WCT TUF-Lugger Instruction Manual

© Copyright 2005
DCD Design & Manufacturing Ltd.
Revision 1.1
TUF-Lugger™ with Tuf-Lugger lite™
OPERATING INSTRUCTION MANUAL
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SAVE THESE INSTRUCTIONS
R
RE EA AD D A AL LL L INSTRUCTIONS
B BE EF FO OR RE E U US SI IN NG G T TH HE E T TU UF F- -L Lu ug gg ge er r™ ™ o or r T Tu uf f- -l lu ug gg ge er r l li it te e™ ™
WARNING:
TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY:
The TUF-Lugger™ is an electrical device. Use only as described in this manual.
Connect to a properly grounded outlet only. See Grounding Instructions.
Do not use with damaged cord or plug.
Do not leave the TUF-Lugger™ when plugged in. Unplug from outlet when not in use and before
servicing.
Do not handle plug or Tuf-lugger lite with wet hands.
Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.
Do not pull or carry by cord, use cord as a handle, close a door on cord, or pull cord around sharp
edges or corners. Do not run over cord. Keep cord away from heated surfaces.
Do not remove or modify the 115/230 VAC plug.
Do not use in wet or damp locations. Do not expose to rain. Store indoors.
Do not use in the presence of flammable liquids or gases.
Follow the recommended work cycle of 15min/hr (to prevent overheating)
IMPORTANT SAFETY INSTRUCTIONS
G
GR RO OU UN ND DI IN NG G I IN NS ST TR RU UC CT TI IO ON NS S
This appliance must be grounded. If it should malfunction or breakdown, grounding provides a path of least
resistance for electric current to reduce the risk of electric shock. This appliance is equipped with a cord
having an equipment-grounding conductor and grounding plug. The plug must be inserted into an appropriate
outlet that is properly installed and grounded in accordance with all local codes and ordinances.
WARNING - Improper connection of the equipment-grounding conductor can result in a risk of electric
shock. Check with a qualified electrician or service person if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug provided with the appliance - if it will not fit the outlet, have a
proper outlet installed by a qualified electrician.
This appliance is for use on a nominal 120-
volt
circuit and has a grounding attachment plug that
looks like the plug illustrated in th
e adjacent sketch.
Make sure that the appliance is connected to an
outlet having the same configuration as the plug.
No adaptor should be used with this appliance.
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TABLE OF CONTENTS
SPECIFICATIONS
OPERATION
TRANSPORT
ACCESSORIES
10
uct Guides
Extension Arms
Floor Mount Adapter
Manhole Adapter
Universal Adapter
Load Monitor
1
5
9
11
12
13
14
15
18
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The TUF-Lugger™ is a capstan winch intended for pulling rope or polyester pull tape.
The Tuf-Lugger lite power source is mounted in a wheeled, pulling frame and can be
unbolted and operated as a stand alone Tuf-lugger Lite winch, part #41000-500.
Footswitch: Cable actuated
Conduit Guides: Standard 2”, 3”, 3-1/2”, 4”
Optional 2-1/2”, 5”, 6”
Maximum Height: 6’-6” (can be extended, see accessories)
Pulling Forces: 5,500 lbs continuous, 15min/hr work cycle
Pulling Speeds: 9.3 feet/min.
SPECIFICATIONS
1
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SPECIFICATIONS
2
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The TUF-Lugger™ can be configured to suit a variety of premise and outside plant
applications. The following sketches detail some of the more common pulling
configurations.
In Overhand Configurations (Type A), the rope passes over both sheaves.
SP
ECIFICATIONS
3
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In the Underhand Configurations (Type B), the rope passes under the Wrist Sheave,
between the Extension Arms, and over the Elbow Sheave.
SPECIFICATIONS
4
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OPERATION
Review the jobsite safety requirements.
Periodically lubricate the drive chains with light machine oil.
Periodically lubricate the drive chains with light machine oil.Periodically lubricate the drive chains with light machine oil.
Periodically lubricate the drive chains with light machine oil.
