Tuff-Built Best Hoist 60138 Manual

122 Paquin Rd. Winnipeg, MB R2J 3V4
Ph: [phone], Fax [phone], Toll Free [phone] www.tuffbuiltproducts.com
August 31, 2020 Form: 132062 rev01
Material Winches
This manual applies to the following Pt#’s;
60138, 60521, 60523
Both “Fixed Handle”and “Power Drive” Models.
Operation &
Maintenance
Manual
Material Winch Rated for: 400 lbs (181 kgs) WLL.
One (1) Pulley reeved system; Working Load Limit of 400 lbs (181 kgs).
Two (2) Pulley reeved system; Working Load Limit of 800 lbs (363 kgs).

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Table of Contents
1. PARTS IDENTIFICATION
2. INTRODUCTION to WINCH APPLICATIONS
3. APPLICATION RESTRICTIONS
5. WINCH INSTALLATION and OPERATION
6. POWER DRIVE APPLICATIONS
7. TRAINING / INSPECCTION
8. MAINTENANCE LUBRICATION and STORAGE
9. SPECIFICATIONS
10. RISK ASSESSEMENT
11. WINCH INSPECTION LOG
12. WINCH LINE INSPECTION LOG
13. SERVICE INTERVAL RECORD

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1.0.PARTS IDENTIFICATION
Fig 1a, Fixed Handle Models Fig 1b, Removable Handle / Power Drive Models
Item Number
Description
1
Pinion Shaft Assembly
2
Drum Spool Assembly
3
LHS Side Plate Assembly
4
RHS Side Plate Assembly
5
Crank Handle Knob Assembly
6
Brake Wear Indicator Label
7
Brake Wear Indicator Window
8
Removable Handle / Power Drive Input Hub Ass’y
9
Rear Frame Spacer
10
Rear Frame Spacer Screw
11
Crank Handle Spring Retainer Disc
12
RHS Cover
13
RHS Cover Label
14
LHS Cover
15
Crank Handle Spring
16
Removable Handle Assembly
17
Brake Wear Indicator Window Retainer Clip
18
Crank Handle Spring Retainer Disc Mounting Screw
19
Crank Handle Knob Assembly Mounting Screw
20
Crank Handle Knob Assembly Retaining Screw
21
Long RHS Cover Mounting Screw
22
LHS Cover Mounting Screw
23
Handle Retainer Snap Ring
24
Short RHS Cover Mounting Screw
Figure 1, Winch Parts and Location
Note: For purposes of honoring warranty claims, wear to brake pads, cable retainer spring bar, labels, and winch lifelines
are considered part of normal winch operation and are not covered by the warranty.
7
11
16
8
23
4

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2.0. INTRODUCTION to WINCH APPLICATIONS
Congratulations on your purchase of a Best Hoist Material Winch.
Pro-Series winches combine many advanced safety features, easy to read visual brake wear indicator, visual overload
indicator integral to the snap hook, and optional usage indicator.
Some versions of these winches feature a unique drive input hub design which allows the winch to be easily switched from
a manual crank to various power drive options to allow the winch to be driven with different types of corded and cordless
power hand drills (See Section 6 for further information on Power Drive options).
The winch may be equipped with a variety of winch line options including, stainless or galvanized steel cable in various
diameters, and ropes in various diameters and constructions to meet your specific job requirements.
This product has been specifically designed and carefully manufactured to provide reliable operation in many different
safety-at-heights applications. These include, but are not limited to:
2.5 MATERIAL HANDLING
The winch may be used for the raising and lowering of tools, equipment, and other material not exceeding the rated
Working Load Limit of the winch. Be aware of and follow the regulations governing your workplace.
3. APPLICATION RESTRICTIONS
There are restrictions and limitations that must be carefully considered in the selection, installation, and operation of this
winch. Serious injury or death may result from failure to consider these factors.
3.1 WORKING LOAD LIMIT
This winch is designed and rated to a working load of 400 lbs (181 kgs) when used in a 1 Pulley Single Reeved System, or a
maximum of 800 lbs (363 kgs) when used in a 2 Pulley Single Reeved System (see Figure 2).
Figure 2, 1 & 2Pulley Single Reeved Systems
Please refer to the Operator’s Manual(s) for all other accessories in the system to determine which reeving option(s) are
applicable to the system.
Note: Please be aware that a 2 Pulley Single Reeved System is rated for a higher working load limit, but that
raising/lowering speed is only half that of a 1 Pulley Single Reeved System.
Ensure that all other system components have a working load limit matching that of the winch. System rating is equal to
that of the lowest rated system component.
1 Pulley single reeved system
2 Pulley single reeved system

