INSTRUCTION MANUAL
11147
®
Ultra Tugger
for use with Greenlee 640 and 6001
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
99950286 REV 3 © 2013 Greenlee Textron Inc. 7/13
Adapter Package
11147 Ultra Tugger® Adapter Package
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information ..................................... 3-4
Identication—Boom Mount Adapter............................ 5
Specications ................................................................ 5
Identication—VersiBoom™ Components .................... 6
Setup
Wheeled Carriage ...................................................... 7
Mounting Components ......................................... 8-10
Typical Setups ........................................................ 11-12
Illustration and Parts List—
Boom Mount Adapter .................................................. 13
Accessories
Nose Unit ................................................................. 14
Elbow Unit ............................................................... 15
Couplers .................................................................. 16
Boom Tubes ............................................................. 16
T-Stand .................................................................... 17
Wheeled Carriage .................................................... 17
Description
The Greenlee 640 Tugger® and 6001 Super Tugger® that
you already own can now attach to the same wheeled
carriage that the Ultra Tugger® cable puller uses.
The Ultra Tugger® 640/6001 Adapter Package comes
pre-assembled. All you need to do is add your cable
puller and you’ll be pulling cable faster and easier, with
no more anchors to set or chains to mount.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee tool:
11147 Ultra Tugger
Replacement manuals are available upon request at no
charge at www.greenlee.com.
®
Adapter Package
All specications are nominal and may change as design
improvements occur. Greenlee Textron Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Tugger, Super Tugger and Ultra Tugger are registered trademarks and
VersiBoom is a trademark of Textron Innovations Inc.
KEEP THIS MANUAL
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
11147 Ultra Tugger® Adapter Package
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for preventing or avoiding the hazard.
Tangle Hazard:
Do not wrap rope around hands,
arms, waist or other body parts.
Do not stand in spent coils or tailed
rope. Hold rope so that it may be
released quickly.
Failure to observe this warning could
result in severe injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
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.
Read and understand all of the
instructions and safety information
in this manual and your cable puller
manual, before operating or servicing
this tool.
Failure to observe this warning could
result in severe injury or death.
Shear Point:
Do not put ngers through holes in
elbow unit. Rotating parts could cut
off ngers.
Failure to observe this warning could
result in severe injury or death.
When using the wheeled carriage to transport the
VersiBoom™:
• Keep personnel out of the path of transport.
• Evaluate the terrain of over which the carriage is to
move. If in doubt, obtain additional help and move
the carriage slowly.
• Do not transport over inclines of more than 15°.
• Do not transport the carriage with boom tubes
longer than the supplied 3' and 4' tubes.
Rope, cable, or a connecting device can break under
tension, causing the rope to whip violently.
• Do not allow any unnecessary personnel to remain
in the area during the pull.
• Do not allow any personnel to stand in line with the
pulling rope.
Failure to observe these warnings could result in
severe injury or death.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Failure to observe this warning, could result in severe
injury or death.
3
11147 Ultra Tugger® Adapter Package
IMPORTANT SAFETY INFORMATION
Flying Debris Hazard:
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in severe eye injury from ying
debris.
Falling Object Hazard:
Do not stand directly under a vertical
pull. Cable could fall suddenly from
the conduit.
Failure to observe this warning could
result in severe injury or death.
For use only with Greenlee Model 640 and 6001 cable
pullers.
Use with other pullers may result in insecure mounting and improper rope alignment.
Failure to observe this warning could result in severe
injury or death.
Inspect and verify the maximum
load-bearing capacity or maximum
strength of all structural supports,
pulling system components and
anchoring systems before setting
up the puller. Any component that
cannot withstand the maximum
cable-pulling forces could break and
strike nearby personnel with sufcient
force to cause severe injury
or death.
