Greenlee 35346 Instruction Manual
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Greenlee 35346 Instruction Manual

Greenlee 35346 Instruction Manual

Capstan retrofit kit for super tugger
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INSTRUCTION MANUAL
35346 Capstan Retrofit Kit
®
for Super Tugger
Models 6000, 6001 and 6006
With Serial Code Prefix VB or VT
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
999 9851.3
© 2019 Greenlee Tools, Inc.
IM 1081 REV 5 3/19

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Summary of Contents for Greenlee 35346

  • Page 1 INSTRUCTION MANUAL 35346 Capstan Retrofit Kit ® for Super Tugger Models 6000, 6001 and 6006 With Serial Code Prefix VB or VT Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

  • Page 2: Table Of Contents

    All specifications are nominal and may change as design Super Tugger to create an entire cable pulling system. improvements occur. Greenlee Tools, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. No single manual can provide instructions for every Super Tugger is a registered trademark of Greenlee Tools, Inc.

  • Page 3: Important Safety Instructions

    Failure to observe this warning could Hazards or unsafe practices which, if not avoided, result in severe injury or death. MAY result in injury or property damage. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 4 A worn or damaged rope can break under tension shut the puller off and have it repaired by an and whip violently. authorized Greenlee service center. • Do not maintain a stationary rope on a rotating Failure to observe this warning could result in severe capstan.
  • Page 5 Inspect puller and accessories before use. Replace Do not wrap rope around hands, any worn or damaged components with Greenlee arms, waist or other body parts. replacement parts. A damaged or improperly Do not stand in spent coils or tailed assembled item can break and strike nearby rope.

  • Page 6: Grounding Instructions

    Do not use an adapter. Do not use an adapter. 15 Amp/125 Volt 15 Amp/250 Volt Plug and Receptacle Plug and Receptacle Plug Receptacle Plug Receptacle Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 7: Identification

    2. Capstan Chain Guard 9. Rope Ramp 3. Handle 10. Pivoting Capstan Arm 4. Motor 11. Positioning Peg 5. Motor Chain Guard 6. Force Gauge with ON/OFF Switch 7. Handle/Cleat Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 8: Specifications

    24.5 - 28.9 kN (5500 - 6500 lb) ......5 minutes on / 15 minutes off Pulling Rope: Average Breaking Strength ....... 115.6 kN (26,000 lb) minimum Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 9: Cable Pulling Glossary

    Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 10: 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 11: Pulling Theory

    Cable Pulling Theory Illustrated Friction Gravity Pulling Force 28.9 kN (6500 lb) Conduit Weight of Cable Tailing Force Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 12: Cable Pulling Forces

    Pulling Force at the Cable Puller’s Anchoring System Pulling Force 28.9 kN (6500 lb) 28.9 kN 28.9 kN (6500 lb) (6500 lb) Maximum Maximum Maximum Pulling Force at Anchoring System Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 13 The Capstan as a Force Multiplier Pulling Force: 28.9 kN (6500 lb) Tailing Force Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • 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. Stored Energy Stored Energy Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 15 Two types of wire connectors—wire grips and pulling provided 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 16 28.9 (6500) 90° 40.8 (9165) 60° 50.0 (11,245) 45° 53.5 (12,025) 30° 55.8 (12,545) 0° 57.8 (13,000) Typical Resultant Force at Sheave Resultant Force= 22.3 kN (5005 lb) Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 17: 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 Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • 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 Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 19: Typical Setups

    Using An Adapter Sheave To Pull Through Exposed Conduit Using an Extension Bushing, Flexible Pipe Adapter, Adapter Sheave, and T-Boom to Pull Through Concealed Conduit Extension Bushing (Thread onto Conduit) Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 20 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 Flexible Pipe Adapter, Adapter Sheave and T-Boom For Overhead Pulls Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 21 ON/OFF switch. Using a Manhole Sheave Using Feeding Sheaves in Manholes Generator UNOCCUPIED MANHOLE UNOCCUPIED MANHOLE ABOVE GROUND UNOCCUPIED MANHOLE Using a Floor Mount Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 22: Setup And Operation

    4. Rotate the vise chain handles, by hand, clockwise injury or death. to fully tighten the chain. Do not use tools, exten- sions or “cheaters”. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 23 11. When the pull is complete, turn the puller OFF. Rope Path, Side View Tie off the rope to the T-shaped cleat and anchor the cable. Positioning Capstan Entrapment Operator Tailing End Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 24: Removing Cable