Follow Standard procedures when accessing vaults and manholes, including gas detection,
Follow Standard procedures when accessing vaults and manholes, including gas detection, Follow Standard procedures when accessing vaults and manholes, including gas detection,
Follow Standard procedures when accessing vaults and manholes, including gas detection,
ventilation, an
ventilation, anventilation, an
ventilation, and work area protection. Failure to do so may result in death or serious injury.
d work area protection. Failure to do so may result in death or serious injury.d work area protection. Failure to do so may result in death or serious injury.
d work area protection. Failure to do so may result in death or serious injury.
Wear re
Wear reWear re
Wear re
cognized safety e uipment including hardhat, safety glasses, safety shoes, and leather
cognized safety e uipment including hardhat, safety glasses, safety shoes, and leather cognized safety e uipment including hardhat, safety glasses, safety shoes, and leather
cognized safety e uipment including hardhat, safety glasses, safety shoes, and leather
work gloves. Failure to do so may result in personal injury.
work gloves. Failure to do so may result in personal injury.work gloves. Failure to do so may result in personal injury.
work gloves. Failure to do so may result in personal injury.
Use extreme caution when working around live electrical circuits. Failure to do so may result in
Use extreme caution when working around live electrical circuits. Failure to do so may result in Use extreme caution when working around live electrical circuits. Failure to do so may result in
Use extreme caution when working around live electrical circuits. Failure to do so may result in
death or serious injury.
death or serious injury.death or serious injury.
death or serious injury.
1
Inspect the condition of the TUF-Lugger™, checking for worn or damaged parts.
2
Have damaged par
Have damaged parHave damaged par
Have damaged parts replaced by an authorized service center. Any attempt to modify the TUF
ts replaced by an authorized service center. Any attempt to modify the TUFts replaced by an authorized service center. Any attempt to modify the TUF
ts replaced by an authorized service center. Any attempt to modify the TUF-
--
-
Lugger
LuggerLugger
Lugger 


or use other than dcd replacement parts will void the warranty and may result in death
or use other than dcd replacement parts will void the warranty and may result in death or use other than dcd replacement parts will void the warranty and may result in death
or use other than dcd replacement parts will void the warranty and may result in death
or serious injury.
or serious injury.or serious injury.
or serious injury.
3
Examine the condition of the pulling rope. Check for contamination with mud, sand, or dirt.
Check for rust discoloration. Check for broken or worn strands.
Use a pulling rope with a maximum rated capacity that meets or exc
Use a pulling rope with a maximum rated capacity that meets or excUse a pulling rope with a maximum rated capacity that meets or exc
Use a pulling rope with a maximum rated capacity that meets or exceeds the TUF
eeds the TUFeeds the TUF
eeds the TUF-
--
-Lugger
LuggerLugger
Lugger 


maximum pulling force of
maximum pulling force of maximum pulling force of
maximum pulling force of 5
55
5,500 lb. Failure to do so may result in death or serious injury.
,500 lb. Failure to do so may result in death or serious injury.,500 lb. Failure to do so may result in death or serious injury.
,500 lb. Failure to do so may result in death or serious injury.
Downgrade or discard pulling rope that has been subject to overload, or physical degradation.
Downgrade or discard pulling rope that has been subject to overload, or physical degradation. Downgrade or discard pulling rope that has been subject to overload, or physical degradation.
Downgrade or discard pulling rope that has been subject to overload, or physical degradation.
Failure to do so may result in death or serious injury.
Failure to do so may result in death or serious injury. Failure to do so may result in death or serious injury.
Failure to do so may result in death or serious injury.
5
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OPERATION
Roll the TUF-Lugger™ into the desired operating location.
4
Grasp the spare Locking Pin and
tilt the TUF-Lugger™ rearwards
until it rests on the base plate.
6
6
Uncoil and unload the footswitch cord and power cord.
5
Remove the
Locking Pin and rotate the Extension
Arm assembly to the desired position. Continue to
rotate past the desired position until the next set of
pin holes aligns. Replace the Locking Pin.
7
Remove the existing uct Guide by removing the Guide Pins and Wrist Pin.
8
Select a uct Guide suitable for the size of conduit being used.
9
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OPERATION
Install the pulling rope over the sheaves. For overhand configurations (Type A), the rope
goes over both sheaves. For underhand configurations (Type B), the rope goes under the
Wrist Sheave, between the Extension Arms, and over the Elbow Sheave. Continue the rope
clockwise around the capstan and around the deflector sheave.
12
7
Install the uct Guide into the conduit.
