2 3 Lowering a load p 18 3 4 2 4 Sending the rope back down p 20 3 4 3 Pulling p 20 3 4 3 1 Releasing the tension p 21 3 4 3 1 1 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 Oil Alert H system p 21 4 0 Maintenance p 21 4 1 Cleaning p 21 4 2 Lubrication p 21 4 3 Honda engine p 22 4 4 Storage p 22 4 5 Spark arrestor p 22 5 0 Complementary information p 22 5 1 Accessories p 22 5 2 Serial number localization p 22 5 3 Warranty p 22 5 4 Exploded view and parts list p 24 5 5 Technical data p 26 5 6 Noise emissions p 26 5 7 Periodical testing p 26 5 8 Manufacturer p 26 uampbsarqgank zd dreuamprbsargank z 11 7 _af tc K_py_bcj PcwtA 7 070 N nhc HARAPMB amp 706 6541 z Dv8l 4 47121 Introduction DCD Design wishes to thank you for purchasing a UF Lugger Lite This manual was written to help you make the best use of your new winch and to use it in the most secure way READ IT CAREFULLY BEFORE USING THE WINCH
4. the rope will already be stretched to its maximum and the rope grabbing system will be very hard to disengage 4 WARNING IF THERE IS ANY RISK THE LOAD MAY FALL OR ROLL BACK DO NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM 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 engine reach its maximum revolution RPM i C e 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 wa a Ce ZE 2 EC EN ET EH bes es ba D K ka i d KE D a s Es w BE 7 os E Ge 20 Uamprbsarqank Zgdmuamnprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z D v8 amp l 4 447121 3 4 3 1 Releasing the tension 4 CAUTION ALWAYS WEAR GLOVES WARNING STRETCH EQUALS DANGER 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 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 7UF Lugger Lite the rope grabbing system engages therefore applies pressur
5. x 15 52 cm wide x 36 cm high x 38 cm deep Rope Double braided polyester not included Unlimited rope length o Minimum diameter 1 2 12 mm o Maximum diameter 1 2 13 mm o Recommended rope with buried eye splice 5 6 Noise emissions Here are the different noise emissions of the 7UF Lugger Lite e Sound pressure level at operator position LpA measured o Engine idling 73 dBA o Full throttle 89 dBA e Sound power level LwA measured o Engine idling 85 dBA o Fullthrottle 102 dBA e Guaranteed sound power level LwA 105 dBA 5 7 Periodical testing some local regulations require lifting equipment to be tested periodically Check with local authorities for testing procedures 5 8 Manufacturer The TUF Lugger Lite is manufactured for DCD Design 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 26
6. 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 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 19 Uamprbsarqank Zgdwuamnprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z DV8l 4 447121 6 Once at desired position let the rubber handle go this will re engage the system if needed 7 lf needed stop the engine with the on off switch 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
7. 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 A 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 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 Start the winch engine 3 Figure 3 Slide the plate on the ball hitch and pull the winch forward 4 Figure 4 Wrap the rope around the drum and start winching The winch will align itself automatically with the load 11 Uampibsarqank Zgdwuamnprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z DV8l 4 447121 5 NOTE Do not leave the winch on the hitch with the engine running the resting position will cause the Oil Alert device to turn the Honda engine off see section 3 5 AA CAUTION USE THE TOWING BALL ADAPTER 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 0 Using the winch support plate 42200 010 with square
