Lug-All 6000-15 User manual

Operating Instructions For Your
LUG-ALL®6000-15 Cable Winch-Hoist
LAC-0308
Rev. 7/08
Copyright 2008 © LUG-ALL Corporation. All rights reserved.
604 Hemlock Road, Morgantown, PA 19543
Phone: [phone] / Fax: [phone] / Web: www.lug-all.com

2
SAFETY
Do not attempt to operate the LUG-ALL until you
carefully read the instructions and
recommendations in this manual.
The LUG-ALL must be properly operated and
maintained to avoid risk of property damage or
bodily injury.
To avoid personal injury or equipment damage:
• Do not exceed load rating.
• Inspect LUG-ALL before each use for damage,
malfunction or worn parts.
• Do not operate if hoist is damaged or malfunctioning.
• Inspect hooks (bent, enlarged opening) and latches.
Remove hoist from service until damaged hooks or
latches are replaced.
• Operate only when hook-to-hook pull is in a
straight line.
• Do not use if the cable has kinks, cuts, broken
strands, fraying or abrasions. The cable must be
replaced even though damage to the cable
appears minor.
• The cable must be evenly wrapped around the drum
TABLE OF CONTENTS
SAFETY.......................................................................2
SHEAR PIN WARNING............................................... 2
REGULAR LOWERING LUG-ALLS.............................. 3
Lifting or Tensioning..........................................3
Lowering or Backing Off
(requires load of 15 lbs or more)...................... 3
Free Release
(will not operate under load).........................3-4
RIGGING.....................................................................4
DAILY CABLE INSPECTIONS...................................... 5
TROUBLESHOOTING................................................. 6
CARE OF THE LUG-ALL CABLE RATCHET
WINCH-HOIST..................................................... 6
CABLE RATCHET WINCH-HOIST
PRE-OPERATIONAL INSPECTION........................ 7
LIMITED WARRANTY................................................ 8
Operating Instructions For Your LUG-ALL®6000-15 Cable Winch-Hoist / Copyright 2008 © LUG-ALL Corporation. All rights reserved.
SHEAR PIN WARNING
In addition to the features found on all LUG-ALL
Winch Hoists, your Model 6000-15 has the
following special features which you should be
aware of.
The handle socket can be moved to either of two
positions. Lifting or pulling and many lowering or
backing off operations can be easily accomplished
with the socket in the standard position parallel to
the edge of the u-frame. To lower or back off
heavy loads, you may want to have the socket in
the other position; this affords, a better leverage
angle, and allows lowering and backing off to be
done more easily. To move the handle socket from
one position to the other, simply remove the socket
cap screw with a 5/16” hex key, slide the socket to
the proper position, and reinsert the screw.
The reversible telescoping handle is aligned in the
handle socket by a pin 5 1/2” from its end and is
fastened in place by tightening the thumb screw
on the socket.
To telescope the handle, loosen the handle locking
nut (right hand thread), slide the smaller tube to
the desired position, and retighten the handle
locking nut by hand. Do not use a wrench.
The shear pin between the handle socket and u-
frame is designed to break if the Winch Hoist is
seriously overloaded. The shearing of the pin will
be readily apparent from the sharp report when it
snaps and the looseness of the socket. While the
Winch Hoist does not become inoperative when
the pin is sheared, an overload condition exists and
the unit should not be used until measures have
been taken to reduce the load. If it is not possible
to reduce the load and the overload condition is
for secure hoist operation. Examine the cable to
ensure it is properly seated in the pulley wheel.
• Do not use to lift people, or loads over people.
• Do not leave an unattended load suspended in
the air.
• Do not lengthen, or make any substitution for the
LUG-ALL reversible handle.
• Do not remove or obscure warning labels.
• Do not use hoist as a load binder.
• Do not snag or pull the cable over edges, as serious
weakening may result.
• Do not use LUG-ALL as a tow line.
• Close latches on hook before using.
• Use only genuine LUG-ALL replacement parts.