For overhand configurations (Type A), pivot the TUF-Lugger™ forward to insert the uct Guide
into the conduit. The pulling forces will maintain the frame in this position.
For underhand configurations (Type B), pivot the TUF-Lugger™ forward to position the uct
Guide at the mouth of the conduit. Pivot the frame rearward to allow the uct Guide to enter
the conduit.
11
Orient the new uct Guide depending on the pulling configuration and sec
ure with the Wrist
Pin. Rotate the uct Guide and secure in position using uct Guide Pins in whichever of the
two holes in the uct Guide that provides the best angular alignment.
10
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OPERATION
Manually apply tension to the tail end of the rope and depress the footswitch to begin
pulling.
Unload the footswitch and ensure footswitch cable is as straight as possible and untangled to
Unload the footswitch and ensure footswitch cable is as straight as possible and untangled to Unload the footswitch and ensure footswitch cable is as straight as possible and untangled to
Unload the footswitch and ensure footswitch cable is as straight as possible and untangled to
prevent the cable from binding inside.
prevent the cable from binding inside. prevent the cable from binding inside.
prevent the cable from binding inside.
Stand at least 30° to either side of the pulling rope while
Stand at least 30° to either side of the pulling rope while Stand at least 30° to either side of the pulling rope while
Stand at least 30° to either side of the pulling rope while
under load. The pulling rope may fail under tension and release stored energy. Failure to do so
under load. The pulling rope may fail under tension and release stored energy. Failure to do so under load. The pulling rope may fail under tension and release stored energy. Failure to do so
under load. The pulling rope may fail under tension and release stored energy. Failure to do so
may result in death or serious injury.
may result in death or serious injury.may result in death or serious injury.
may result in death or serious injury.
8
1
5
Plug the TUF-Lugger™ into a 120 V, 15 A grounded outlet or extension cord.
14
Use only a three prong grounded extension cord with the proper wire size for the length of cord.
Use only a three prong grounded extension cord with the proper wire size for the length of cord. Use only a three prong grounded extension cord with the proper wire size for the length of cord.
Use only a three prong grounded extension cord with the proper wire size for the length of cord.
For lengths less than 50ft, use a 14Ga cord as a minimum. Lengths from 50
For lengths less than 50ft, use a 14Ga cord as a minimum. Lengths from 50For lengths less than 50ft, use a 14Ga cord as a minimum. Lengths from 50
For lengths less than 50ft, use a 14Ga cord as a minimum. Lengths from 50-
--
-100ft,
100ft, 100ft,
100ft,
use a 12 Ga
use a 12 Ga use a 12 Ga
use a 12 Ga
cord as a minimum. Failure to do so may result in overheating and damage to the
cord as a minimum. Failure to do so may result in overheating and damage to thecord as a minimum. Failure to do so may result in overheating and damage to the
cord as a minimum. Failure to do so may result in overheating and damage to the electric motor.
electric motor.electric motor.
electric motor.
Read all electrical safety instructions located on the first page of this manual before using th
Read all electrical safety instructions located on the first page of this manual before using thRead all electrical safety instructions located on the first page of this manual before using th
Read all electrical safety instructions located on the first page of this manual before using th
e
e e
e
TUF
TUFTUF
TUF-
--
-Lugger
LuggerLugger
Lugger 

 . Failure to do say may result in serious injury or death.
. Failure to do say may result in serious injury or death.. Failure to do say may result in serious injury or death.
. Failure to do say may result in serious injury or death.
Wrap rope around capstan and ensure shaft support pin is in place
13
Remove the support pin and wrap the rope around the capstan in a counter clockwise direction
Remove the support pin and wrap the rope around the capstan in a counter clockwise direction Remove the support pin and wrap the rope around the capstan in a counter clockwise direction
Remove the support pin and wrap the rope around the capstan in a counter clockwise direction
as shown and around the rope guide.
as shown and around the rope guide.as shown and around the rope guide.
as shown and around the rope guide.
Important: Replace the shaft support pin and uick releas
Important: Replace the shaft support pin and uick releasImportant: Replace the shaft support pin and uick releas
Important: Replace the shaft support pin and uick releas
e pin prior to use. Failure to do so will
e pin prior to use. Failure to do so will e pin prior to use. Failure to do so will
e pin prior to use. Failure to do so will
cause damage to the machine
cause damage to the machinecause damage to the machine
cause damage to the machine
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Rotate the uct Guide into the position
sho
1
Rotate the TUF
-
Lugger
™
Extension Arms
into the p
osition shown.