8. E 15 uanpbsargank zd druanprbsargank z 11 7 _ af tc K_py_bcj PcwA 7 070 N nh c HARAPMB amp 706 5541 z Dv l 4 47121 The great variety of situations encountered when winching prevents us from providing specific instructions however you need to consider the following points 4 WARNING CHECK WINCH POSITION ROPE CONDITION SOLIDITY OF THE ANCHOR POINT KNOTS CARABINERS OR SHACKLES IN ORDER TO PREVENT INJURIES OR MATERIAL DAMAGE 4 WARNING INSTALL THE ROPE IN SUCH A WAY THAT IT DOES NOT RUB AGAINST OTHER OBJECTS OR THROUGH AN OBSTRUCTION A GENERALLY IF THE ROPE TOUCHES AN OBJECT YOUR INSTALLATION IS INCORRECT 4 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 PULLEY 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 DO NOT OPERATE WITH THE WINCH TILTED OR THE OIL ALERT WILL KICK IN SEE SECTION 3 5 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 D
9. ING FOR A FEW SECONDS WITH THE POLE MOUNT RELEASE THE TENSION OFF THE TUF LUGGER LITE CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING AGAIN 3 3 4 2 With the vertical pull winch support 42200 050 After the installation of the tree 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 R pin 3 Figure 3 Attach the winch anchor hooks to the eye bolts of the vertical pull winch support Uampibsarqank Zgdmuamnprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z D V8l 4 447121 4 Figure 4 Wrap the rope around the drum and align the vertical support pulley with the rope axe and start to pull A WARNING IMPORTANT DONT GO OVER THE ROPE ENTRY PULLEY OF THE WINCH WITH THE ROPE FIGURE 2 BELOW AS IT WILL CREATE FRICTION AND WILL REDUCE LIFTING CAPACITY GO UNDER THE ROPE ENTRY PULLEY FIGURE 1 BELOW IN THIS CASE THE ROPE ENTRY PULLEY OF THE WINCH WILL NOT BE USED A WARNING IMPORTANT AFTER PULLING FOR A FEW SECONDS RELEASE THE TENSION AND CHECK THE SOLIDITY OF THE INSTALLATION AND TIGHTEN THE SLING OF THE TREE POLE MOUNT AGAIN 3 4 Moving a load 4 WARNING USING COMMON SENSE WHILE MOVING A LOAD IS THE KEY TO A SECURE WINCH USAG
10. Number of wraps on the capstan drum 4 WARNING Never use only one wrap on the drum 4 WARNING 75 sO 176 Ib 440 Ib 81 kg 200 kg 441 Ib 570 Ib 201 kg 260 kg 3 4 2 2 Lifting operation 4 CAUTION ALWAYS WEAR GLOVES To lift a load you will need to decide which anchoring accessories you will use Refer to section 3 3 Winch anchor to decide 4 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 LIFTING IT IS RECOMMENDED TO HAVE A 10 TO 1 SAFETY FACTOR FOR ALL ACCESSORIES Refer to the charts in section 3 4 2 1 Load lifting charts for the correct drum size and number of wraps of rope to use 3 4 2 3 Lowering a load CAUTION ALWAYS WEAR GLOVES WARNING YOUR TUF LUGGER LITE 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 18 uanpbsargank zqdruanprbsargank z 11 7 _ af tc K_py_bcj PcwA 7 070 Ninhc s HARAPMB amp 706 5541 z Dv l 4 47121 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 THE TUF LUGGER LITE IS NOT DESIGNED FOR LOWERING HEAVY LOADS OVER LONG DISTANCES FRICTION OF THE RO
11. OES NOT CROSS OVER ON IT IF IT HAPPENS RELEASE THE TENSION ON THE ROPE AND STOP THE ENGINE WHILE UNDOING THE CROSS OVER 4 WARNING po 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 3 4 1 Installing the rope on the TUF Lugger Lite A WARNING NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM OR THE ROPE ENTRY PULLEY WHEN THE WINCH IS RUNNING 16 Uamprbsarqank Zgdruamprbsarqank z 11 7 _ af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z DV8l 4 447121 1 Figure 1 Open the rope grabbing system no 1 and lock in place with spring pin no 2 2 Start the engine and let it idle for 30 seconds to warm up 3 Figure 2 Run the rope OVER the rope keeper and the rope entry pulley no 1 and UNDER the drum except when using vertical pull winch support see section 3 3 5 2 Then wrap the rope around the drum 3 or 4 turns no 2 4 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 5 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 6 Figure 5 As you pull the rope no 1 the