Note: Keep all decals clean and legible, and replace
when necessary.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
11147 Ultra Tugger® Adapter Package
Identification—Boom Mount Adapter
50111450
5
3
2
4
6
7
1
Boom Mount Adapter
1. Frame
2. Shaft
3. Roll Pin
4. Hitch Pin Clip
5. Hex Screw
6. Wheel Unit
7. Bushing
Specifications
Weight ......................................................................................................20.4 kg (45 lb)
Length........................................................................................................94 cm (37 in)
Width ...........................................................................................................18 cm (7 in)
Height ........................................................................................................30 cm (12 in)
Use with: Greenlee 640 and 6001 Cable Pullers only
Load Rating ....................................................................................................... 6500 lb
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification—VersiBoom
9
0
2
3
6
3
1
11
11147 Ultra Tugger® Adapter Package
1
1
8
7
14
5
VersiBoom Components
1. Elbow Unit (optional)
2. Sight Hole
3. 4' Boom Tube
4. Sight Hole
5. Boom Mount Adapter
6. T-Stand (optional)
7. Wheeled Carriage
8. Slip-in Coupler
9. Nose Unit
10. Mounting Pins
11. Hitch Pin Clips
12. 3' Boom Tube (optional)
13. Long Pin
14. Tray
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Setup
Wheeled Carriage
Requires: Adequate clearance.
See “Typical Setups.”
1. Mount the boom mount to the wheeled carriage.
Align the boom mount holes with the top holes
in the wheeled carriage, as illustrated. Install a
pin through the top hole in the boom mount and
wheeled carriage. Secure the pin with a hitch pin
clip. Place a second pin in the lower hole.
11147 Ultra Tugger® Adapter Package
1st pin
2nd pin
2. Set puller on boom mount frame so that the puller
mounting feet sit inside the frame opening, between
the two side rails. Slide the puller up against the
stop and chain it down securely.
Puller up
against stop
For use only with Greenlee Model 640 and 6001 cable
pullers.
Use with other pullers may result in insecure mounting and improper rope alignment.
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
7
Setup (cont’d)
11147 Ultra Tugger® Adapter Package
Mounting Components
Boom with Nose Unit
• Use only straight 3" diameter rigid steel conduit or
Schedule 40 steel pipe for the boom tubes.
• Do not use boom tubes longer than 3 meters (10').
Longer booms may bend or break.
Failure to observe this warning could result in severe
injury or death.
STRAIGHT EDGE
Set up the elbow unit as shown.
Improper setup will cause the elbow
unit to collapse.
Failure to observe this warning could
result in severe injury or death.
Use these boom tubes only:
• boom tubes supplied with the VersiBoom
• 3" rigid steel conduit (3 meters or 10 feet maximum)
• 3" schedule 40 pipe (3 meters or 10 feet maximum)
1. Slide the boom tube into the boom mount until the
tube bottoms out. Sight the tube through the sight
hole to be sure the tube is fully inserted. Tighten the
set screw.
2. Slide the nose unit onto the tube until the tube
bottoms out. Sight the tube through the sight hole
to be sure the tube is fully inserted. Tighten the set
screw.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Setup (cont’d)
11147 Ultra Tugger® Adapter Package
Mounting Components (cont’d)
Booms with Elbow Unit and Nose Unit
• Use only straight 3" diameter rigid steel conduit or
Schedule 40 steel pipe for the boom tubes.
• Do not use boom tubes longer than 3 meters (10').
Longer booms may bend or break.
Failure to observe this warning could result in severe
injury or death.
STRAIGHT EDGE
Set up the elbow unit as shown.
Improper setup will cause the elbow
unit to collapse.
Failure to observe this warning could
result in severe injury or death.
Use these boom tubes only:
• boom tubes supplied with the VersiBoom
• 3" rigid steel conduit (3 meters or 10 feet maximum)
• 3" schedule 40 pipe (3 meters or 10 feet maximum)
1. Slide the boom tube into the boom mount until the
tube bottoms out. Sight the tube through the sight
hole to be sure the tube is fully inserted. Tighten the
set screw.
2. Slide the elbow unit onto the tube until the tube
bottoms out. Sight the tube through the sight hole
to be sure the tube is fully inserted. Tighten the set
screw.
