USER MANUAL
Contents
1. The TUF Lugger Lite is covered as follows Winch components o Private use Five 5 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 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 Retain 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 complete warranty on www dcddesign com if you have any questions 5 3 Serial number localization The winch serial number is indicated on the safety 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 DCD pad bunpui pede pat awaj Bud pon uox ubrsappop MAMMA TET TOO SER T6 RE epeue 28 UEJIADIN 0799 081 5 4 Exploded view and parts list PART NUMBER ITEM DESCRIPTION QTY 1 HCS 12. load Pull HORIZONTALLY on the rope The tension you exert on the rope will keep the winch level Do not operate with the winch tilted or the Oil Alert will kick in A DANGER DO NOT WRAP THE ROPE AROUND YOUR HANDS OR YOUR BODY ALSO BEWARE OF THE ROPE ACCUMULATING IN FRONT OF YOU MAKE SURE YOUR FEET DO NOT GET TANGLED IN IT WARNING CAREFULLY WATCH THE CAPSTAN DRUM DURING THE OPERATION AND MAKE SURE THAT 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 3 6 2 Winching 3 6 2 1 If the rope slips If the rope slips on the drum while winching add a fourth wrap of rope on the drum When the winch reaches its maximum capacity the engine stalls You then have to redo your set up add pulleys or rock the load see section 3 6 2 2 3 6 2 2 To rock the load Pull the rope until the engine comes close to stalling and release the tension Pull again on the rope to put tension and repeat as needed CAUTION BE CAREFUL WITH THIS METHOD SINCE IT GENERATES HEAT AND CAN WEAR THE ROPE QUICKLY WARNING IF THE WINCH IS PULLING THE ROPE BUT THE LOAD DOES NOT MOVE OFTEN THE CASE WHEN USING A VERY LONG ROPE IT S BECAUSE YOUR ROPE IS STRETCHING AND COULD REACH THE BREAKING POINT AND RECOIL TOWARDS YOU SLOWLY RELEASE THE TENSION ON THE ROPE BUT BEWARE OF THE ACCUMULATED TENSION YOU COULD GET BURNED FROM THE ROPE EXITING YOUR HANDS QUICKLY OR
3. 1 2 12 13 mm 41000 200 Gear ratio 110 1 e Pulling force according to drum diameter o Installed 2 1 4 57 mm drum 2200 Ib 1000 kg o Optional 3 3 8 85 mm drum 1400 Ib 635 kg Speed according to drum diameter o Installed 2 1 4 57 mm drum 40 min 12 m min o Optional 3 3 8 85 mm drum 60 min 18 m min 41000 300 e Gear ratio 53 1 e Pulling force according to drum diameter o Installed 3 3 8 85 mm drum 700 Ib 350 kg o Optional 2 1 4 57 mm drum 1100 Ib 500 kg e Speed according to drum diameter o Installed 3 3 8 85 mm drum 120 min 36 m min o Optional 2 1 4 57 mm drum 80 min 24 m min 5 6 Noise emissions Here are the noise emissions of the TUF Lugger Lite Sound pressure level at operator position LpA measured o Engine idling 73 dBA o Fullthrottle 89 dBA 5 7 Manufacturer The TUF Lugger Lite 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 22 DCD
4. 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 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 4 A 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 10 DCD 3 3 3 Using the winch support plate 42200 010 with 2 50 mm square tubin 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 42200 020 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 MAK
5. 2 13 X 6 GR5 ZN FLAT WASHER 1 2 ZN BUSHING FOR SAFETY HOOK SAFETY HOOK 3 4 TON BHCS 1 4 20 1 55 ALUMINIUM ROPE EXIT HOOK VINYL GRIP WINCH HANDLE ROPE INSTALLATION LABEL TUF LUGGER LITE ON OFF SWITCH WITH SUPPORT PLATE FOR GXH 50 70 0023 ENGINE 35 0006 FLAT WASHER 1 4 ZN 39 0007 METAL SCREW NO 10 X 1 2 PAN HEAD SQ DR 31 0019 HCS 3 8 24 X 1 GR5 ZN 33 0005 NYLON LOCKNUT 1 2 13 ZN 44 0028 UNIVERSAL SERIAL NUMBER amp WARNING LABEL DCD DESIGN 44 0023 DECIBEL WARNING 93 dB LABEL 10 0103 ROPE KEEPER 10 0101 ROPE ENTRY PULLEY 10 0119 SHOULDER BOLT 5 8 X 1 1 2 ZN 10 0100 ROPE GUIDE FOR CAPSTAN DRUM 2 1 4 43 0013 SHAFT KEY FOR CAPSTAN DRUMS 2 1 4 amp 3 3 8 31 0025 BHCS 1 4 20 X 3 4 SS 10 0096 CAPSTAN DRUM 57 MM 10 0102 DRUM RETAINING WASHER 10 0001 CAPSTAN DRUM 85 MM 31 0025 BHCS 1 4 20 X 3 4 SS 10 0106 ROPE GUIDE FOR CAPSTAN DRUM 3 3 8 31 0010 35 0004 10 0098 42430 020 31 0024 10 0099 44 0019 10 0094 44 0027 N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 21 5 5 Technical data 41000 200 and 41000 300 Engine 4 stroke Honda GXH 50 cc Gear box Aluminum alloy Unit weight dry 35 Ib 16 kg Dimensions overall 13 wide x 14 high x 15 deep 33 cm x 36 cm x 38 Rope Low stretch double braided polyester not included Unlimited rope length o Minimum diameter 3 8 10 mm o Maximum diameter 5 8 16 mm o Recommended
