Greenlee Ultra Tugger Instruction Manual
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Greenlee Ultra Tugger Instruction Manual

Cable puller and pulling packages
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INSTRUCTION MANUAL
Ultra Tugger
®
Cable Puller and Pulling
Packages
with Serial Code ABJ
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99920751
© 2007 Greenlee Textron Inc.
IM 1259 REV 22 11/07

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Summary of Contents for Greenlee Ultra Tugger

  • Page 1 ® Cable Puller and Pulling Packages with Serial Code ABJ Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99920751 © 2007 Greenlee Textron Inc. IM 1259 REV 22 11/07...

  • Page 2: Table Of Contents

    Maintenance ............38-39 At the Connectors ..........18 Exploded Views / Parts Lists: At the Sheaves ............. 19 Ultra Tugger (with wiring diagram) ...... 40-41 Tailing the Rope: Gearmotor (50006460) ........42-43 Control of the Pull ..........20 Motor (50006649) ............ 44 Amount of Tailing Force ........

  • Page 3: Ultra Tugger

    Greenlee Textron Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Ultra Tugger is a registered trademark of Greenlee Textron Inc. Versi-Boom is a trademark of Greenlee Textron Inc. Loctite and 242 are registered trademarks of Loctite Corporation.

  • Page 4: Important Safety Information

    Failure to observe this warning will result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 5 Average Breaking Strength: result in severe injury or death. at least 143 kN (32,000 lb) Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 6 Do not stand in spent coils or tailed rope. Hold rope so that it may be Parts may strike nearby personnel. released quickly. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 7: Important Safety Information

    ® IMPORTANT SAFETY INFORMATION Inspect puller and accessories before use. Replace When using the wheeled carriage to transport the any worn or damaged components with Greenlee Ultra Tugger: replacement parts. A damaged or improperly assem- • Keep personnel out of the path of transport.

  • Page 8: Grounding Instructions

    Do not use an adapter. 20-Amp / 115-Volt Plug and Grounded Receptacle Plug Receptacle Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 9: Identification

    Ultra Tugger Cable Puller and Pulling Packages ® Identification Ultra Tugger Cable Puller 7. Right Angle Sheave 1. Motor 8. Rope Ramp 2. Circuit Breaker/Switch 9. Hitch Clip 3. Mounting Plates 10. Gearbox 4. Rope Tie-Off 11. Mounting Pin 5. Adjustable Sheave Bracket 12.

  • Page 10: Identification

    12. Mounting Pins 4. Sight Hole 13. Hitch Pin Clips 5. Boom Mount 14. 3' Boom Tube 6. T-Stand 15. Long Pin 7. Puller 8. Force Gauge Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 11: Specifications

    28.9 kN - 35.6 kN (6500 - 8000 lb) ......15 minutes on / 15 minutes off Pulling Rope: Required Rope ....... 7/8" diameter, double-braided, polyester composite Average Breaking Strength .......... 143 kN (32,000 lb) minimum Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 12: Cable Pulling Glossary

    Newtons (metric) or pounds; a cable puller is usually described by the maximum pulling force that it can develop Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 13: Cable Pulling Principles

    The maximum the text. rated capacity of every component must meet or Greenlee strongly recommends that each member of exceed the cable puller’s maximum pulling force. the cable pulling crew review this section of the manual before each cable pull.

  • Page 14: Pulling Theory

    Cable Pulling Theory Illustrated Friction Gravity Pulling Force 35.6 kN (8000 lb) Conduit Weight of Cable Tailing Force Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 15: Cable Pulling Forces

    Pulling Force at the Cable Puller’s Anchoring System Pulling Force 35.6 kN (8000 lb) 35.6 kN (8000 lb) 35.6 kN Maximum (8000 lb) Maximum Maximum Pulling Force at Anchoring System Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 16: At The Capstan

    The Capstan as a Force Multiplier Pulling Force: 35.6 kN (8000 lb) Tailing Force Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 17: At The Pulling Rope

    Double-braided composite rope is the only type of rubber band when it is stretched. Failure of the rope or rope recommended for use with the Ultra Tugger cable any other component of the pulling system can cause a puller. Select a double-braided composite rope with...