minor, the stops on the u-frame will allow you to
complete your immediate operation. DO NOT
BEGIN A SUBSEQUENT OPERATION BEFORE
REPLACING THE BROKEN SHEAR PIN!
To replace shear pin: (1) remove the handle from
the socket; (2) push the pieces of the broken shear
pin out from the u-frame side with a small hex
wrench, a nail, or other small shaft; (3) push the
replacement shear pin into place with your fingers.
It is easier to replace the shear pin if the screw
holding the handled socket is loosened first.
3
REGULAR LOWERING LUG-ALLS
The regular lowering LUG-ALL has three modes of
operation:
• Lifting or tensioning
• Lowering or backing off
• Free release
Lifting or lowering operations are carried out while
the hoist is under load (at least 15 lbs). The
position of the reverse lever to either hold the U-
frame pawl against or away from the ratchet teeth
(under spring tension) determines the action. Free
release quickly unwinds the cable from the drum.
Lifting and Tensioning
1) Rotate the reverse lever toward the drum to
engage the U-frame pawl against the
ratchet teeth.
2) Operate the handle as required to lift the load
or apply the required tension.
(SEE FIGURE 1)
Lowering or Backing Off
(requires load of 15 lbs or more)
1) Rotate the reverse lever away from the drum to
move the U-frame pawl away from the ratchet
teeth (FIGURE 2).
2) Move the handle until the U-frame pawl and
the main frame pawl spring engages a ratchet
tooth. Additional handle pressure in the same
direction will release the main frame pawl, once
Free Release (will not operate under load)
1) Rotate the reverse lever away from the drum
to move the U-frame pawl away from the
ratchet teeth.
FIGURE 1
FIGURE 2
Operating Instructions For Your LUG-ALL®6000-15 Cable Winch-Hoist / Copyright 2008 © LUG-ALL Corporation. All rights reserved.
U-Frame Pawl
U-Frame Pawl
Engaged
the pawl engages the main spring and forces
the main frame pawl to disengage.
3) Ease off handle pressure and the load will lower
one ratchet tooth.
(SEE FIGURE 2)

4
RIGGING
The LUG-ALL cable ratchet winch-hoist will operate in
any position: right side up, upside down or at any angle
as a hoist or horizontally as a winch. The lifting and
pulling power of the winch-hoist depends on whether it
is single-line rigged or double-line rigged with the use of
a pulley block. Rig the winch-hoist with double-line for
full rated capacity or single-line for one half-rated
capacity and twice the lifting distance and operating
speed.
Always rig the LUG-ALL so that it will hang freely and be
free to move from side-to-side. If the frame is jammed
out of line it is subjected to undue stress from uneven
loading and would not be free to move sideways, which
is necessary to allow even wrapping of the cable on the
drum. Hooks should be placed so the point of contact is
in line with the center of the shank or eye. When
rigging a LUG-ALL that will be used in rapid lowering
mode it must be done so a full stroke of the handle is
possible. For example, if working from a ceiling with the
LUG-ALL right side up it would be necessary to use a
choker or extension to lower the LUG-ALL sufficient
distance to allow the handle to travel its full arc, which
carries it above the top hook.
Single Rigged
(1/2 Capacity)
Double Rigged
(Full Capacity)
Alternate Single
Rigging
(1/2 Capacity)
FIGURE 3
Operating Instructions For Your LUG-ALL®6000-15 Cable Winch-Hoist / Copyright 2008 © LUG-ALL Corporation. All rights reserved.
2) Press the trigger to hold the main frame pawl
away from the ratchet teeth and pull out the c
cable the required distance.
(SEE FIGURE 3)
U-Frame Pawl