3. Adjust the elbow to an appropriate angle and lock
it in place with a pin. Secure the pin with a hitch
pin clip.
4. Slide the boom tube into the elbow unit until the
tube bottoms out. Sight the tube through the sight
hole to be sure the tube is fully inserted. Tighten the
set screw.
5. Slide the nose unit onto the tube until the tube
bottoms out. Sight the tube through the sight hole
to be sure the tube is fully inserted. Tighten the set
screw.
Sight Hole
Sight Hole
Sight Hole
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Setup (cont’d)
11147 Ultra Tugger® Adapter Package
Mounting Components (cont’d)
Slip-in Coupler
Requires: One pin to connect to Nose Unit
1. Select the coupler that best ts the conduit.
2. Slide the coupler into the conduit until the coupler
seats on the end of the conduit.
Note: If the coupler does not seat on the conduit,
see “Straddling the Conduit with a Slip-In Coupler.”
Coupler
Pull
Conduit
Coupler must seat
on the Conduit here
3. Slide the nose unit over the coupler. Align any set of
holes and insert one pin. Secure the pin with a hitch
pin clip.
Note: If possible, add a second pin and hitch pin
clip.
Straddling the Conduit with Slip-in Coupler
Requires: Two pins to connect to Nose Unit
1. Select a coupler at least 25 mm (1") larger than the
conduit.
2. Place the coupler over the conduit.
Note: Do not use this method if the coupler does not
seat on a support structure that can support 35.6 kN
(8000 lb) of force.
Coupler
Conduit must
not protrude
past here
Support
Structure
Pull
Conduit
Nose Unit
Coupler
Pin secured with
Hitch Pin Clip
3. Slide the nose unit over the coupler. Align any two
sets of holes and insert two pins. Secure the pins
with hitch pin clips.
Coupler
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
10
11147 Ultra Tugger® Adapter Package
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.
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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
11147 Ultra Tugger® Adapter Package
Typical Setups (cont’d)
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.
Pulling Horizontally in Manhole
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 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
12
11147 Ultra Tugger® Adapter Package
Illustration and Parts List—Boom Mount Adapter
5
4
6
7
2
3
1
Key Part No. Description Qty
1 50028391 Frame ........................................................................................................ 1
2 50007556 Shaft .......................................................................................................... 1
3 90507002 Pin, roll, .187 x 1.5" ................................................................................... 1
4 90503023 Clip, hitch pin #8 ....................................................................................... 1
5 Screw, 3/8-16 x 1" hex head ..................................................................... 1
6 50009206 Wheel unit ................................................................................................. 1
7 50167987 Bushing ..................................................................................................... 2
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
Accessories
Nose Unit (50008641)
11147 Ultra Tugger® Adapter Package
2
8
1
7
5
3
6
4
Key Part No. Description Qty
1 50008323 Elbow, adjustable ...................................................................................... 1
2 50008439 Sheave unit, 12" ........................................................................................ 1
3 50007904 Shaft, elbow .............................................................................................. 1
4 50007432 Puller pin ................................................................................................... 1
5* 90507002 Pin, roll, .187 x 1.50" ................................................................................. 3
6* 90503023 Clip, hitch pin #8 ....................................................................................... 1
7 Screw, 3/8-16 x 1" hex head ..................................................................... 1
8 90548388 Bushing ..................................................................................................... 2
9 50010425 Decal, Warning .......................................................................................... 1
9
Repair Kits
* 50061887 Puller pin kit (includes one each of
the items marked with an asterisk) ........................................................... 2
50061925 Elbow shaft kit (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
14
Accessories (cont’d)
Elbow Unit (50008633)
9
8
6
11147 Ultra Tugger® Adapter Package
3
1
2
4
6
7
5
Key Part No. Description Qty
1 50008323 Elbow, adjustable ...................................................................................... 1
2 50008285 Elbow, pivot............................................................................................... 1
3 50008439 Sheave unit, 12" ........................................................................................ 1
