Lug-All 6000-15SH User guide

1
®
OPERATING
AND
SERVICING
INSTRUCTIONS
FOR
YOUR
Winch
Hoist
LUG-ALL
MORGANTOWN,PA.19543
Since 1949 - More Than
5 Decades Of Excellence
Provided by: www.hoistsdirect.com

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LUG-ALL values your opinions and comments.
Please assist our continuous improvement plan
by logging on to LUG-ALL’s website and
completing our on-line customer survey.
www.lug-all.com
For parts list drawings, log on to our website.
www.lug-all.com
THE HOISTS DESCRIBED IN THIS
BOOKLET ARE INTENDED FOR
INDUSTRIAL USE AND NOT FOR
LIFTING OR SUPPORTING HUMAN
OR ANIMAL CARGO.
WARNING

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TABLE OF CONTENTS
LUG-ALL Model Number................................................4
Hoist Safety & You...........................................................5
Safe Hoisting Procedures ...............................................8
HowTo Operate RegularLowering LUG-ALLs...............12
Operating Instructions For The Rapid Lowering LUG-ALLs..13
Rigging Position ............................................................14
Suggestions For Rigging Your Car Door Puller .............15
The Reversible Handle .................................................15
Cable Return Crank ......................................................16
HOW TO TAKE CARE OF YOUR LUG-ALL
How to Take Care of Your LUG-ALL..............................17
Servicing Instructions For Regular Lowering LUG-ALL
and LUG-ALL Car Door Pullers....................................18
Servicing Instructions For Rapid Lowering LUG-ALLs.......... 21
Trouble Shooting ...........................................................22
Servicing Instructions For Model 6000-15SH................23
Servicing Instructions for Models 2, 3, and 4 .................25
LimitedWarrantyStatement...........................................28
Form 281-A 11/02 Printed in U.S.A.

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You will need to know your LUG-ALL model number to order
replacement parts. See the LUG-ALL parts list or the LUG-ALL
website for correct part numbers.
MORGANTOWN BUSINESS PARK
604 HEMLOCK ROAD
MORGANTOWN, PA 19543
610-286-9884
FAX: [phone]
www.lug-all.com
[email protected]
FINDYOURLUG-ALLMODELNUMBER HERE

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HOIST
SAFETY
& YOU
No matter how many safety features a
manufacturer builds into a tool, true operational
safety depends largely on the user. Likeallother
mechanicalequipment,LUG-ALL mustbe properly
operated and maintained to avoid risk of property
damage or bodily injury.
Please do not attempt to operate your LUG-ALL
until you carefully read the instructions and
recommendations in this booklet. We also
suggest that you save this booklet for reference
in servicing your hoist.
Play it safe. Take good care of your LUG-ALL and
it will reward you with many years of dependable,
trouble-free service.

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use LUG-ALLs to
support human or animal
cargo in any manner
use LUG-ALLs as load
binders

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load your LUG-ALL
beyond rated capacity.
use anything but
factory-engineered
LUG-ALL replacement
parts.
lengthen, or make any
substitution for the
LUG-ALL reversible
handle.
let the LUG-ALL cable
or webstrap come in
contact with any other
surface.
use a LUG-ALL cable
or webstrap as a choker.
leave a load
unattended and/or
suspended in air.
use a LUG-ALL
as a tow line.
fail to check your
LUG-ALL before each
use for damage,
malfunction, or worn
parts.