5
Broken Wires
The frayed condition of this cable indicates
broken wires and an unsafe condition. Cable
deficiencies of this type are usually caused by
abrasion. This can easily happen in a hoist
operation if the operator allows the cable to
come in contact with any other surface. This
cable is considerably weakened and must be
replaced before the hoist can be safely
operated.
Kinks
Kinks can result from improper uncoiling and
unspooling, or they can be formed in hoist
operation. Cable loops can occur in a slack
line, or in a line under tension. If a loop
occurs, it should be removed immediately.
Otherwise the loop may be pulled through
when tension is applied to the line and form a
permanently deforming kink. Kinks in a cable
are always dangerous as they create unequal
tension in the rope and in the strands. A cable
with kinks must be replaced before the hoist
can be safely operated.
DAILY CABLE INSPECTIONS
Drum Crushing and Spiraling
The badly deteriorated condition of this cable
clearly indicates that it is unsafe for operation.
Cable damage of this type is usually caused by
hoist abuse and by repeatedly overloading the
hoist beyond its rated capacity. A hoist with this
cable condition should not be used under any
circumstances, and the cable must be replaced
before the hoist can be safely operated.
Cut Cable
The condition of this cable indicates that it has
been cut by a sharp object. This is apparent to the
eye because several of the strands appear to be of
equal length. It goes without saying that this cable
must be replaced before the hoist can be safely
operated.
Operating Instructions For Your LUG-ALL®6000-15 Cable Winch-Hoist / Copyright 2008 © LUG-ALL Corporation. All rights reserved.
The pictures below illustrate the more obvious
types of severely damaged cables. Cables
exhibiting damage of this sort to any degree must
be replaced immediately.

6
TROUBLESHOOTING
If your LUG-ALL will not lower or back off
automatically, the following tests can be made:
1) Inspect cable on drum to see that it is not “wedged”
or “jammed”. Test by operating free release. The
cable should pull out freely.
2) Examine U-frame pawl spring. With the reverse lever
in the lifting position, the spring should hold the
pawl against ratchet teeth. In the lowering position,
the spring should hold the pawl away from the
ratchet teeth.
3) Check the button on the side of the U-frame pawl for
excessive wear. Its width should be approximately 1
1/2 times the diameter of the main frame pawl
spring. Place the reverse lever in the lowering
position, move the U-frame until the pawl button
comes in contact with the spring. If the button is not
worn excessively and slips past the spring, then the
U-frame is twisted and the winch-hoist should
be repaired.
4) If the pawl button contacted the main frame pawl
spring and guided the U-frame pawl into the ratchet
wheel, then test the main frame pawl spring for
fatigue. With the reverse lever in the lowering
position and the hoist under light tension, place the
handle in the full lowering position so that the
U-frame pawl engages the ratchet wheel. If the main
frame pawl does not release, continue to press on the
handle and at the same time press the “trigger”. If
the “trigger” pressure releases the main frame pawl,
but spring pressure does not, it indicates the spring is
fatigued and should be replaced.
5) If, when the above test is made, pressure on the
“trigger” does not release the main frame pawl, test
the U-frame pawl for excessive wear. To test, place
an object (knife blade, nail, paper clip, etc.) between
the U-frame pawl and the tooth it would normally
engage for lowering. If it lowers one notch under
this test with the unit under light tension, then the
trouble is located. This condition is more likely to
develop after a LUG-ALL has been repaired and a new
main frame pawl installed but not a new U-frame
pawl. Under normal conditions the two pawls wear
evenly and seldom give any difficulty.
6) Check both U-frame and main frame pawls for
“snappy” spring action. Sluggish action can result
from dirt or corrosion on the shafts and in the shaft
holes. Remove shafts and clean with fine steel wool.
Clean the shaft holes in the pawls. The U-frame and
main frame pivot points are equipped with OILITE
Operating Instructions For Your LUG-ALL®6000-15 Cable Winch-Hoist / Copyright 2008 © LUG-ALL Corporation. All rights reserved.
CARE OF THE LUG-ALL CABLE
RATCHET WINCH-HOIST
Your LUG-ALL is designed to provide many years of
satisfactory performance if used properly. Always
hang it freely with a straight line between the top
hook and the load hook (do not jam against a
stationary object). And remember, LUG-ALL hoists
are intended for industrial use, not for lifting or
supporting human or animal cargo, or lifting over
people.
The LUG-ALL is extremely easy to care for. Its open
construction makes it simple to clean after use in
mud, ice, sand or other extreme conditions. Strip
the cable from the drum and flush the drum with
water or steam. A quick check of the hoist takes
only seconds. Years of life can be added to the
hoist by following these recommendations.
• Do not snag or pull the cable over sharp or rough
edges as this will wear and fray the cable. LUG-ALLs
are equipped with high quality cable, and with
reasonable care will give satisfactory service.
• When rewinding the cable on the drum, apply light
(10 lbs) tension. This assures even wrapping and will
prevent the cable from “wedging” the next time it is
used under heavy load.
• Stop pulling when the cable clamp reaches the cable
guide or pulley wheel, or the pulley wheel reaches t
the cable guide (depending on rig used), as continued
pulling will damage parts.
• Use a steady, straight pull to operate the LUG-ALL.
• When operating the LUG-ALL under load, do not
allow the handle to “fly” as this can cause damage to
the U-frame.
bearings. Apply light oil on all bearing surfaces and
reassemble.
7) Check to see that both pawls engage solidly at the
base of the ratchet teeth in both lifting and
lowering cycles.
8) If main frame pawl on rapid lowering model does not
fully engage, check the actuating pin and edge of
projection on the rapid lowering assembly that
engages the actuating pin to see if it is bent.
9) The U-frame pawl should align with the ratchet teeth,
if it does not, check to see if the U-frame is twisted
from someone having let go of the handle while
handling a load.