12. ON REPLACE ANY SAFETY LABELS THAT ARE DAMAGED ILLEGIBLE OR MISSING 4 WARNING NEVER PUT YOUR HANDS ON THE CAPSTAN DRUM THE ROPE GRABBING SYSTEM THE ROPE ENTRY PULLEY OR NEAR THE ROPE GUIDE WHEN THE ENGINE IS RUNNING WARNING ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA DANGER NEVER PULL ROLLING OBJECTS THAT MIGHT ROLL OUT OF YOUR CONTROL 4 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 4 WARNING siDE PULL OF LOAD IS NOT ALLOWED WITH THE TUF LUGGER LITE Uamprbsarqank Zgdmuamprbsargqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z D val 4 447121 4 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 LIFTING IT IS RECOMMENDED TO HAVE A 10 TO 1 SAFETY FACTOR FOR ALL ACCESSORIES 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 Is the engine ready to work 2 2 1 Engine oil Fill the Honda engine with a maximum of 0 25 litre of SAE 10W 30 API SJ
13. PE 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 4 WARNING NEVER GO OVER THE RATED LIFTING CAPACITY 555 LB 250 KG SINGLE LINE A WARNING NEVER BYPASS THE ROPE GRABBING SYSTEM 4 WARNING NEVER SHOCKLOAD THE SYSTEM WARNING BEWARE OF ROPE SNARLS WHILE LOWERING IF ROPE GETS TANGLED PULL ON ROPE WHILE ENGINE IS RUNNING UNTIL CLEARED CAUTION po NOT TOUCH THE CAPSTAN DRUM IMMEDIATELY AFTER OPERATION AS IT WILL GET HOT AND BURN BARE SKIN When you stop lifting with the 7UF Lugger Lite 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 throttle 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 WARNING DO NOT COMPLETELY DISENGAGE THE ROPE GRABBING SYSTEM IN CASE OF EMERGENCY SIMPLY LET THE RUBBER HANDLE GO THE SYSTEM WILL RE ENGAGE A WARNING NEVER LET THE PULLING ROPE SLIDE SUDDENLY IF A LOAD IS SUSPENDED 3 Figure 1 no
14. ROPE AROUND YOUR HAND CAUTION ALWAYS WEAR GLOVES 3 1 2 Rope maintenance CAUTION VISUALLY INSPECT YOUR ROPE BEFORE EACH USAGE IF IT SHOWS ANY SIGN OF DETERIORATION CUT STRANDS EXCESSIVE ABRASION REPLACE IT 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 Uamprbsarqank Zgdrwuamprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m cio ARAPMB amp 4706 6541 z D val 4 447121 3 2 At the end of the rope 3 2 1 Recommendations since the 7UF Lugger Lite can be used for pulling and lifting there are some guidelines to follow 3 2 1 1 Pulling 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 change the hook Moreover it retains about 70 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 1 2 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 it is STRONGLY RECOMMENDED to use the DCD Design rope with buried eyed splice The installati
15. e on the rope and keeps it under tension To release it follow steps 1 to 7 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 7UF Lugger Lite you simply have to release tension gradually to lower the winch gently to the ground 3 5 Oil Alert system The GX 50 Honda engine is equipped with an Oil Alert system that automatically turns off the ignition when the oil level goes below a safe level The Oil Alert system also turns off the ignition when the winch is operating at an angle greater than 20 degrees 4 degrees Make sure that your set up keeps the winch at a relatively horizontal level while winching and idling 4 0 Maintenance 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 4 and clean around the shaft figure 1 above Accumulated debris can damage the shaft seal Apply a bit of oil on the shaft to prevent i A i cigar Corrosion x d Es ae ja ai 4 2 Lubrication The rope entry pulley figure 1 no 1 must turn freely Lubricate it regularly with light oil Dirt and grime lodged between the pulley and the shaft may prevent it from turning freely If required d
16. he 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 pole or tree Insert the sling s hook into 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 13 Uampibsarqank Zgdwuamnprsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m cio ARAPMB amp 4706 6541 z D V8l 4 447121 3 3 4 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 Attach 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 e ebe 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 A WARNING AFTER PULL