6. BE PULLED TOWARDS THE WINCH 3 6 2 3 How to pause while winching SLOWLY release the tension on the rope and let it slip on the capstan drum A CAUTION DO NOT LET THE ROPE SLIP FOR MORE THAN A FEW SECONDS ON THE DRUM WHILE IN TENSION THE HEAT CREATED BY THE FRICTION COULD MELT OR DAMAGE THE ROPE DCD 3 6 2 4 How to maintain a load without releasing the tension You may maintain tension on the end of the rope either by holding it or attaching it 1 Shut the engine off 2 Wrap the rope twice around the rope hook to relieve tension from your hands figure 1 3 lie two half knots around the rope hook figure 2 Figure 1 3 6 2 5 How to resume winching You must release some tension before restarting the winch engine First untie the two half knots Let go of some of the rope to release some tension While holding the rope with one hand start the engine by pulling on the crank and pull the throttle up You can now resume winching 3 6 2 6 If you must keep tension on the rope at start up You can install a rope grab device or a Prussik knot attached to your anchor point in order to keep tension on the rope 3 6 2 7 If your rope is too short If your rope is too short you will have to link two ropes together 1 Figure 1 no 1 Using the bowline knot section 3 2 1 link your two ropes together 2 Figure 1 no 2 IMPORTANT Leave about 3 1 m of rope tailing out of
7. IF YOUR ROPE IS DIRTY WASH IT DIRTY ROPES DETERIORATE FASTER AND CAUSE PREMATURE WEAR ON PARTS WHICH ARE IN CONTACT WITH THE ROPE 3 2 At the end of the rope 3 2 1 Recommended knots 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 will keep about 7596 of your rope s capacity DCD 3 2 2 Recommended hooks If you usually pull with a choker chain use a grab hook figure 1 or grab hook with latch figure 2 If you usually pull a sling or a ring use a safety hook with latch figure 3 or shackle figure 4 3 3 Winch anchor OPTION 1 In most cases the winch 15 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 OPTION 2 Alternately the winch can be anchored to the load that needs to be moved and the rope end is tied to a fixed point The winch and the load are therefore pulled toward the fixed point where the rope end is tied This method is useful when you need to guide the load while you operate the winch
8. the knot on the rope MM the load You will need it to resume winching after undoing the knots 3 Figure 2 A WARNING otop the winch BEFORE the knot reaches the rope entry pulley of the winch since it CANNOT GO THROUGH it 4 Release tension off the rope If necessary attach the load to a fixed object 5 Undo the knots and use the remaining length 3 or 1 m to wrap around the capstan drum and start winching again 17 DCD 3 6 3 Stopping the winch 1 Release tension gradually to lower the winch gently to the ground 2 Bring throttle down to idle 3 Turn ignition switch off 4 0 Maintenance 4 1 Cleaning Once your job is done you should clean and dry your winch A CAUTION INSPECT THE WINCH HOOKS ROPE KNOTS AND POLYESTER SLING TO DETECT J ANY DAMAGE OR SIGNS OF WEAR Periodically remove the capstan drum section 2 2 4 and clean around the shaft figure 1 Accumulated debris can damage the shaft seal Apply oil to prevent corrosion 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 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 rem