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SAFE HOISTING
PROCEDURES
1. LUG-ALLs must never be used to support human
or animal cargo in any manner.
It is always unsafe to use a LUG-ALL, or LUG-ALLs, to life or
support humans or animals, or any type of scaffolding or vehicle
onwhichhumansaresupported.
2. LUG-ALLs must never be used as load binders.
Resist the temptation to use your LUG-ALL as a load binder. You
couldbe inviting trouble. It was notdesignedforthispurposeandis
notsafetouseinthismanner.The LUG-ALL hoist must always be
operatedwiththecable or web strap in a straight line.Thecableor
web strap must never be wrapped around any object as this will
damage the cable or web strap and may lead to future accidents.
3. Never load your LUG-ALL beyond rated capacity.
Cheating on capacities is a dangerous trick. Overloading a
LUG-ALL cancauseaccidental injury to the operator,the hoist, or
the load. It can also damage the hoist so that it may fail in the
future.
Therated capacity of your LUG-ALL is clearly marked on thecable
shield, and on the teeth side of the drum (It may be necessary to
rotatethe drum in ordertobringthe load capacity intoview).Ifthere
is any doubt about the weight of your load, use the next larger
capacityLUG-ALL.
4. Use only factory-engineered LUG-ALL replacement
parts.
LUG-ALLsare precisionengineeredfordependableoperation,and
any substitution of parts, other than LUG-ALL factory parts, can
seriously damage its safe performance. When repairing your
LUG-ALL, replace any damaged member with a new LUG-ALL
replacement part. It is unsafe to repair LUG-ALL components by
healing,welding,bending,straightening,oranyothermeans.

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5. Never lengthen, or make any substitution for the
LUG-ALL reversible handle.
The LUG-ALL reversible handle is designed to bend as a warning
when the hoist is loaded at more than 100% capacity. If the handle
shouldbreakthroughhoist overload or improper use, the LUG-ALL
mustnotbeuseduntila LUG-ALL replacementhandleisobtained.
Makeshift handles, or handle extensions are dangerous. They can
increasetheleverageso thatthehoistmayeasily exceeditscapacity
withouttheuser’sknowledgeandresult in physical harm.
6. Keep the hoist cable or web strap free at all times
and never let it come in contact with any other
surface.
Alwaysrigyour LUG-ALLso that ithangsfreelyandcanmovefrom
side to side. The cable or web strap should hang in a straight line
betweenthe top hook and the load hook.Neverjamtheframeout of
the line as this subjects it to extra stress for uneven loading. Cable
or web strap must be in a straight line to assure even wrapping on
thedrum.
Donot snagorpullthe cable orwebstrapover sharporroughedges
asthiswillbreakthe wires.Neverbendthecableorwebstrap around
any object or surface.
7. Observe safe rigging practices.
Become familiar with proper rigging practices before you operate
yourLUG-ALL.Consult the illustrations on pages 6 and 7 to protect
against improper use of your LUG-ALL. All LUG-ALL ratings are
basedon freelysuspendedloads.LUG-ALLs cannotbesafely used
forsideloading.
Whenrigging, always make sure thatthe loadis securelyseatedin
the throat of the hook before hoisting.
8. Stand clear of all loads. Never leave an unattended
load suspended in air.
Most safety instructions are merely common sense. Stay alert and
stay safe.
9. Never use your LUG-ALL as a tow line.
Your LUG-ALL must never be used for external loading. The
LUG-ALL isdesignedonlyforapplicationswherethesafetyhandle
is the controlling force in load movement. The safety handle must
alwaysbemanually engaged for safe operation of yourLUG-ALL.

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10.Check your LUG-ALL periodically for damage,
malfunction or worn parts.
Youshouldexamine yourLUG-ALLbeforeeachuseand thoroughly
check it periodically for signs of damage or wear.Any imperfection
inthehoistshould bereportedto yoursupervisorimmediately.Under
no circumstances should you operate a LUG-ALL that is not in
goodrepair.
InspectHooks
Check hoist hooks carefully. If hooks are bent , or hook openings
enlarged, the hoist should be removed from service until the hooks
arereplaced.
Latches on hooks should be carefully inspected to make sure that
thelatch is properly engaged. Damaged latchesshouldbereplaced
immediately.
InspectCable
Examinecable for kinks, cuts,brokenstrands,fraying,or abrasions.
The cable is not safe for use if any of these conditions exist in any
degree(compare cable with that shown onpage11forillustrationof
dangerouscable conditions).Notethatcable mustbereplacedeven
thoughdamagetocableappearsminor.
Cablemust beevenlywrapped arounddrumfor safehoistoperation.
Examine the cable to make sure it is properly seated in the pulley
wheel.
InspectWebStrap
Examine the web strap (where applicable) for cuts, fraying, broken
stitches,orexcessivewear.Replaceifany of these conditions exist
to a significant degree. WARNING: The web strap may have some
insulating properties when it is clean and dry. It is NOT to be
consideredaninsulatingmember.Usean appropriateinsulating stick
toachieveproperworkingdistances.
Inspect for Cleanliness
The LUG-ALL is extremely easy to care for. Its open construction
makes it simple to clean after use in mud, sand, or ice. Simply
unwind the cable from the drum and flush the frame with water or
steam.
Followingtheserecommendations can add years of satisfactory service
to the life of your LUG-ALL.

