Textron GREENLEE Ultra Tugger 8 Instruction Manual
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Textron GREENLEE Ultra Tugger 8 Instruction Manual

Textron GREENLEE Ultra Tugger 8 Instruction Manual

8 cable puller and pulling packages
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INSTRUCTION MANUAL
Ultra Tugger
8
®
Cable Puller and
Pulling Packages
Serial Code ABJ
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
99920751
© 2012 Greenlee Textron Inc.
IM 1259 REV 27 8/12

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Summary of Contents for Textron GREENLEE Ultra Tugger 8

  • Page 1 Cable Puller and Pulling Packages Serial Code ABJ Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Register this product at www.greenlee.com 99920751 © 2012 Greenlee Textron Inc. IM 1259 REV 27 8/12...

  • Page 2: Table Of Contents

    Motor ............... 42 Force Gauge ............43 All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for Mobile Carriage and Boom ......... 44-45 damages resulting from misapplication or misuse of its products.

  • Page 3: Important Safety Information

    Electric shock hazard: Disconnect the cable puller from the power supply before servicing. 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 4 • 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 5 Parts may strike nearby personnel. rope. Hold rope so that it may be released quickly. 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: Grounding Instructions

    This path of least resistance is intended to reduce the risk of electric shock to the operator. Plug Receptacle Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 7: Identification

    3. Mounting Plates 10. Gearbox 4. Rope Tie-Off 11. Mounting Pin 5. Adjustable Sheave Bracket 12. Force Gauge with 6. Tapered Steel Capstan Remote ON/OFF Switch Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 8 10. Storage Tray 11. Brake 12. Swivel Caster 13. Transport Handle 14. Boom Mount 15. Ring Pull Detent Pin 16. Location for Additional Adapter Storage Racks Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 9: Specifications

    28.9 kN to 35.6 kN (6500 lb to 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 10: Cable Pulling Glossary

    (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 11: Cable Pulling Principles

    Typical Cable Pulling System Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 12: Pulling Theory

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

  • Page 13: Cable Pulling Forces

    (8000 lb) 35.6 kN (8000 lb) 35.6 kN Maximum (8000 lb) Maximum Maximum Pulling Force at Anchoring System Pulling Force at the Cable Puller’s Anchoring System Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 14 0.125. cannot determine an exact amount of pulling force. Pulling Force: 35.6 kN (8000 lb) Tailing Force The Capstan as a Force Multiplier Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 15 40 meters and store 1,000,000 joules of energy. This is enough energy to throw a 900 kilogram object, such as a small automobile, 113 meters into the air. Stored Energy Stored Energy Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 16 279.4–319.3 3.50–3.99 88.9–101.3 12.57–14.14 319.3–359.2 4.00–4.49 101.6–114.0 Maximum 14.14–15.71 359.2–399.0 4.50–4.99 114.3–126.7 Pulling Force 35.6 kN (8000 lb) A Typical Grip Setup—Swivel and Pulling Grip Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 17 50.2 (11,300) 60° 61.6 (13,800) 45° 65.8 (14,800) 30° 68.7 (15,400) 0° 71.2 (16,000) 135° Resultant Force 27.4 kN (6160 lb) Typical Resultant Force at Sheave Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 18: 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 19: 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 20: Boom Operation

    Teepee Position Twist to lock. Never pull cable with the detent pins locked inward; both the elbow and nose must be locked from pivoting before pulling. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 21 • Because the weight will be too great to use the crank to raise and lower the boom, manual assist is required. Ring Pull Detent Pin Slip-in Coupling Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 22: Boom Assembly/Disassembly

    Assemble in the reverse order, making sure that all detent pins are fully seated before releasing your hold. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 23: Boom Setup

    3. Raise or lower the boom until the nose is just above Insert Conduit Adapter and Raise above Conduit the conduit to be pulled from. Conduit Lower into Conduit Position Nose Higher than Conduit Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 24: Down Pull Starting From Teepee Position

    Roll the carriage forward until the nose is under the coupling, pull the detent ring, and raise the nose onto the coupling. Typical Down Pull Setup Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 25: Horizontal Pull

    (or the nose into the cou- pling for the screw-on adapters). Single Boom Setup Horizontal Pull in Underground Vault Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 26: Boom Components

    Always keep elbow unit locked with pivot pin except while adjusting. 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 27: Transporting The Boom

    Handle Position for Pulling 3. Fold the handle down on top of the puller head when not in use to keep it out of the way. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 28: Other 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. Chain Mount—Secured to Steel Conduit or Pipe Floor Mount—Secured to a Concrete Floor Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 29: Setup-Pipe Adapter

    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 30 Do not use tools, extensions or “cheaters.” 5. Put the sheave back onto the frame. Install the pin and hitch pin clip. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 31: Setup-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 32 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 33: Setup-Floor Mount

    Note: Use a 5/8" carbide-tipped masonry bit 5. Have the installation checked by a qualified manufactured in accordance with ANSI standard B94.12-77. inspector. 3. Vacuum the debris from the holes. Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 34: 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 35: 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 36: 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 37 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 38: Illustrations And Parts Lists

    8 Cable Puller and Pulling Packages ® Illustration and Wiring Diagram–Ultra Tugger 8 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 39 (includes one each of the items marked with an asterisk) ......2 Decals Decal, warning ..................1 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 40: Gearmotor

    Ultra Tugger 8 Cable Puller and Pulling Packages ® Illustration—Gearmotor (50006460) Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 41 (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 42: Motor

    Brush assembly plate ................1 91865611 Magnet housing ..................1 91865620 Armature ....................1 90543483 Belleville washers ..................2 91860717 Bearing ...................... 1 91869145 Threaded rod ..................... 2 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 43: Force Gauge

    Nut, hex, #8–32 ........4 Decals 90531949 Screw, self-tapping, #10–16 x .250 Phillips head..........6 50303929 Decal, damp warning ......1 Decal, identification ........ 1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 44: Mobile Carriage And Boom

    Ultra Tugger 8 Cable Puller and Pulling Packages ® Illustration—Mobile Carriage and Boom Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 45 3" screw-on conduit adapter ....1 Nut, 5/16-18 flange ......... 4 00586 3-1/2" screw-on conduit adapter ... 1 00587 4" screw-on conduit adapter ....1 Decal Decal, warning ........3 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...

  • Page 46: Accessories

    50296302 Handle unit, vise chain ......2 50356615 Screw unit, vise chain ......2 50007734 Block, pivot ..........2 Decal, warning (not shown) ....1 Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 47 Ultra Tugger 8 Cable Puller and Pulling Packages ® Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070...
  • Page 48 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 An ISO 9001 Company • Fax: 800-451-2632 Fax: 800-524-2853 Fax: +1-815-397-9247 Greenlee Textron Inc. is a subsidiary of Textron Inc. www.greenlee.com...

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