9. vertically figure 2 below the friction of the rope on the plastic cover might damage the rope and or the cover 2 2 4 Capstan drum Your 7UF Lugger Lite is equipped with either a 2 1 4 57 mm or 3 3 8 85 mm diameter capstan drum If you wish to change the drum follow these simple installation steps All bolts require a 5 32 4 mm hex wrench included with your winch manual 1 Remove the rope guide figure 1 2 Remove the bolt located at the end of the drum shaft figure 2 3 Remove the original drum from the shaft figure 3 If necessary you may push it forward with two screwdrivers Make sure that the shaft key stays in place Install bolt and washer 4 Replace it with the new drum figure 4 5 Install the rope guide included with the new drum using the two 2 bolts IMPORTANT Make sure that the rope guide is not in contact with the capstan drum In certain areas it is forbidden to use gas petrol engine without spark arrestor Check local regulations An optional spark arrestor is available from DCD Design amp Manufacturing Ltd and or Honda Power Products dealers 2 2 5 Spark arrestor Installation 1 Insert the spark arrestor into the exhaust tube Make sure the holes are aligned figure 1 2 Fasten lightly the metal screw provided with the appropriate screwdriver figure 2 Refer to page 10 of the Honda engine user manual for the spark arrestor cleaning instructions e
10. 3 3 4 Oil system p 14 3 5 Rope installation p 14 3 5 1 Rope p 14 3 5 2 Pulley p 14 3 5 8 Direction p 15 3 5 4 Onahill p 15 3 6 Pulling a load p 15 3 6 1 Wrapping the rope on the capstan drum p 15 3 6 2 Winching p 16 3 6 2 1 If the rope slips p 16 3 6 2 2 To rock the load p 16 3 6 2 3 How to pause while winching p 16 3 6 2 4 How to maintain a load without releasing the tension p 17 3 6 2 5 How to resume winching p 17 3 6 2 6 If you must keep tension on the rope at start up p 17 3 6 2 7 If your rope is too short p 17 3 6 3 Stopping the winch p 18 4 0 Maintenance p 18 4 1 Cleaning p 18 4 2 Lubrication p 18 4 3 Honda engine p 18 4 4 Storage 18 4 5 Spark arrestor p 19 5 0 Complementary information p 19 5 1 Accessories p 19 5 2 Warranty p 19 5 3 Serial number localization p 19 5 4 Exploded view and parts list p 20 5 5 Technical data p 22 5 6 Noise emissions p 22 5 Manufacturer p 22 DCD DCD Design amp Manufacturing Ltd wishes to thank you for purchasing TUF Lugger M 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 For any problems or questions contact us directly Introduction 1 0 Safety quidelines The TUF Lugger Lite is designed
11. 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 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 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
12. DCD Design part number 42120 000 e Honda part number 350 2M7 801 3 0 Winch usage A WARNING MOST WINCHING SITUATIONS PRESENT POTENTIAL DANGERS 3 1 Rope A WARNING STAY OUT OF THE WINCH LINE S PATH 3 1 1 Rope type Use only low stretch rope We recommend using double braided polyester rope with a minimum diameter of 3 8 10 mm Maximum rope diameter is 5 8 16 mm For most situations we recommend using 1 2 12 mm double braid polyester rope Please contact us for other rope types suitability A WARNING DO NOT USE 3 STRAND POLYPROPYLENE YELLOW ROPE 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 DCD WARNING stretcu EQUALS DANGER A stretched can recoil and cause serious burns as the leaves your hand 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 stretched can recoil and bring your hand towards the winch causing severe injuries NEVER WRAP THE ROPE AROUND YOUR HAND A CAUTION a ways WEAR GLOVES 3 1 2 Rope maintenance A CAUTION VISUALLY INSPECT YOUR ROPE BEFORE EACH USAGE IF IT SHOWS ANY SIGN OF DETERIORATION CUT STRANDS EXCESSIVE ABRASION REPLACE IT
13. E 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 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 pole or tree 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 11 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 3 3 4 1 With the winch support plate 42200 010 After the installation of the tree pole mount section 3 3 4 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 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 12 A CAUTION IF YOU NEED TO PULL DOWNWARD YOU WILL NEED TO INSTALL EITHER A PULLEY OR A ROLLER TO PREVENT DA