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INSPECT YOUR LUG-ALL DAILY FOR THESE
DANGEROUS CABLE CONDITIONS
Pictured here are examples of more obvious types of cable damage. These examples
are intended to illustrate severely damaged cables. Cables exhibiting damage of
this sort to any degree should be replaced immediately.
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.
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.
REPLACE THIS
REPLACE THIS
REPLACE THIS
REPLACE THIS
Drum Crushing and
Spiraling
Cut Cable
Broken Wires
Kinks

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HOW TO OPERATE REGULAR LOWERING LUG-ALLs
These models have three actions:
1. Liftingorpulling
2. Loweringorbackingoff
3. Freerelease
Thefirsttwoare completelyautomaticwhentheunitisunderload.Setting
the reverse lever (1) so it either holds the frame pawl against or away
fromtheratchetteeth(underspringtension)determinestheaction.LUG-ALLs
will lower or back off only when under a load of 15 lbs. or more. Free
release quickly unwinds the cable from the drum. It will not operate
whentheLUG-ALL is under load.
TO LIFT:
1. Set the reverse lever to hold the u-frame pawl against the ratchet
teeth(Fig.1).
2. Apply handle pressure (2) to lift one, two, three or a full stroke of the
handle(fourratchet teeth).
TO LOWER: (requiresloadof15 lbs. or more)
1. Set reverse lever to hold the u-frame pawl away from the ratchet
teeth(Fig.2)
2. Movehandleuntilu-framepawlengagesratchettooth.Additionalhandle
pressure in the same direction will release the main frame pawl.
3. Ease off handle pressure and the load will lower one ratchet tooth.
This action is similar to the operation of a bumper jack.
FREE RELEASE: (willnot operate under load)
1. Set reverse lever to hold the u-frame pawl away from the ratchet
teeth.(Fig.2)
2. Whilepressing on the “trigger”tohold the main framepawl away from
the ratchet teeth-pull out the cable the required distance.
(1) Older models have reverse discs instead of levers.
(2) Up or down pressure is determined by position in which reversible handle
is mounted.

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OPERATINGINSTRUCTIONSFORTHERAPIDLOWERINGLUG-ALLs
TherapidloweringLUG-ALL modelsoperateonthesamebasicprinciples
as the regular lowering LUG-ALLs but have an additional action rapid
lowering. A mechanism allows these models to lower four ratchet teeth
per full stroke of the handle in addition to the notch-per-cycle regular
lowering.Thereliabilityandbasic simplicity oftheoriginalunitis retained
butthegreaterspeedandsmoothnessinloweringoffersanoperational
advantage.Itis smoother because the starting and stoppingof theload
is reduced 75%.
TO LIFT:
1. Set the reverse lever to hold the u-frame pawl
against the ratchet
teeth(Fig.1page 15)
2. Place rapid lowering “switch”in the “OFF”position (ON and OFF
positions are identified on the side of the main frame).
3. Apply handle pressure to lift one, two, three, or a full stroke on the
handle(fourratchetteeth).
TO LOWER: (requiresload of 15 lbs. or more)
1. Forregular lowering (one ratchettooth-per-stroke-of-the-handle)use
the instructions on the previous page
plus placing the rapid lowering
“switch”inthe“OFF”position.
2. Fortherapidlowering(fourratchetteeth-per-stroke-of-the-handle)the
sameasfor regular lowering except with therapid loweringswitch to
the“ON”position.
IMPORTANT: When using rapid lowering the operator should position
himselfin suchaway thathecancontrol thetorqueof thehandlethrough
the full travel of the arc, which is four times longer than with the regular
lowering.When firstengagingrapid lowering thefirststroke ofthehandle
maylowerfrom one to four ratchet teeth depending onthecamposition.
Followingstrokeswill lower four ratchet teeth.
FREE RELEASE: (willnot operate under load)
Thesameasforregular lowering models except with the rapid lowering
switch is in the “OFF”position.
NOTE: See Handle and Rigging sections for other important
information.