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3.2 SITE CHARACTERISTICS, PHYSICAL and ENVIRONMENTAL FACTORS
Work sites have associated with them any of several hazards related to the site itself. These may include but are not
limited to poisonous or explosive atmospheric conditions, poisonous or corrosive chemical hazards, hot surfaces, electrical
hazards, sharp edges, engulfment hazards, or moving machinery.
All these factors must be taken into consideration when selecting equipment for a given application.
5. WINCH INSTALLATION and OPERATION
5.0 INTRODUCTION
This winch is designed for use in conjunction with various styles of support structures to meet different requirements.
These include tripods, davits, and pole hoists as well as a variety of special applications or custom structures. This product
is intended for use only with products designed, manufactured and/or approved by Tuff Built Products Inc. Other
applications must be designed, installed, and used under the supervision of a Qualified Person. All installations must be
approved by a Qualified Person.
5.1 WINCH INSTALLATION
This winch may be used in conjunction with a wide variety of accessory products. Please refer to the Operator’s Manual
provided with all Tuff Built Products Inc. accessories at the time of purchase for detailed information on the installation of
the winch onto the system.
For systems not supplied by Tuff Built Products Inc. the Qualified Person responsible for the design, installation, and use of
the system must provide detailed information regarding the installation of the winch onto the system.
5.2 WINCH OPERATION
Once the winch has been properly installed into the system, the operation of the winch is as outlined below. No person
shall use this winch without receiving proper training as outlined in Section 6. Any user must fully read and understand this
manual and any other instruction manual(s) related to the system being used, or have the instructions explained to them,
before using this equipment.

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5.2.1 INSPECTION
This winch must be inspected before each use as outlined in Section 7.1.
Daily inspection instructions are also given on the label on the handle-side
cover of the winch (see Figure 4).
Any problems must be reported immediately to your supervisor, and the
equipment labeled to prevent further use until it has been repaired.
5.2.2 ATTACHING A WORKER TO THE WINCH LINE
Any worker who is connected to this winch MUST wear a full body harness
designed, tested, and approved for fall arrest. The winch line MUST be
connected to the dorsal (rear) D-Ring on the harness, unless otherwise
instructed by a qualified person.
Extend sufficient winch line to allow the line to be easily attached to the
worker’s dorsal D-Ring. Be sure to maintain sufficient tension in the line to
prevent “bird-nesting” of the winch line.
Attach the winch line to the worker’s dorsal D-Ring, making sure that the
snap hook operates smoothly and fully locks when attached.
Retract the winch line until the line is snug, and have the worker slowly lift
their feet off the ground to verify system integrity.
**DO NOT TEST SYSTEM INTEGRITY OVER AN OPENING OR WHERE
THERE IS A CHANCE OF FALLING**
5.2.3 RAISING OR LOWERING A WORKER
Equipment can be lowered by cranking the winch handle counterclockwise and raised by cranking the winch handle
clockwise. DO NOT use the winch if the rotation of the winch handle is reversed, or if the winch does not make a regular
clicking sound when cranking the winch handle in a clockwise direction.
Crank the handle at a smooth and steady pace that you find comfortable to maintain.
Wear gloves if your hands will come in contact with the winch line.
Maintain sufficient tension on the winch line, either from the weight of the equipment or manually, to ensure that the line
winds evenly onto the spool. Do not allow any slack line to accumulate between the winch and the worker if there is any
risk of a fall occurring. Serious injury or death may result if equipment is connected to a slack winch line.
Figure 4, Daily Inspection Instructions