17. ied eyed splice and a minimal breaking strength of 6945 Ib 3150 kg 1 3 Safety information A WARNING DO NOT LET CHILDREN USE THE TUF LUGGER LITE KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA 4 WARNING NEVER LET SOMEONE WITHOUT TRAINING USE THE TUF LUGGER LITE MAKE SURE THE USER KNOWS ABOUT THE SAFETY AND USAGE PROCEDURES AND HAS READ THIS MANUAL AND THE HONDA ENGINE USER MANUAL THE OPERATOR SHOULD BE ABLE TO OPERATE A LIFTING DEVICE AND BE AWARE OF ALL ASPECTS OF SUCH OPERATIONS HE SHOULD ALSO BE AWARE OF LOCAL REGULATION uanpbsargank z hruampbsargank z 11 7 _af tc K_py_bcj PcwA 7 070 Ninhc s HARAPMB amp 706 5541 z D 4 47121 WARNING INFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE PROCEDURES WARNING FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY GUIDELINES BEFORE WORKING WITH THE WINCH WARNING MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT INTO THE WINCH MOBILE PARTS WARNING NEVER USE THE TUF LUGGER LITE TO LIFT PEOPLE A WARNING USE ONLY 1 2 12 MM 13 MM DIAMETER DOUBLE BRAID DCD DESIGN POLYESTER ROPE WITH THIS WINCH 4 WARNING NEVER LIFT OBJECTS OVERHEAD OF PEOPLE 4 WARNING ALWAYS USE THE TUF LUGGER LITE HORIZONTALLY USING A PULLEY OR THE VERTICAL PULL WINCH SUPPORT TO REDIRECT THE ROPE VERTICALLY DANGER THE EXHAUST GAS CONTAINS TOXIC CARBON MONOXIDE NEVER RUN THE ENGINE IN A CLOSED AREA WITHOUT PROPER VENTILATION CAUTI
18. isassemble it to clean the shaft Use an 8 mm hex key 21 Uamprbsarqank Zgdwuamnprbsarqank z 11 7 _af tc K_py_ bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z D v8 amp l 4 447121 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 SAE80W90EP gear box oil 4 3 Honda engine Maintain the engine according to the instructions found in the Honda engine user manual provided 4 4 Storage Always store your 7UF Lugger Lite seated on its guard plate Refer to the Honda engine user manual for engine storage instructions 4 5 Spark arrestor If your TUF Lugger Lite is equipped with the optional spark arrestor 42120 000 you must clean it every hundred 100 hours to keep it running properly Refer to the Honda engine user manual for cleaning instructions 5 0 Complementary information 5 1 Accessories A complete line of accessories is available 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 products are warranted against defec
19. nprsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 1Z zz ez ep a vz sz o 9z zz e i T i Ba H oe yA 6e ge C3 oe te ze SCH 24 Uamprbsarqank Zgdmuamnprsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z DV8l 4 447121 eros BHOSTaaoxT sS SSS e fos posman OOO e 70 0008 ONOFF SWITCH WITH SUPPORT PLATE FOR GXHS0ENGINE 1 np 39 0007 METAL SCREW NO 10 X 1 2 PAN HEAD SQ DR CABLE HOUSING FEET o e2002 HEX FLANGE SERRATED BOLT MeT X12 e ES ES EW WER E E EE Set uanpbsargank z hruampbsargank z 11 7 _af tc K_py_bcj PcwA 7 070 Ninhcds HARAPMB amp 706 5541 z Dv l 4 47121 31 0025 BHCS 1 4 20 X 3 4 SS 10 0106 ROPE GUIDE FOR CAPSTAN DRUM 3 3 8 44 0001 UNIVERSAL SERIAL NUMBER amp WARNING LABEL DCD DESIGN 44 0029 DECIBEL WARNING 105 dB LABEL E 44 0022 ROPE LABEL DANGER WER 44 0026 ROPE INSTALLATION LABEL FOR 41000 400 amp 41000 500 Ee 5 5 Technical data Engine 4 stroke Honda GXH 50 cc Maximum pulling force single line 1000 Ib 450 kg Rated lifting capacity single line 555 Ib 250 kg Speed 40 ft min 12 m min Capstan drum 2 1 4 57 mm diameter o Upto 4 wraps of 1 2 12 13 mm rope Gear box Aluminum alloy Gear ratio 110 1 Unit weight 42 Ib 19 kg Clutch Centrifugal Rope grabbing system can be disabled Dimensions overall 20 x 14