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RIGGING POSITIONS
LUG-ALLWinchHoists will operateinanyposition: right side up,upside
down or at any angle as a hoist or horizontally as a winch. Rig double
cableforfullratedcapacity(allmodelsexcept½ton capacity,whichare
notequippedwith pulleyblocks),orsinglecableforonehalfratedcapacity
in any of the positions mentioned above.
When used single cable, the lifting distance and operating speed are
doubled(except ½ton which arenot equipped with pulley blocks).
ALWAYS RIGYOURLUG-ALLSO THAT ITWILLHANG FREELYAND
BE FREE TO MOVE FROM SIDE TO SIDE. If the frame is jammed out
oflineit is subjected to undue stress from uneven loading andwouldnot
befreetomove sideways which is necessary to alloweven wrapping of
thecableonthedrum. 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 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
allowthehandletotravel its full arc, which carries it above the top hook.

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RIGGING YOUR CAR DOOR PULLER
Suggestions for Rigging
Your Car Door Puller
#2 hook #3 hook
#1 hook
Because box cars vary as to length, door arrangements, etc., we want
to point out different ways in which your LUG-ALL Car Door Puller can
berigged.
There are three hook arrangements: (the distances given apply to the
ModelHDR-30).
1. When used as shown above it has a 3000 lb. capacity with a 15 ft.
pullingdistance.
2. Itcanberiggedsinglecapacitywiththepulleyblockridingfree,offer-
ing a 1500 lb. capacity and a 30 ft. pulling distance.
3. You can increase the double cable reach by using a three point at-
tachmentandstill obtain a 3000 lb. capacity.Just make sure to locate
the #2 hook towards the puller, so as to give double cable strength.
After the door has moved some distance it may be necessary to
relocate the #2 hook.
THE REVERSIBLE HANDLE
The handle is designed to bend before your LUG-ALL is dangerously
overloaded. This protects the operator, the load and the hoist - thus
avoidingthepossibilityofcostlyaccidents.Ifthe handle bends, the load
shouldbebackedoff.ThehandleshouldthenbereplacedwithaLUG-ALL
factory replacement before any further use. Never use a makeshift or
extendedhandle.
A steady application of pressure on the handle, rather than sudden,
jerking pulls, will prolong its life. Impact loads should never be used to
actuateaLUG-ALL.
Thehandlecan be mounted to give either a downward or upward stroke
todo your lifting and lowering. Itisusuallymoredesirable to do the lifting
(or lowering) on a downward stroke of the handle. This is possible
regardlessofwhich way the hoist is rigged, either right side up or upside
down.
Ifconditions require riggingintight quarters wherethehandlemovement
isrestrictedin one position, it is likelythat byreversing thehandle there
wouldbeampleroom to operate.