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6. POWER DRIVE APPLICATIONS
In applications involving repeated positioning activities or long vertical entries, it is
sometimes desirable to have a powered winch rather than relying on manual
cranking.
The winches are designed with a unique input drive hub (see Figure 5) that allows
for convenient switching between manual crank and powered operation while
maintaining a manual backup in the event of power failure or mechanical
problems.
Depending on the nature of the application, the regulations governing the use of
powered winches to raise and lower equipment in various jurisdictions, and the
type and specifications of power drills available, there are several configurations
of Power Drive accessories that may be appropriate (see Figure 6).
Figure 6, Pro-Series Winch Power Drive Accessories.
Configuration are
per figures #
Minimum Drill
Torque (FT-LB /N-m)
Maximum Drill Speed
(RPM)
for Rescue / Material
handling (310lbs/140 kgs)
Maximum Drill
Speed (RPM) for
Work Positioning
RECCOMENDED DRILL MAKE &
MODEL
Figure 8 (page 12)
40 / 54.2
300
NOT permitted
Milwaukee Hole Hawg Drill
(Model #1676-6) Corded 120V AV
Figure 9 (page 12)
10 / 13.6
600
400
Milwaukee Right Angle Drill
(Model #0721-21) Cordless 28V DC
Figure 10 (page 13)
40 / 54.2
300
Not permitted
Milwaukee Hole Hawg Drill
(Model #1676-6) Corded 120V AC
Figure 11 (page 13)
10 / 13.6
600
400
Milwaukee Right Angle Drill
(Model #0721-21) Cordless 28V DC
While Tuff Built Products recommends the above Milwaukee products, any drill meeting the same specifications of the above drills can
be used.
The use of HIGH SPEED (RPM) drills will result in damage and premature failure of winch components.
Figure 7, Drill Requirements for Various Configurations.
Part#
Description
Includes
60110
4:1 Gear Reduction
60110
60126
Overload Protection Clutch (310/620 lbs.)
60126
60186
Adapter, Crank Hub to 3/4” Drive (2.25” Long)
60186
60187
Adapter, Drill Chuck to 3/4” Drive
60187
60188
Adapter, Drill Chuck to 1/2” Drive
60188
60189
Adapter, Crank Hub to 3/4" Drive (3.50” long)
60189
60248
Pro-Series Winch Crank Handle (Removable)
Handle & Snap Ring
60193
Kit, Direct Drive
60186 w/ 60187
60194
Kit, Direct Drive w/ Overload Clutch
60126 w/ 60187
60195
Kit, 4:1 Gear Reduction w/ Overload Clutch
60126, 60110 w/ 60188
60196
Kit, Direct Drive
60189 w/ 60187
60197
Kit, Direct Drive w/ 4:1 Gear Reduction
60189, 60110 w/ 60188
Combine these accessories as shown in Figures 7-10 to make the configuration best
suited to your application.
Figure 5, Winch Input Drive Hub

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Figure 8 below shows the simplest option of directly driving the input hub using a solid drive shaft and a low speed high
torque drill.
Rescue and Material Handling 400 lbs (181 kgs).
Figure 8, Direct Drive Configuration –1:1 application (Pt# 60193 kit)
Figure 9 shows a direct drive configuration using the 4:1 gear reduction to allow use of a higher speed, lower torque drill if
desired.
Rescue, Material Handling 400 lbs (181 kgs).Work Positioning.
Figure 9, Direct Drive Configuration –using a 4:1 gear reduction assembly (Pt# 60197 kit)
These direct drive configurations are NOT SUITABLE for personnel handling applications and is
intended ONLY FOR MATERAIL HANDLING or cable spooling operations.
The Direct Drive configurations are ONLY for rescue or material use. It is not recommended for work
positioning or continuous use. Extended use of the Direct Drive configuration will decrease the life
expectancy of the winch.

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Figure 10 shows the most basic configuration driving the input hub
straight from the drill through an overload clutch designed to slip.
Rescue and Material Handling 400 lbs (181 kgs).
Figure 11 shows the combination of the 4:1 gear reduction drive
with the overload clutch to allow Work Positioning using a
higher speed, lower torque drill if desired.
Rescue, Material Handling 400 lbs (181 kgs),
Work Positioning.
7.TRAINING
Users must fully read and understand this manual and any other instruction manual(s) related to the system being used, or
have the instructions explained to them, before using this equipment.
7.INSPECTION
7.1 DAILY INSPECTION
The winch must be inspected before each use as described in Sections 7.1.1 to 7.1.5. Report any problems or concerns to
your supervisor, and do not use the equipment until they have approved doing so.
7.1.1 Cleaning and Lubrication
If required, clean and lubricate the winch and all its parts as outlined in Section 8. Do not use solvents or other chemicals to
clean the winch.
Figure 10, 1:1 Direct Drive with Overload Clutch
(Pt# 60194 kit).
Figure 11, 4:1 Reduction Drive with Overload Clutch
(Pt# 60195 Kit).

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7.1.2 Physical Damage
Inspect the winch, winch line, snap hook, and mounting brackets for physical damage; bent parts, cracked housings, dented
covers, loose or missing hardware or parts, missing, or illegible labels (see Figure 5). Replacement labels are available from
your dealer by ordering the part number shown on each label.
Note: Not all labels shown may be present on your winch, as some are related to standards and certifications that may not
apply to your jurisdiction.
Figure 5, Winch Labels
While minor cosmetic damage will not impair the function of the winch, a seriously damaged winch MUST BE removed from
service and returned to an authorized service center for repair prior to further use.