4 50008366 Shaft, pivot ................................................................................................ 1
5* 50008374 Pin, elbow ................................................................................................. 1
6* 90507002 Pin, roll, .187 x 1.50" ................................................................................. 3
7* 90503023 Clip, hitch pin #8 ....................................................................................... 1
8 Screw, 3/8-16 x 1" hex head ..................................................................... 2
9 90548388 Bushing ..................................................................................................... 2
10 50013971 Lanyard ..................................................................................................... 1
11 50010328 Decal, warning .......................................................................................... 1
10
11
8
Repair Kits
* 50061941 Elbow pins kit (includes one each of
the items marked with an asterisk) ........................................................... 1
50061950 Pivot pins kit (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
15
Accessories (cont’d)
11147 Ultra Tugger® Adapter Package
Slip-in Couplers
Key Part No. Description Qty
1 50008048 Slip-in coupler for 2-1/2" conduit (EMT, IMC or Rigid) ............................. 1
1 50008110 Slip-in coupler for 3" conduit (EMT, IMC or Rigid) .................................... 1
1 50008153 Slip-in coupler for 3-1/2" conduit (EMT, IMC or Rigid) ............................. 1
1 50008200 Slip-in coupler for 4" conduit (EMT, IMC or Rigid) .................................... 1
1 50008277 Slip-in coupler for 5" conduit (EMT, IMC or Rigid) .................................... 1
Screw-on Couplers
2
3
1
5
7
6
4
Key Part No. Description Qty
— 50008684 Screw-on coupler set for 2-1/2", 3", 3-1/2" & 4" conduit
(includes items 2–4)
2 50036610 Screw-on coupler for 2" IMC or Rigid only ............................................... 1
2 50007815 Screw-on coupler for 2-1/2" IMC or Rigid only ....................................... 1
2 50007823 Screw-on coupler for 3" IMC or Rigid only ............................................... 1
2 50007831 Screw-on coupler for 3-1/2" IMC or Rigid only ....................................... 1
2 50007840 Screw-on coupler for 4" IMC or Rigid only ............................................... 1
3 50007998 Adapter for screw-on IMC or Rigid only ................................................... 1
4 50008773 Screw assembly (includes items 5–7) ....................................................... 2
5 50007955 Screw ........................................................................................................ 1
6 50007963 Handle ....................................................................................................... 1
7 90527178 Roll pin ...................................................................................................... 1
Boom Tubes
Key Part No. Description Qty
8
9
8 50008358 3' Boom tube ............................................................................................ 1
9 50007912 4' Boom tube ............................................................................................ 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Accessories (cont’d)
T-Stand (50008676)
11147 Ultra Tugger® Adapter Package
8
4
4
Wheeled Carriage
9
7
(50008706)
5
6
3
4
8
Key Part No. Description Qty
1 50007700 Frame ........................................................................................................ 1
2 90533909 Wheel, rubber, 12 x 3 ................................................................................ 4
3 50007688 Axle ........................................................................................................... 2
4 90517407 Washer, at, .812 x 1.50 x .140 ............................................................... 16
5* 50007432 Puller pin ................................................................................................... 2
6* 90507002 Pin, roll, .187 x 1.50" ................................................................................. 2
7* 90503023 Clip, hitch pin #8 ....................................................................................... 2
8 90515285 Retaining ring, .750", Truarc #5160-75-S-PP ........................................... 4
9 50010638 Decal, warning .......................................................................................... 1
4
1
4
8
4
2
8
4
4
Repair Kits
* 50061887 Puller pin kit (includes one each of
the items marked with an asterisk) ........................................................... 2
52066231 Wheel service kit (set of 4) ........................................................................ 1
52066332 Wheel service kit (single wheel) ................................................................ 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
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
USA Tel: 800-435-0786
Fax: 800-451-2632
Canada Tel: 800-435-0786
Fax: 800-524-2853
International Tel: +1-815-397-7070
Fax: +1-815-397-9247
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