14. GHT ROLL OUT OF YOUR ONTROL O P DCD WARNING tHe TUF LUGGERT LITE IS NOT INTENDED FOR LIFTING PURPOSES A WARNING NEVER USE THE 7TUF LUGGER LITE TO LIFT PEOPLE A CAUTION WE RECOMMEND WEARING HEARING PROTECTION CAUTION DO NOI TOUCH THE CAPSTAN DRUM IMMEDIATELY AFTER OPERATION AS IT WILL GET HOT AND BURN BARE SKIN 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 liter of SAE 10W 30 API SJ oil For special usage or conditions such as extreme weather refer to page 7 of 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 PETROL Do not use oil gas petrol mixture your TUF Lugger Lite is equipped with a 4 stroke engine Refer to page 7 of the Honda engine user manual 2 2 3 Engine start up Refer to page 3 of the Honda engine user manual for start up instructions FIRST USE LET THE ENGINE RUN FIVE 5 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 Make sure to pull on the recoil starter in the axis of the rope outlet figure 1 below If you pull
15. MAGE 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 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 pole mount section 3 3 4 follow these steps 1 Figure 1 Insert the vertical pull winch support onto the square tubing of the tree 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 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 THE JTUF LUGGER LITE 15 NOT INTENDED FOR LIFTING PURPOSES 13 WARNING IMPORTANT DON T 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 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 Oil Alert system The GX 50 Honda engine is equipped with an Oil Alert
16. READ CAREFULLY BEFORE USE Design amp Manufacturing Ltd TUF Lugger Lite 41000 200 and 41000 300 USER MANUAL Models 41000 200 Maximum pulling capacity single line 2200 Ib 1000 kg 41000 300 Maximum pulling capacity single line 700 Ib 350 kg 2012 DCD Design amp Manufacturing Ltd All Rights Reserved English version Summary Introduction p 3 1 0 Safety guidelines p 3 1 1 Safety messages p 3 1 2 Labels p 1 2 1 Warning label p 3 1 2 2 Sound pressure level label p 4 1 3 Safety information p 4 2 0 Before first use 5 2 1 Upon receiving the winch p 5 2 2 15 the engine ready to work 5 2 2 1 Engine oil p 5 2 2 2 Gas petrol p 5 2 2 3 Engine start up p 5 2 2 4 drum p 6 2 2 5 Spark arrestor p 7 3 0 Winch usage p 7 3 1 Rope p 7 3 1 1 Rope type p 7 3 1 2 Rope maintenance p 8 3 2 At the end of the rope p 8 3 2 1 Recommended knots p 8 3 2 2 Recommended hooks p 9 3 3 Winch anchor p 9 3 3 1 Using the polyester sling included with the winch p 9 3 3 2 Using the towing ball adapter for tow balls to 2 50 mm diameter p 10 3 3 3 Using the winch support plate with 2 50 mm square tubing p 11 3 3 4 Using the tree pole mount with anchor strap p 11 3 3 4 1 With the winch support plate p 12 3 3 4 2 With the vertical pull winch support p 1
17. e the Winch LX l inching speed engine is running 4 Never use the winch for lifting people Serial number Year manufactured DCD 1 2 2 Sound pressure level label housing figure 1 1 The guaranteed measured sound pressure level LpA at operator position is 93 dB We recommend wearing hearing protection when using your TUF Lugger Lite 1 3 Safety information A WARNING DO NOT LET CHILDREN USE THE TUF LUGGER LITE KEEP CHILDREN AND ANIMALS AWAY FROM THE WORK AREA A 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 WARNING NFORM ALL USERS OF THE SAFETY GUIDELINES AND USAGE PROCEDURES WARNING FAMILIARIZE YOURSELF WITH THE PRODUCT AND THE SAFETY GUIDELINES BEFORE WORKING WITH THE TUF LUGGER LITE WARNING MAKE SURE THAT YOUR CLOTHES ARE NOT GOING TO GET CAUGHT INTO THE TUF LUGGER LITE MOBILE PARTS DANGER THE EXHAUST GAS CONTAINS TOXIC CARBON MONOXIDE NEVER RUN THE ENGINE IN A CLOSED AREA WITHOUT PROPER VENTILATION A CAUTION REPLACE ANY SAFETY LABELS THAT ARE DAMAGED ILLEGIBLE OR MISSING WARNING NEVER put YOUR HANDS ON THE CAPSTAN DRUM NEAR THE ROPE GUIDE OR THE ROPE ENTRY PULLEY WHEN THE ENGINE IS RUNNING A WARNING ALWAYS KEEP BYSTANDERS OUTSIDE THE WORKING AREA DANGER NEVER PULL ROLLING OBJECTS THAT MI
