Greenlee Tugger 640 Instruction Manual
  1. Manuals
  2. Brands
  3. Greenlee Manuals
  4. Power Tool
  5. Tugger 640
  6. Instruction manual
Greenlee Tugger 640 Instruction Manual

Greenlee Tugger 640 Instruction Manual

640-series cable pullers effective with serial code yj for 115 volt pullers and serial code acr for 220 volt pullers
Hide thumbs Also See for Tugger 640:
Table of Contents

Advertisement

Quick Links

INSTRUCTION MANUAL
640-Series
®
Tugger
Cable Pullers
Effective with Serial Code YJ for 115 Volt Pullers
and Serial Code ACR for 220 Volt Pullers
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99997657
© 2006 Greenlee Textron Inc.
IM 1076 REV 14 2/06

Advertisement

Table of Contents
loading

Related Manuals for Greenlee Tugger 640

Summary of Contents for Greenlee Tugger 640

  • Page 1 Effective with Serial Code YJ for 115 Volt Pullers and Serial Code ACR for 220 Volt Pullers Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99997657 © 2006 Greenlee Textron Inc. IM 1076 REV 14 2/06...

  • Page 2: Table Of Contents

    All specifications are nominal and may change as design improve- ments occur. Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Mobilgrease is a registered trademark of Mobil Oil Corporation.

  • Page 3: Important Safety Information

    Hazards which, if not avoided, COULD result in severe injury or death. Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage. Greenlee / A Textron Company 640-Series Tugger ® Read and understand all of the...
  • Page 4 Greenlee service center. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 640-Series Tugger ® Locate the puller so that it is close to the conduit.
  • Page 5 Failure to observe this warning could result in severe injury or death. Inspect puller and accessories before use. Replace any worn or damaged components with Greenlee replacement parts. A damaged or improperly assembled item can break and strike nearby personnel with great force.

  • Page 6: Grounding Instructions

    Do not use an adapter. 20 Amp/125 Volt Plug and Receptacle Plug Greenlee / A Textron Company 640-Series Tugger 220-Volt Model This tool must be grounded. In the event of a malfunction or breakdown, an electrical ground provides a path of least resistance for the electric current.

  • Page 7: Identification

    3. Guarded ON/OFF Switch and Circuit Breaker 4. Motor 5. Motor Chain Guard 6. Force Gauge with ON/OFF Switch (optional) Greenlee / A Textron Company 640-Series Tugger Tugger Identification 7. Handle/Cleat 8. Right-Angle Idler Sheave 9. Tapered Capstan 10. Rope Ramp 11.

  • Page 8: Specifications

    15.6 - 17.8 kN (3500 - 4000 lb) (alarm will sound) ... 5 minutes on / 15 minutes off Pulling Rope: Average breaking strength ...71.2 kN (16,000 lb) minimum Greenlee / A Textron Company 640-Series Tugger 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ®...

  • Page 9: Cable Pulling Glossary

    Greenlee / A Textron Company 640-Series Tugger ® pulling force the amount of pulling tension developed by the cable puller, rated in Newtons (metric) or pounds;...

  • Page 10: Cable Pulling Principles

    The shading indicates components that are associated with the text. Greenlee strongly recommends that each member of the cable pulling crew review this section of the manual before each cable pull. Greenlee / A Textron Company...

  • Page 11: Pulling Theory

    Gravity Weight of Cable Greenlee / A Textron Company 640-Series Tugger To accomplish a cable pull, the cable pulling system must develop more force than the combination of gravity and friction.