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

  • 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. Dual Pulling Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 26: Maintenance

    (47). Electric shock hazard: Disconnect the cable puller from the power supply before servicing. Failure to observe this warning can result in severe injury or death. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 27 Do not operate puller if the anti-reverse mechanism is not working. Failure to observe this warning can result in severe injury or death. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 28 Use a continuity checker to check the electrical circuit. sembly, inspect each part. Replace any worn, damaged, Lack of continuity in the following procedure indicates or missing parts with Greenlee replacement parts. that a repair is necessary. Replace the needle bearings (74 and 75) regardless of 1.
  • Page 29 (Blue) Note: Wire colors for the 220-volt model appear in parentheses ( ). Second Pole: Black 220-Volt Green (Brown) Model only (Green with Yellow Stripe) White (Blue) Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 30: Exploded Views And Parts Lists

    Black Connector Black 503 1470.0 – Control Box Unit (220-Volt) Green with Yellow Stripe Power Cord Brown – Brown Brown Force Meter Switch Blue Brown Blue Brown Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 31: Troubleshooting

    Broken sprocket in gearbox or stripped Disassemble puller. See disassembly shaft in motor. instructions under Inspecting the Chains and Ratchet Pawl. Replace any worn or damaged drive components. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 32 6000-Series Super Tugger Cable Pullers Exploded View Torque Specifications 4.52 Newton-meters (40 in-lb) 10.8 Newton-meters (8 ft-lb) 13.6 Newton-meters (10 ft-lb) 20.3 Newton-meters (15 ft-lb) Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 33 6000-Series Super Tugger Cable Pullers Exploded View (cont’d) Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 34 503 0098.9 Sprocket, #60, 8 teeth ................1 502 9669.8 Washer, thrust, 1.12 X 2.00 X .062 .............1 502 9684.1 Washer, flat, 1.39 X 2.00 X .031 fiber ..........1 Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 35 Decal, capstan rotation...............1 50356631 Decal, Read IM (120-volt model) ............1 50359878 Decal, Read IM (220-volt model) ............1 50357050 Decal, rope path .................1 50357069 Decal, mounting..................1 50362763 Decal, caution, rope................1 Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 36 6000-Series Super Tugger Cable Pullers Exploded View Motor and Gearbox Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 37 Cap, brush ..................2 91860695 Holder, brush ..................2 91869226 Rod, threaded, 1/4 – 28 x 6.093 ............4 91869234 Rod, threaded, #8 – 32 x 2.500 ............2 50299638 Shaft, splined ..................1 Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 38 6000-Series Super Tugger Cable Pullers Exploded View 503 1465.1—Control Box Unit, 120-Volt Attach this end of the spring to the ninth link of the chain. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 39 Chain, link, #8 x 24" ................1 Decals for the Force Gauge: 50303929 Decal, damp warning ................1 50327186 Decal, adjustment zero ...............1 50302116 Decal, identification (120-volt model) ..........1 Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 40 6000-Series Super Tugger Cable Pullers Exploded View 503 1470.0—Control Box Unit, 220-Volt Attach this end of the spring to the ninth link of the chain. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 41 Chain, link, #8 x 24" ................1 Decals for the Force Gauge: 50303929 Decal, damp warning ................1 50327186 Decal, adjustment Zero ..............1 50302116 Decal, identification (220-volt model) ..........1 Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 42 6000-Series Super Tugger Cable Pullers 35346 Capstan Retrofit Kit The 35346 Capstan Retrofit Kit is intended to improve early Super Tugger cable pullers with VB or VT serial number prefix. The main components of the kit are a capstan unit, which includes a tapered capstan and rope ramp, and capstan arm.
  • Page 43 Rope Path Decal 10. Affix the new decals to the puller. 7. Slide the idler arm up until the chain is snug. Tighten the idler arm bolt. Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 44 Decal, rope path .................1 4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070 USA Tel: 800-435-0786 Canada Tel: 800-435-0786 International Tel: +1-815-397-7070 ©2019 Greenlee Tools, Inc. • An ISO 9001 Company Fax: 800-451-2632 Fax: 800-524-2853 Fax: +1-815-397-9247 www.greenlee.com Greenlee Tools, Inc.

This manual is also suitable for:

Vb 6000Vb 6001Vb 6006Vt 6000Vt 6001Vt 6006

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