2
Place the spare locking pin in the elbow plate. Place your foot on the front axle. Grasp the
locking pin and pull forwards to pivot the TUF-Lugger™ into the transport position. Wrap the
foot switch cord around the winch. Stee the Tuf-lugger by spuhing down on the spare
locking pin, riaing the rear wheel and rotating about the front wheels.
3
5
TRANSPORT
9
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There are several accessories available for the TUF-Lugger™ to enhance its capabilities.
ACCESSORIES
10
Extension Arms
Floor Mount Adapter
Manhole Adapter
Universal Adapter
Load Monitor
uct Guides
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The TUF-Lugger™ comes standard with Duct Guides to suit 2”, 3”, 3-1/2”, and 4”
conduit. Guides are also available as optional accessories to suit 2-1/2”, 5”, and 6”
conduit.
Part
Number
Conduit
Size OD ID Std Opt
40010-200 2” 1.91” 1.67” X
40010-250 2-1/2” 2.38” 2.07” X
40010-300 3” 2.88” 2.50” X
40010-350 3-1/2” 3.54” 3.11” X
40010-400 4” 3.93” 3.43” X
40010-500 5” 5.00” 4.50” X
40010-600 6” 6.00” 5.50” X
ACCESSORIES
11
uct Guides
C # 40010
-
XXX
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The range of the TUF-Lugger™ may be extended by replacing the standard Extension
Arms with longer sections of 2” steel rigid conduit or 2” Sch40 steel pipe. This will
allow higher box pulls and deeper vault pulls.
Loosen the two bolts in the Outboard
Arm Fitting and remove the Fitting.
B1
Cut two identical lengths of 2” steel rigid conduit or 2” Sch40 steel pipe.
Use only 2” steel rigid conduit or 2” Sch40 steel pipe. Failure to do so may result in death
Use only 2” steel rigid conduit or 2” Sch40 steel pipe. Failure to do so may result in death Use only 2” steel rigid conduit or 2” Sch40 steel pipe. Failure to do so may result in death
Use only 2” steel rigid conduit or 2” Sch40 steel pipe. Failure to do so may result in death
or serious injury.
or serious injury.or serious injury.
or serious injury.
Loose
n the two bolts in the Inboard Arm
Fitting and remove the Extension Arms.
Do not exceed a maximum length of 14 feet. Failure to do so may result in death or serious
Do not exceed a maximum length of 14 feet. Failure to do so may result in death or serious Do not exceed a maximum length of 14 feet. Failure to do so may result in death or serious
Do not exceed a maximum length of 14 feet. Failure to do so may result in death or serious
injury
injuryinjury
injury.
..
.
Re-assemble the new Extension Arms to the Inboard and Outboard Arm Fittings.
B4
ACCESSORIES
12
B2
B3
Extension Arms
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TUF-Lugger™ Power Pack may be removed from the frame and secured to a concrete
floor using the Floor Mount Adapter.
ACCESSORIES
13
Align the Floor Mount Adapter with the direction of pull and secure to the floor with 4 x 5/8”
concrete inserts.
C1
Use only concrete inserts with an ultimate pullout
Use only concrete inserts with an ultimate pullout Use only concrete inserts with an ultimate pullout
Use only concrete inserts with an ultimate pullout
force of 8,000 lb. ensure that they are installed in
force of 8,000 lb. ensure that they are installed in force of 8,000 lb. ensure that they are installed in
force of 8,000 lb. ensure that they are installed in
accordance with the instructions provided by the
accordance with the instructions provided by the accordance with the instructions provided by the
accordance with the instructions provided by the
insert manufacturer. Failure t
insert manufacturer. Failure tinsert manufacturer. Failure t
insert manufacturer. Failure t
o do so may result in
o do so may result in o do so may result in
o do so may result in
death or serious injury.
death or serious injury.death or serious injury.
death or serious injury.
Place the TUF-Lugger Lite™ and capstan assembly into the Floor Mount Adapter and secure
using the pins provided with the adapter.