18. e touches the ground while pulling your installation is incorrect 3 5 4 On a hill A WARNING DO 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 6 Pulling a load WARNING CHECK WINCH POSITION ROPE CONDITION SOLIDITY OF THE ANCHOR POINT KNOTS CARABINERS OR SHACKLES IN ORDER TO PREVENT INJURIES OR MATERIAL DAMAGE 3 6 1 Wrapping the rope on the capstan drum NEVER YOUR HANDS ON THE CAPSTAN DRUM THE ROPE GUIDE OR THE ENTRY PULLEY WHEN THE ENGINE IS RUNNING 1 Start the engine and let it idle for 30 seconds to warm up 2 Run the rope OVER THE ROPE KEEPER and the rope entry C pulley and under the drum l figure 1 no 1 2 3 Wrap the rope around the drum 3 or 4 turns figure 1 no 2 4 Bring the rope behind the rope hook figure 1 no 3 5 Stand about 3 1 m winch and pull gently and horizontally on the rope to get the slack until you feel the tension rising the rope 6 Look at your set up to make sure that the winch anchor and the rope entry pulley are aligned with the rope 7 Check that the rope does not rub against objects along the path 8 Pull the throttle up and start winching 15 While winching position yourself away from the winch order to see both the winch and the
19. ove the oil plug figure 1 no 2 Use an 8 mm hex key Lean it toward you some oil should leak out of the hole If needed you can add type SAE80W9OEP 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 TUF Lugger M Lite seated on its protection plate Refer to the Honda engine user manual for engine storage instructions 18 DCD 4 5 Spark arrestor If your TUF Lugger Lite is equipped with the optional spark arrestor 42120 000 sold separately 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 You will find the list on our website at www dcddesign com 5 2 Warranty DCD Design amp Manufacturing Ltd products are warranted against defects 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 amp Manufacturing Ltd retailer as shown by the original sales receipt 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
20. 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 3 5 Rope installation A WARNING USING COMMON SENSE WHILE INSTALLING THE ROPE IS THE KEY TO 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 3 5 1 Rope Use a low stretch rope in good condition with a minimum diameter of 3 8 10 mm and a maximum diameter of 5 8 16 mm with good knots We strongly suggest the bowline knot see section 3 2 1 Use pulleys to redirect the rope and to multiply the pulling capacity when the load is near or over the pulling capacity of the winch 3 5 2 Pulley Using a pulley at some distance in front of the winch offers many advantages e Pulling angle lifts the load and reduces friction e The winch is maintained at a relatively horizontal position Winch and operator are away from the load s path 14 3 5 3 Direction Install the rope in such a way that it does not rub against other objects Try to set up the rope so that the front of the load is slightly lifted Do not pull downwards or through an obstruction A Generally if the rop
21. to pull non rolling objects usually at a plus or minus 45 degree angle from the horizontal use of a pulling device implies serious risks of injuries property damage or even death Do not underestimate its potential danger 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 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 WARNING You COULD be MORTALLY or SEVERELY INJURED if you do not follow these instructions CAUTION You COULD be INJURED if you do not follow these instructions 1 2 Labels 1 2 1 Warning label DCD Design amp Manufacturing Ltd The warning label is positioned on the right side of the 180 6620 McMillan Way oe IO winch housing See the meaning of all four icons in the On A RA ee aa 3 figure 1 1 888 794 8357 604 232 4445 www dcddesign com 1 Read this instruction manual and Honda engine Model user s manual prior to using the winch 2 Only use low stretch rope Minimum diameter 3 8 10 mm Maximum diameter 5 8 16 mm Rated lifting awiy 3 Never place your hands near the drum whil
Download Pdf Manuals
Related Search