  • Page 12: Cable Pulling Forces

    These explanations are based on the concepts presented in the previous section, Pulling Theory. Pulling Force at the Cable Puller’s Anchoring System Greenlee / A Textron Company 640-Series Tugger ® At the Cable Puller Anchoring System The cable puller will exert its maximum pulling force on cable puller’s anchoring system.
  • Page 13 0.125. Pulling Force: 17.8 kN (4000 lb) Greenlee / A Textron Company 640-Series Tugger The following table is based on the formula above. The input, or tailing force, is constant at 44.5 Newtons (10 lb).
  • Page 14 34 meters into the air. The double- braided composite rope stores much less energy and has much less potential for injury if it were to break. Greenlee / A Textron Company 640-Series Tugger Double-braided composite rope is the only type of rope recommended for use with the Tugger cable puller.
  • Page 15 Cut off and discard the tail. Then cut the tie strap and measure its length.) Use the table pro- vided to find the correct size. 3. See the maximum rated capacities in the Greenlee catalog. Pulling Grip Size Table...

  • Page 16: Cable Pulling Forces

    The resultant amount of force depends on the angle of the change in direction. A brief table is provided here; for more details, see IM 1363 (99929988). Greenlee / A Textron Company 640-Series Tugger Resultant Force Table for the Tugger (17.8 kN or 4000 lb Maximum Pulling Force)

  • Page 17: Tailing The Rope

    Too much tailing force is any amount more than is necessary to stop the rope from slipping on the capstan. Excessive tailing force will not increase the pulling force or pulling speed. Greenlee / A Textron Company 640-Series Tugger ® Number of Wraps of Rope Around the Capstan An experienced operator should choose the number of times the rope is wrapped around the capstan.

  • Page 18: Summary Of Cable Pulling Principles

    • Control the pull by tailing the rope. Be familiar with the interaction of the rope and capstan. • Do not allow a rope overlap to develop. Greenlee / A Textron Company 640-Series Tugger ® Planning The Pull •...

  • Page 19: Typical Setups

    Using Two Booms, Nose Unit, Elbow Unit and Slip-in Coupler Pulling Horizontally in Manhole Using Two Booms, Nose Unit, Elbow Unit and Slip-in Coupler Greenlee / A Textron Company 640-Series Tugger ® 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 Cable Pullers...
  • Page 20 Pulling Up Using One Boom, Nose Unit and Slip-in Coupler Pulling Up Using Two Booms, Nose Unit, Elbow Unit and Slip-in Coupler Greenlee / A Textron Company 640-Series Tugger ® 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 21: Typical Setups

    Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view of the meter and quick access to its ON/OFF switch. Using a Manhole Sheave Generator Greenlee / A Textron Company 640-Series Tugger Using Feeding Sheaves in Manholes UNOCCUPIED MANHOLE...

  • Page 22: Setup And Operation

    Greenlee / A Textron Company 640-Series Tugger ® Install the vise chains properly. • Follow the vise chain tightening instructions carefully.

  • Page 23: Setup And Operation

    Positioning Entrapment Operator Tailing End Greenlee / A Textron Company 640-Series Tugger 6. Check the ON/OFF switch on the puller to be sure it is OFF. Plug the puller into the receptacle of the standard force gauge. Plug the force gauge into an appropriate power supply (see Grounding Instruc- tions in this manual).

  • Page 24: Removing Cable

    Start over with a puller and components of a higher force rating. Greenlee / A Textron Company 640-Series Tugger ® Puller Placement...

  • Page 25: Dual Pulling

    Connect the two pullers to the cables in parallel—use two sets of ropes, grips, and other accessories to avoid overloading any component of the pulling system. Greenlee / A Textron Company 640-Series Tugger Dual Pulling 4455 Boeing Dr.

  • Page 26: Maintenance

    Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 640-Series Tugger Lubricating the Drive Chains (every 20 hours) 1. Remove the right guard (45) and left guard (3).
  • Page 27 Do not operate puller if the anti-reverse mechanism is not working. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 640-Series Tugger ® Inspecting the Commutator Brushes (every 40 hours) 1.
  • Page 28 Replace the frame if it appears damaged. During dis- assembly, inspect each part. Replace any worn, dam- aged, or missing parts with Greenlee replacement parts. Replace the needle bearings (61) regardless of their appearance.