  • Page 18: At The Connectors

    Two types of wire connectors—wire grips and pulling vided to find the correct size. grips—are available. The wire grip uses a set screw 3. See the maximum rated capacities in the Greenlee to clamp onto the conductors of the cable. The pulling catalog.

  • Page 19: At The Sheaves

    Cable Puller and Pulling Packages ® Cable Pulling Principles (cont’d) Cable Pulling Forces (cont’d) Resultant Force Table for the Ultra Tugger (35.6 kN or 8,000 lb Maximum Pulling Force) At the Sheaves Sheaves are used to change the direction of the pull.

  • Page 20: Tailing The Rope

    When the rope resumes its normal path, apply tailing force and continue the pull. There is no suggested remedy for a rope overlap. Do not allow the rope to overlap! Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 21: 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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 22: Typical Setups

    ON/OFF switch. Chain Mount Floor Mount Secured to Steel Conduit or Pipe Secured to a Concrete Floor Locked and folded for transport Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 23: T-Stand

    Nose Unit and Slip-in Coupler Elbow Unit and Slip-in Coupler T-Stand Pulling Up Using One Boom Tube, Nose Unit and Slip-in Coupler Down-pull using boom with threaded coupler Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 24: Wheeled Carriage

    Pulling Horizontally in Manhole Using Two Booms, Pulling Up Using Two Booms, Nose Unit, Nose Unit, Elbow Unit and Slip-in Coupler Elbow Unit and Slip-in Coupler Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 25 2. Position the frame against the conduit. Mount pipe adapter only to conduit to be pulled from. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 26: Cable Puller And Pulling Packages

    Improperly tightened chains can allow the Note: If the 18" sheave interferes with existing puller to slide or break loose and strike nearby structures, install a 12" sheave (Greenlee 00843). personnel. • Do not allow the vise chains to bind at the corners...

  • Page 27: T-Stand

    6. Install two pins. Secure the pins with hitch pin clips. Insert Pins Here T-Stand 7. Continue with Setup: Mounting Components later in this manual. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 28: Wheeled Carriage

    Lower the puller onto the boom mount. Install two pins from the motor side. Secure the pins with two hitch pin clips. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 29: Boom With Nose Unit

    ® Setup—Mounting Components Boom with Nose Unit Use these boom tubes only: • boom tubes supplied with the Ultra Tugger • 3" rigid steel conduit (3 meters or 10 feet maximum) • Use only straight 3" diameter rigid steel conduit or •...

  • Page 30: Booms With Elbow Unit And Nose Unit

    ® Setup—Mounting Components (cont’d) Booms with Elbow Unit and Nose Unit Use these boom tubes only: • boom tubes supplied with the Ultra Tugger • 3" rigid steel conduit (3 meters or 10 feet maximum) • Use only straight 3" diameter rigid steel conduit or •...

  • Page 31: Slip-In Coupler

    Can clear obstructions around conduit (other conduit, Must be seated against support structure capable of pull box, door edges, etc.). supporting 8000 pounds. Requires two pins to attach to boom. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 32 3 full threads in good condition to support the pulling loads. PULL CONDUIT SCREW-ON COUPLER LOCKING SCREWS COUPLER ADAPTER KEEPERS Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 33: Straddling The Conduit With Slip-In Coupler

    Secure the pins with hitch pin clips. Nose Unit Coupler Coupler Pin secured with Hitch Pin Clip Conduit must not protrude past here Support Structure Pull Conduit Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 34 ® Setup—Versi-Boom™ System: Assembling Boom Components Using Double Boom, Elbow and Nose Units: Use only Greenlee supplied boom tubes, 3" rigid steel conduit or 3" schedule 40 steel pipe (less than 10') with the Versi-Boom™ systems. 1. Place boom tube into receptacle of boom mount.
  • Page 35 Damage to the coupler and rope may result. Use the wheeled carriage or T-stand to support the weight of the puller at the motor and capstan. Rotating Boom Nose and Elbow Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 36 Do not transport with boom tubes longer than the stock 3' and 4' lengths. Improper transport may result in tipping causing serious injury. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 37: Chain Mount

