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INSTRUCTION MANUAL
Español ............... 37
Français .............. 73
UT10 Ultra Tugger®
Cable Puller and
Pulling Packages
Serial Codes ANB and BBD
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
52059725 REV 10 © 2020 Greenlee Tools, Inc. 3/20
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Page 2
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Table of Contents
Description
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
General Safety Rules ..................................................... 3
Specic Safety Rules and Symbols ........................... 4-7
Grounding Instructions .................................................. 7
FUNCTIONAL DESCRIPTION
Identication ............................................................... 8-9
Specications .............................................................. 10
Cable Pulling Glossary ................................................ 11
Cable Pulling Principles .......................................... 12-20
Cable Pulling Systems ............................................. 12
Pulling Theory .......................................................... 13
Cable Pulling Forces .......................................... 14-18
Tailing the Rope ....................................................... 19
Summary of Cable Pulling Principles....................... 20
Planning the Pull .......................................................... 20
ASSEMBLY
Boom Assembly/Disassembly ..................................... 21
Boom Setup ........................................................... 22-25
Up Pull Starting from Teepee Position ..................... 22
Down Pull Starting from Teepee Position ................ 23
Horizontal Pull .......................................................... 24
Single Boom Pull ..................................................... 24
Boom Components ................................................. 25
Transporting the Boom ................................................ 26
OPERATION
Boom Operation ..................................................... 27-28
Puller Operation ........................................................... 29
Removing Cable .......................................................... 30
SERVICE ...................................................................... 31
Maintenance ........................................................... 31-32
ACCESSORIES ........................................................... 33
Setup—Chain Mount .............................................. 34-35
Setup—Floor Mount .................................................... 36
Illustration and Parts Lists
Ultra Tugger 10 ............................................... 109-110
Gearmotor ....................................................... 111-112
Mobile Carriage and Boom ............................. 113-114
Accessories ........................................................... 115
The Greenlee UT10 Ultra Tugger® Cable Puller is
intended to be used to pull cable through conduit and in
tray. The UT10 will develop 44.5 kN (10,000 lb) of pulling
force. Refer to a Greenlee catalog for sheaves, pulling
rope, and other cable pulling accessories to create an
entire cable pulling system.
No single manual can provide instructions for every
possible cable pulling application; this manual contains
general information necessary to accomplish cable pulls
of many different setups.
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
Greenlee UT10 Ultra Tugger® Cable Puller.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
All specications are nominal and may change as design
improvements occur. Greenlee Tools, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Ultra Tugger is a registered trademark of Greenlee Tools, Inc.
Loctite and 242 are registered trademarks of Henkel Corporation.
KEEP THIS MANUAL
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
GENERAL SAFETY RULES
WARNING! Read and understand all instructions.
Failure to follow all instructions listed below may result
in electric shock, re, and/or serious personal injury.
SAVE THESE INSTRUCTIONS
WORK AREA SAFETY
Keep your work area clean and well lit. Cluttered
benches and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases, or dust. Power tools create sparks
which may ignite the dust or fumes.
Keep bystanders, children, and visitors away while
operating a power tool. Distractions can cause you to
lose control.
ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet prop-
erly installed and grounded in accordance with all
codes and ordinances. Never remove the grounding
prong or modify the plug in any way. Do not use any
adapter plugs. Check with a qualified electrician if
you are in doubt as to whether the outlet is properly
grounded. If the tools should electrically malfunction or
break down, grounding provides a low resistance path
to carry electricity away from the user.
Avoid body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerators. There
is an increased risk of electric shock if your body is
grounded.
Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
Do not abuse the cord. Never use the cord to carry
the tools or pull the plug from an outlet. Keep cord
away from heat, oil, sharp edges or moving parts.
Replace damaged cords immediately. Damaged
cords increase the risk of electric shock.
When operating a power tool outside, use an
outdoor extension cord marked “W-A” or “W.” These
cords are rated for outdoor use and reduce the risk of
electric shock.
PERSONAL SAFETY
Stay alert, watch what you are doing and use
common sense when operating a power tool. Do not
use tool while tired or under the influence of drugs,
alcohol, or medication. A moment of inattention while
operating power tools may result in serious personal
injury.