For ease of movement, disconnect the T
For ease of movement, disconnect the TFor ease of movement, disconnect the T
For ease of movement, disconnect the TUF
UFUF
UF-
--
-
Lugger
LuggerLugger
Lugger Lite
LiteLite
Lite 


from the Capstan assembly when
from the Capstan assembly when from the Capstan assembly when
from the Capstan assembly when
moving
moving
moving
moving
. Use proper lifting techni ue when
. Use proper lifting techni ue when . Use proper lifting techni ue when
. Use proper lifting techni ue when
moving the pow
moving the powmoving the pow
moving the pow
er pack. Failure to do so may
er pack. Failure to do so may er pack. Failure to do so may
er pack. Failure to do so may
result in personal injury.
result in personal injury.result in personal injury.
result in personal injury.
C2
Floor Mount Adapter
C # 40000
-
400
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The Manhole Adapter allows the TUF-Lugger™ to pull cable into a manhole using
guides and sheaves located in the manhole. It features two independent stop plates and
an independent guide plate which allow the rope to be pulled from any position in the
manhole.
Manhole Range: 18” – 36” Diameter
The adapter requires the use of a 6” Duct Guide.
ACCESSORIES
14
Install the TUF
-
Lugger™ into the
Manhole Adapter.
3
Place the manhole adapter over the manhole and slide the guide plate to the
desired rope
position.
1
Loosen the locking handles on the stop
plates and adjust the plates against the
inside edges of the manhole.
2
Manhole Adapter
C # 40000
-
300
DCD
SWL 10,000 LB
40000-300
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For horizontal pulls, the TUF-Lugger™ must be positioned directly in line with the
conduit. For some applications, this is not possible as the TUF-Lugger™ is physically
restricted by a manhole, or sidewall.
This problem can be overcome with the Universal Adapter. It is a second set of
extension arms with a joint that can bend and rotate. It is installed between the
standard Extension Arms and the Duct Guide. The Universal Adapter allows the TUF-
Lugger™ frame to be set at an angle to the line of pull.
ACCESSORIES
15
Universal Adapter
C # 40000
-
500
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Adjust the angle of the extension arms on the
TUF
-
Lugger™. For Overhand Pulls (Type A), the
outboard end of the arms should be below the height of the conduit. For Underhand Pulls
(Type B), the outboard end should be above the height of the conduit.
E1
ACCESSORIES
16
Universal Adapter
C # 40000
-
500
I
nstall the uct Guide onto the sheave end of the Universal Adapter. For Overhand Pulls (Type
A), the slot in the plate should be up. For Underhand Pulls (Type B), the slot in the plate
should be down.
E2
Overhand Pulls (Type A) Underhand Pulls (Type B)
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Insert the uct Guide into the end of the conduit. Loosen the nut on the adjustment plate and
rotate the Universal Adapter so that it will align with the Extension Arms.
ACCESSORIES
17
Universal Adapter
C # 40000
-
500
Install the pull rope. It may pass between the TUF
-
Lugger™ Extension Arms but must not
pass between the Universal Adapter Arms. When correctly installed, the rope will run
parallel to the Universal Adapter Arms.
E5
Install the Un
iversal Adapter onto the TUF
-
Lugger™ Extension Arms and secure in place
using the Wrist Pin and uct Guide Pins. Tighten the nut on the adjustment plate.
E4
E3
The added weight of the Universal
The added weight of the Universal The added weight of the Universal
The added weight of the Universal
Adapter will make the assembly
Adapter will make the assembly Adapter will make the assembly
Adapter will make the assembly
unstable until all of the pins
unstable until all of the pins unstable until all of the pins
unstable until all of the pins
are
are are
are
installed. Exercise caution. Failure
installed. Exercise caution. Failure installed. Exercise caution. Failure
installed. Exercise caution. Failure
to do so may result in personal
to do so may result in personal to do so may result in personal
to do so may result in personal
injury.
injury.injury.
injury.
Ensure that the rope does not pass
Ensure that the rope does not pass Ensure that the rope does not pass
Ensure that the rope does not pass
between the arms of the universal
between the arms of the universal between the arms of the universal
between the arms of the universal
adapter. Failure to do so may result in
adapter. Failure to do so may result in adapter. Failure to do so may result in
adapter. Failure to do so may result in
death or serious injury.
death or serious injury.death or serious injury.
death or serious injury.
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