    The vise chain must be uniformly tight at all points. Failure to observe this warning could result in severe injury or death. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 38 2. Set the puller into the cradle of the chain mount. 3. Install two pins from the motor side. Secure the pins with two hitch pin clips. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 39: Floor Mount

    ® Setup—Floor Mount Installation Requires: A concrete floor with the following characteristics: Greenlee recommends using Greenlee 35607 Wedge • fully cured structural-type concrete Anchors. If another type of anchor is used, they must have an ICBO (International Conference of Building •...

  • Page 40: Operation

    Surface A contacts the rope. c. Push the ramp toward the mounting plate and rotate it counterclockwise until it locks into place. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 41: Removing Cable

    You must be able to turn off the puller before the pulling grip, connector, or swivel contacts the capstan. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 42: Maintenance

    2. Do not hammer capstan onto shaft. Use a 65 mm holes are towards the rear of the motor. (2-1/2") or longer bolt to draw the capstan onto the shaft. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 43: Maintenance

    10 and 11 o’clock. 4. Position mounting plates so the screw heads on the capstan side fit into the counterbores of the mounting plates. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 44 Ultra Tugger Cable Puller and Pulling Packages ® Exploded View and Wiring Diagram – Ultra Tugger BLACK MOTOR BLACK WHITE BLACK BLACK WIRING DIAGRAM 28, 29 16, 17 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 45 (includes one each of the items marked with an asterisk) ....2 Decals 50010298 Decal, warning ..................1 50010590 Decal, read IM ................... 1 99935767 Decal, technical assistance ............... 1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 46: Gearmotor (50006460)

    Ultra Tugger Cable Puller and Pulling Packages ® Exploded View—Gearmotor (50006460) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 47 (includes 5, 6, 10, 15, 16, 22, 24, 29[2], 34, 35) 50022970 Gearmotor repair group #3 (includes 7-9, 13, 14, 21, 24, 30[2], 31, 34, 35) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 48 Magnet housing ..................1 91865620 Armature ....................1 90543483 Belleville washers ..................2 91860717 Bearing ...................... 1 91869218 Screen ....................... 1 91869145 Threaded rod ..................... 2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 49: Force Gauge

    Screw, cap, #6 – 32 x .750", socket button head ........3 90506324 Nut, hex, #6 – 32 ..................3 Decals 50303929 Decal, damp warning ................1 50010719 Decal, identification ................... 1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 50: Accessories

    50007963 Handle ....................1 90527178 Roll pin....................1 Boom Tubes Part No. Description 50008358 3' Boom tube .................... 1 50007912 4' Boom tube .................... 1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 51 Retaining ring, .750", Truarc #5160-75-S-PP ........... 4 50010638 Decal, warning ..................1 Repair Kit 50061887 Kit, puller pin (includes one each of the items marked with an asterisk) ....2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 52 (includes one each of the items marked with an asterisk ) ....2 50061917 Kit, shaft (includes one each of the items marked with a plus sign)..... 1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 53 (includes one each of the items marked with an asterisk) ....2 50061925 Kit, elbow shaft (includes one of item 3 and two of item 5) ..........2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 54 (includes one each of the items marked with an asterisk) ....1 50061950 Kit, pivot pins (includes one of item 4 and two of item 6) ..........1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 55 Accessories (cont’d) Floor Mount (50008650) Part No. Description 50007890 Frame ......................1 50356070 Anchor, wedge, .625 x 6.00" ..............4 50010476 Decal, warning ..................1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 56 815-397-7070 Fax: 815-397-1865 Canada 800-435-0786 Fax: 800-524-2853 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 Printed in USA...

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