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CAUTION: The handle should be pulled in the same plane of travel as
the“leg”oftheu-frame to which it is attached. Sideward pull will bend
the handle before it is actually overloaded and can break the wing
nut or handle bolt; or bend the u-frame.
IMPORTANT
Whenusingrapid lowering, the operator should position himselfso that
he can control the torque of the handle through the full travel of the arc,
asit is four timesgreaterthan when using regularlowering.
OPTIONAL CABLE RETURN CRANK
The cable return crank is available at extra cost on all models except
6000-15SH to allow quick and easy return of slack cable to the drum. It
is especially useful on long cable models. The crank is easily detached
whenitis necessary to use your LUG-ALL inclosequarters.The crank
should not beusedforraisingorloweringloadsasitsshortlengthprovides
verylimitedleverage.Ashearpinprotectsagainstdangerousoverloading.
Crank conversion kits are available for all models, except 6000-15SH.
1. To Place crank on shaft: Pullout shear pin untilit doesnot obstruct
shaft hole and slide crank on drum shaft. Push in shear pin until its
end rides in groove on shaft thus captivating it.
2. To engage crank for rewinding cable: After above, rotate crank
while pressing on shear pin until end of pin enters hole in groove on
shaft.Torewindturn crank counter clockwise.
3. To disengage crank after rewinding: Pullshearpinoutfar enough
to allow crank to rotate on shaft but is still captivated on it.
4. To remove crank from shaft: Pull out shear pin while turning it 1/8
turn until crank is free to slide off of shaft.
5. To replace shear pin: Same as 4 but pull pin completely out. New
pins are available at nominal cost.
NOTE: Always have light tension on the cable when rewinding to
assure tight, even wrapping on the drum.

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HOW TO TAKE CARE OF YOUR LUG-ALL
Your LUG-ALL is designed to give you many years of satisfactory
performance if used properly.Always hang it freely with a straight line
betweentop hook (No. 1) and load hook(donotjamagainsta stationary
object).Andremember,LUG-ALL hoistsareintendedforindustrialuse,
notforlifting or supporting human or animalcargo.
TheLUG-ALL is extremely easytocarefor.Itsopen constructionmakes
itsimple to clean after useinmud,ice,sand or other extremeconditions.
Strip the cable from the drum and flush it out with water or steam. A
quickcheck of its workingparts takes only seconds. You can addyears
to its life by following these recommendations.
1. Do not snag or pull the cable over sharp or rough edges as this will
breakthe wires. LUG-ALLs are equipped with highqualitycable,and
with reasonable care will give satisfactory service.
2. When rewinding the cable on the drum, apply light (10 lbs.) tension.
Thisassures evenwrappingand willpreventthecable from“wedging”
the next time it is used under heavy load.
3. Stop pulling when cable clamp reaches cable guide or pulley wheel,
orpulleywheel reaches cable guide (depending on rig used), as con-
tinuedpullingwilldamage parts.
4. To operate the LUG-ALL, use a steady, straight pull. See “The
ReversibleHandle”Page 12.
5. Whenoperatingthe LUG-ALL under load, do not allow the handle to
“fly”as this can cause damage to the u-frame.
See“Rigging Positions”Page 11for otheruseful information which,
if followed, will extend the service life of your LUG-ALL.

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SERVICING INSTRUCTIONS
FOR REGULAR LOWERING LUG-ALL WINCH HOISTS
AND LUG-ALL CAR DOOR PULLERS
Fieldservicingissimple andpractical.TheLUG-ALL’s advanced design,
allows service work to be done in the field or in your shop. Only snap
rings and locking pins securely lock the hoist together.
Themodel number (see page4)isneeded to order thecorrectparts.Itis
locatedon theratchetside ofthedrumin anarcbelow theteeth.Rotation
of the drum may be necessary to view the model number.
SERVICING INSTRUCTIONS
FOR REGULAR LOWERING LUG-ALL WINCH HOISTS
AND LUG-ALL CAR DOOR PULLERS
Cable Assembly
To remove cable:
1. Unreelcablefromdrum.(It is not necessary to remove cable shield to
replacecable).
2. If cable is not broken (but frayed, whiskered, etc.) cut clean. If to be
reused, cut at cable clamp.
3. Slip old cable out through drum.
4. Cut eye hook from cable and save for installation on replacement
cable.
To replace cable:
1.Thread cable first through the drum (start on counter-bored side Fig.
1),thenthroughcableguide,pulleyblock,cable clamp and then over
thimbleplacedthrueyeofhook.Thecableisthenbroughtbackthrough
the cable clamp. Allow enough cable around thimble to install cable
clamps.
2. Draw cable tight around thimble and have cable clamp at the end of
the thimble, then tighten. If fist grip cable clamps are used (Fig. 2),
two are required to be placed six cable diameters. apart. Nuts on
clamps should be retightened after initial load is applied.
fig. 1 fig. 2