20. oil For special usage or conditions such as extreme weather refer to the Honda engine user manual Check the oil level on a horizontal surface The oil level should be up to the edge of the opening 2 2 2 Gas petrol Fill the gas petrol tank with UNLEADED GASOLINE Do not use oil gas petrol mixture your TUF Lugger Lite is equipped with a 4 stroke engine Refer to the Honda engine user manual 2 2 9 Engine start up Refer to the Honda engine user manual for Start up instructions FIRST USE LET THE ENGINE RUN FIVE 5 S PE MINUTES AT IDLE BEFORE FIRST PULL The engine on off switch is located on the winch housing to the left of the handle figure 1 to the left uampbsargank Zgdruamprsarqank z 11 7 _af tc K_ mg bcj PcweA 7 070 z N m c UY ARAPMB amp 4706 6541 z D va amp l 4 447121 Make sure to pull on the recoil starter in the axis of the rope outlet figure 1 below If you pull vertically figure 2 below the friction of the rope on the plastic cover might damage the rope and the cover 2 2 4 Capstan drum Your 7UF Lugger Lite is equipped with the 2 1 4 57 mm diameter capstan drum and the 4 5 8 117 mm diameter safety lip If you wish to change the drum for the 3 3 8 85 mm drum sold separately you will also need to purchase and install the 5 127 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
21. on 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 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 10 Uampibsarqank Zgdwuamnprsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m cio ARAPMB amp 4706 6541 z D V8l 4 447121 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 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 A CAUTION 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 A CAUTION
22. s are aligned 2 Figure 2 Fasten lightly the metal screw provided with the appropriate screwdriver uanpbsargank z hruampbsargank z 11 7 _af tc K_py_bcj PcwA 7 070 Ninhcds HARAPMB amp 706 5541 z Dv l 4 497121 Refer to the Honda engine user manual for the spark arrestor cleaning instructions e Portable Winch part number 42120 000 e Honda part number 350 2M7 801 3 0 Winch usage WARNING MOST WINCHING SITUATIONS PRESENT POTENTIAL DANGERS 3 1 Rope 4 WARNING stay OUT OF THE WINCH LINE S PATH 3 1 1 Rope type 4 WARNING USE ONLY LOW STRETCH 1 2 12 OR 13 MM DIAMETER DCD DESIGN 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 po NOT USE 3 STRAND POLYPROPYLENE YELLOW ROPE A Polypropylene and polyethylene ropes are dangerous for winching because of their great elasticity and low melt point Make sure the rope is not damaged and that it offers an adequate resistance to pull the load WARNING STRETCH EQUALS DANGER A A stretched rope can recoil and cause serious burns as the rope leaves your hand A All ropes stretch a longer one more than a shorter one The more you pull the more it stretches A A stretched rope can also move the load in an unpredictable or dangerous way A A stretched rope can recoil and bring your hand towards the winch causing severe injuries NEVER WRAP THE
23. these instructions CAUTION You COULD be INJURED if you do not follow these instructions uanpbsargank z hruampbsargank z 11 7 af tc K_py_bcj PcwA 7 070 Ninhcds HARAPMB amp 706 5541 z Dv l 4 47121 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 Tas 1 to the right Read this instruction manual and Honda engine user s SER cs Ltd manual prior to using the winch Richmond BC Canada re ini d VEW 1J7 2 Only use low stretch rope Minimum diameter 1 2 12 1 888 794 8357 604 232 4445 m Maximum diameter 1 2 13 mm www dcddesign com 3 Never place your hands near the moving parts while the Model engine is running Mitte eege 4 Never use the winch for lifting people PASS Rated lifting capacity i Year manufactured OO 1 2 1 Sound power level label The sound power level label is also positioned on the right side of the winch housing The meaning of the icon in figure 1 to the right is 1 The guaranteed sound power level is 105 dB We recommend wearing hearing protection when using your TUF Lugger Lite 1 2 3 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 double braided polyester rope 1 2 12 13 mm with bur