7
Cable Ratchet Winch-Hoist Pre-Operational Inspection
Unit Number: ___________________ Model: ____________________ Date: ____________________
Inspection Point Inspection Result (✓)
Pass Fail
1) Inspect hooks and latches for deformation, cracks, and
wear. An elongated or bent hook is an indication that the
hoist was overloaded.
2) Check operation of latches. Safety latches on the hooks
should not be defeated by wiring it open or by removal.
3) Inspect cable for kinks, cuts, broken strands, fraying or
abrasions.
4) Check ratchet teeth for gouges, burred edges or other
physical damage.
5) Check for bent or broken metal parts, rounded edges, and
elongated holes.
6) Check metal parts for corrosion.
7) Check pawls and levers for bends, cracks or other damage.
8) Check integrity of springs.
9) Operate U-frame and verify that the U-frame does not rub
against main frame during operation.
10) Test operating functions (lifting, lowering, free release)
of hoist.
NOTE: The cable should be pulled from the drum during inspection. The hoist should be removed from service if any inspection points fail.

LIMITED WARRANTY
Seller warrants that the LUG-ALL described is free from defects in material and workmanship for a term
of one year from the date of purchase by the original consumer. In the event of a defect, malfunction
or other failure of the LUG-ALL product not caused by unreasonable use, failure to provide reasonable
and necessary maintenance or damage to the product while in the possession of the consumer, the seller
will remedy the defect or failure within 30 days of return to seller at the address specified below. The
remedy will consist solely of repair or replacement of the product at the seller's option. If after a
reasonable number of attempts by the seller to remedy the defect, malfunction or other failure and the
remedy fails of its essential purpose, the consumer is entitled to elect either a refund or a replacement,
without charge.
This warranty does not apply to defects caused by modification, alteration, repair or service of the LUG-
ALL by anyone other than LUG-ALL. The warranty extends to only the original purchaser of the LUG-
ALL.
In order to obtain performance under the warranty, the consumer must deliver the LUG-ALL and all
ancillary parts thereto to LUG-ALL Corporation, 604 Hemlock Road, Morgantown, PA 19543, together
with written explanation of the defect or failure (Telephone: [phone]; Fax: [phone]).
Delivery expenses and insurance for warranty service to and from LUG-ALL are the responsibility of the
Buyer. Proof of purchase, such as sales receipt or other documentation is required when requesting
warranty service.
This warranty gives you specific legal rights, and you may also have other rights that vary from state to
state.
In no event shall seller (including its affiliates, subsidiaries, contractors, directors, employees and agents)
be liable for any consequential, incidental, economic, direct, indirect, general or special damages of any
kind, including, without limitation, lost business, lost savings, lost data and lost profits, regardless of the
cause and whether arising in contract (including fundamental breach), tort (including negligence), or
otherwise, even if the seller has been advised of the possibility of such damages. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the exclusion or limitation
in this paragraph may not apply to you.
Buyer shall notify Seller promptly, and in any event within thirty (30) days of its becoming aware of any
accident or malfunction involving Seller's products that arise out of or relate to any personal injury or
damage to property and shall cooperate fully with Seller in investigating and determining the cause of
such accident or malfunction. To the extent that Buyer fails to give such notice to Seller and provide
such cooperation, Buyer shall be liable to Seller for the consequences of such failure.
Copyright 2008 © LUG-ALL Corporation. All rights reserved.