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Main Frame Assembly
To Remove the drum and/or the u-frame:
1. Removethehandle and unreel cable from the drum.
2. Ifthe drum is tobereplaced,cutcable at eyehook andslipoutthrough
thedrum.
3. Drive out the 1/8”locking pin that locks the drum to the drum shaft.
4. Driveout the drum shaft.Thedrumand u-frame are now free.
To replace drum and/or u-frame:
If a new u-frame is to be used, follow steps on page
15tocompletethatassembly before installing on the
mainframe
.
1. Place main frame so the name LUG-ALL cast on
the side at the top is on the left.
2. Slip the drum into the cable shield on the main
framewithratchetteethtotheright.Ifnewdrumis
used thread the cable through drum, (starting on
thecounter-boardside)beforeplacinginposition.
3. Slip u-frame into place with the right side on the
outsideofthemainframe,andtheleftsidebetween
drumand the main frame.Positionu-framesothat
pawl is on the right side. See Fig. 3.
Fig. 3
4. Alignholesofthedrum, u-frame and the main frame. A rounded pilot
is helpful.
5. Slip drum shaft into place with small locking pin hole to left of center
and parallel with matching hole in the hub of the drum.
6. Drive shaft in until locking pin holes are even, then drive in locking
pin.
To remove cable shield.
1. Unreelthecable.
2. Lift retaining ring from position by placing screw driver under edge
and force out of groove.
3. Press down on cable shield to free cable shield pin, then slide shield
arounddrum and remove.
To remove main frame pawl spring #131:
1. Placepointofscrewdriver in loop of spring (#1 end) at spring anchor
and pawl stop position. Pick up tension of spring with screw driver.
2. Slip loop past spring anchor and release the tension slowly.
3. Slip loop at other end off spring anchor pin on main frame pawl.
4. Springthencan be removed.

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Removal and replacement of main frame pawl spring #200
To remove main frame pawl and pawl shaft:
1. Removesnapwasher by placing screw driver point ateach endand
force out of groove.
2. Drive out main frame pawl shaft from the small hole end.
3. Themain frame pawl,springandshaft are then free. Note :Ona main
frame pawl replacement the spring anchor pin is included and sup-
plied attached to the new pawl.
➀
➀SWING U FRAMEAWAY FROM SPRING IN FIG. 1 & 2
➁LOOP SNAPS OFF PIN, PUSH HERE TO REMOVE
➂INSERT SPRING BETWEEN RATCHET & MAIN FRAMEAS SHOWN
➃SWING U FRAME TOWARD SPRING & PRESS DOWN
➄WITH LOOP SNUG
➅UNTIL THIS LOOP SNAPS ON ANCHOR PIN
FIG.2 FIG. 3
TO INSTALL
FIG. 1
TO REMOVE
➀➀
➁➂
➃➄
➅
To replace main frame pawl and main pawl shaft:
1. Place frame so the name LUG-ALL cast on the side at the top is on
left.
2. Placeloop ofspringat#1 endonspringanchor onthemainframe with
the hoop of the spring between the ratchet wheel and the frame.
3. Withtriggerend of pawl toward you, place spring anchor pin in loop at
#2 end of spring.
4. Pressingdown on the pawl alignthehole with those in theframe and
insert the shaft, shouldered end first.
5. Replacethesnapwasher.
To replace main frame pawl spring #131:
1. Place #2 end of spring between ratchet wheel of drum and the main
frame, with the large hoop of the spring facing #1 hook position.
2. Hookthe loop onthe#2end over springanchorpinon the mainframe
pawl.
3. Place screw driver in loop at #1 end, then draw beyond the spring
anchoron the main frame.
4. Easetensiononthespring so the #1 end will be secure on the spring
anchoronthe frame.