24. throttle 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 7 Stand about 1 m 3 from the winch and pull gently and horizontally on the rope to get the slack until you feel the tension rising on the rope 8 Look at your set up to make sure that the winch anchor and the rope entry pulley are aligned with the rope 9 Check that the rope does not rub against objects along the path 10 Pull on the rope the throttle will go up and the winching will start 3 4 2 Lifting 3 4 2 1 Load lifting charts 4 WARNING BEFORE ATTEMPTING TO LIFT A LOAD IT IS IMPERATIVE TO EVALUATE ITS APPROXIMATE WEIGHT When lifting a load you may figure the minimal number of wraps required on the capstan drum in order to move the load Below are two charts in accordance with the capstan drum size used These charts are 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 17 uanpbsargank z dhruampbsargank z 11 7 af tc K_py_bcj PcwA 7 070 2 Ninhcds HARAPMB amp 706 5541 z Dv l 4 47121 ieee capstan drum Never use only one wrap on the drum 176 Ib 375 Ib 81 kg 170 kg 376 Ib 1000 Ib 171 kg 450 kg
25. ts in materials and workmanship while owned by the original purchaser as defined below The original purchaser is defined as the party or entity which purchases the winch and or accessories from an authorized DCD Design 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 22 uanpbsargank zqdruanprbsargank z 11 7 _ af tc K_py_bcj PcwA 7 070 Ninhc s HARAPMB amp 706 5541 z Dv l 4 47121 The TUF Lugger Lite is covered as follow e Winch components o Private use Two 2 year warranty service by DCD Design o Commercial use One 1 year warranty service by DCD Design e Engine The Honda engine is warranted by Honda Motor Corporation and the duration varies according to country and usage All Honda service centers can repair the winch engine 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 will replace or repair at its option any defective product All other winch accessories are covered by a complete one 1 year warranty Please refer to the DCD Design warranty policies on www dcddesign com if you have any questions 23 z N m c DJ ARAPMB n 706 6541 z Dv l 4 447121 u anpbsarqank Zdgdruam
26. tubing 50 mm 2 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 Ji d d 42200 020 Uampibsarqank Zgdwuamnprbsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m c ARAPMB amp 4706 6541 z D V8l 4 447121 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 A CAUTION MAKE SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 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 A CAUTION wake SURE THE ANCHORING VEHICLE S HAND BRAKE IS ON AND WORKING PROPERLY POSITION BLOCKS BEHIND THE WHEELS TO PREVENT ROLL BACK 3 3 4 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 t
27. wrench included with your winch e An 7 16 11 mm wrench or adjustable wrench not included 1 Figure 1 Remove the two bolts holding the rope guide 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 Uampibsarqank Zgdwuamnprsarqank z 11 7 _af tc K_ mg bcj PcwA 7 070 z N m cio ARAPMB amp 4706 6541 z D v8 amp l 4 447121 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 3 3 8 85 mm drum on the winch shaft Insert the washer the 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 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 2 2 5 Spark arrestor In certain areas it is forbidden to use a gas petrol engine without a spark arrestor Check local regulations An optional spark arrestor is available from DCD Design and or Honda Power a i V 2 P e Ze Dn ee da IK e k dee ien Products dealers Installation 1 Figure 1 Insert the spark arrestor into the exhaust tube Make sure the hole
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