  • Page 29: Troubleshooting

    Should the puller become inoperative, refer to the troubleshooting table below. While performing any repairs, inspect the motor, capstan, and drivetrain. Problem Motor will not run. Capstan does not rotate while motor is running. Greenlee / A Textron Company 640-Series Tugger Probable Cause No power at supply circuit. Faulty switch or wiring. Motor faulty.

  • Page 30: Exploded Views And Parts Lists

    640-Series Tugger ® Cable Pullers Parts List Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 31 90533186 90527917 90516672 50179160 50353454 90537300 Greenlee / A Textron Company 640-Series Tugger Description Screw, self-tapping, #10 –16 x .250, Phillips head ... 11 Screw, cap, 3/8 – 16 x 2.75 skt head ... 4 Guard, left ... 1 Screw unit, lubricating ... 1 Washer, lock, .643 x 1.08 x .156 spring ...
  • Page 32 Decals For The Tugger 50356623 50358995 99935767 50353292 50299360 Greenlee / A Textron Company 640-Series Tugger Description Sprocket, #35, 60 teeth ... 1 Washer, shim, 1.00 x 1.50 x .062 ... 3 Washer, shim, 1.00 x 1.50 x .032 ... 1 Guard, right ...
  • Page 33 640-Series Tugger ® Cable Pullers Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 34 Exploded View Gear-Motor Unit Greenlee / A Textron Company 640-Series Tugger 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ® Cable Pullers...
  • Page 35 91863970 90516869 90507509 91863961 90508688 90516745 91863996 91864003 Greenlee / A Textron Company 640-Series Tugger Description Brush cap ... 2 Brush ... 2 End cap assembly ... 1 Bushing, strain relief ... 1 Field assembly (120-volt model) ... 1 Field assembly (220-volt model) ... 1 Washer, Belleville 10mm ...
  • Page 36 640-Series Tugger ® Cable Pullers Exploded View 50371711—Force Gauge Unit with Serial Code ZZ (120-Volt Models) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 37 90539346 91862639 Decals for the Force Gauge: 50303929 50327186 50356674 Greenlee / A Textron Company 640-Series Tugger Description Force gauge unit Wire, 12 AWG x 3.00, black ... 1 Wire, 12 AWG x 7.00, black ... 1 Wire, 12 AWG x 4.00, green ... 1 Box ...
  • Page 38 640-Series Tugger ® Cable Pullers Exploded View 50057260—Force Gauge Unit with Serial Code ACP (220-Volt Models) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 39 90539346 91862639 Decals for the Force Gauges: 50303929 50327186 50057243 Greenlee / A Textron Company 640-Series Tugger Description Force gauge unit Wire, 14 AWG x 3.00, brown ... 1 Wire, 14 AWG x 6.00, brown ... 1 Wire, 14 AWG x 5.00, green with yellow stripe ... 1 Wire, 14 AWG x 6.00, blue ...

  • Page 40: Wiring Diagrams

    Wiring Diagram Tugger BLACK Horn BLACK BLACK (BROWN) 220-Volt Cord Greenlee / A Textron Company 640-Series Tugger SECOND POLE — 220-volt model only BLACK (BROWN) Circuit Board (BLUE) Current Transformer Unit (includes circuit board) WHITE (BLUE) 120-Volt Cord GREEN (GREEN with YELLOW stripe) 4455 Boeing Dr.

  • Page 41: Wiring Diagrams

    91866847 Force Gauge, 220-Volt Models (05726) Power Cord 50079379 Blue Brown Receptacle 91869129 Blue Greenlee / A Textron Company 640-Series Tugger 91863830 Black Green Green with Yellow Stripe Brown 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070 ®...
  • Page 42 Fax: Canada 800-435-0786 Fax: International +1-815-397-7070 Fax: +1-815-397-9247 4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070 An ISO 9001 Company Greenlee Textron Inc. is a subsidiary of Textron Inc. • www.greenlee.com 800-451-2632 815-397-1865 800-524-2853 Printed in USA...

This manual is also suitable for:

Tugger 640-22Tugger 642-22Tugger 642Tugger 676Tugger 686Tugger 686-22

Table of Contents