Dress properly. Do not wear loose clothing or
jewelry. Contain long hair. Keep your hair, clothing,
and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
Avoid accidental starting. Be sure switch is off
before plugging in. Carrying tools with your nger on
the switch or plugging in tools that have the switch on
invites accidents.
Remove adjusting keys or switches before turning
the tool on. A wrench or a key that is left attached to a
rotating part of the tool may result in personal injury.
Do not overreach. Keep proper footing and balance
at all times. Proper footing and balance enables better
control of the tool in unexpected situations.
Use safety equipment. Always wear eye protection.
Dust mask, non-skid safety shoes, hard hat, or hearing
protection must be used for appropriate conditions.
TOOL USE AND CARE
Use clamps or other practical way to secure and
support the workpiece to a stable platform. Holding
the work by hand or against your body is unstable and
may lead to loss of control.
Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer
at the rate for which it was designed.
Do not use tool if switch does not turn it on and off.
Any tool that cannot be controlled with the switch is
dangerous and must be repaired.
Disconnect the plug from the power source before
making any adjustments, changing accessories,
or storing the tool. Such preventive safety measures
reduce the risk of starting the tool accidentally.
Store idle tools out of reach of children and other
untrained persons. Tools are dangerous in the hands of
untrained users.
Maintain tools with care. Keep cutting tools sharp
and clean. Properly maintained tools, with sharp cutting
edges, are less likely to bind and are easier to control.
Check for misalignment or binding of moving parts,
breakage of parts, and any other condition that may
affect the tool’s operation. If damaged, have the tool
serviced before using. Many accidents are caused by
poorly maintained tools.
Use only accessories that are recommended by the
manufacturer for your model. Accessories that may
be suitable for one tool may become hazardous when
used on another tool.
SERVICE
Tool service must be performed only by qualified
repair personnel. Service or maintenance performed by
unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instructions in the “Maintenance”
section of this manual. Use of unauthorized parts or
failure to follow maintenance instructions may create a
risk of electric shock or injury.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
SPECIFIC SAFETY RULES AND SYMBOLS
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.
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.
Do not operate the cable puller in
a hazardous environment. Hazards
include ammable liquids and gases.
Failure to observe this warning will
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 before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
Do not mount puller as shown above.
Inside of capstan should be centered over conduit.
The chain mount could break away from the mount-
ing, causing severe injury or death.
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.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
SPECIFIC SAFETY RULES AND SYMBOLS
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.
Do not allow anything other than the
pulling rope to contact the capstan.
A grip, swivel, or other component
could break and strike nearby personnel with great force.
Failure to observe this warning could
result in severe injury or death.
Locate the puller so that it is close to the conduit.
Rope, cable, or connectors can break under tension,
causing the rope to whip violently.
Failure to observe this warning could result in severe
injury or death.
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.
An under-rated or worn rope may break and whip
violently. Use a double-braided composite rope with
the following minimum characteristics:
Average Breaking Strength:
at least 143 kN (32,000 lb)
Failure to observe this warning could result in severe
injury or death.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
SPECIFIC SAFETY RULES AND SYMBOLS
• Check the condition of the entire rope before use.
A worn or damaged rope can break under tension
and whip violently.
• Do not maintain a stationary rope on a rotating
capstan. The wear generated may cause the rope
to break under tension and whip violently.
Failure to observe these warnings could result in
severe injury or death.
Attach the pulling rope to the cable with appropriate types of connectors as described in this manual.
Select connectors with a maximum rated capacity
of 44.5 kN (10,000 lb). An under-rated connector can
break under tension.
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 may cut
off ngers.
Failure to observe this warning could
result in severe injury or death.
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.
Do not allow the rope to become overlapped on
the capstan. If an overlap begins to develop, relax
the tailing force immediately and shut off the cable
puller.
Failure to observe this warning could result in severe
injury or death.
Use this tool for manufacturer’s intended purpose
only. Do not use the cable puller as a hoist or winch.
• The cable puller cannot lower a load.
• The load may fall.
Failure to observe this warning could result in severe
injury or death.
Keep hands away from the capstan.
Rope at the capstan can crush a
hand.
Failure to observe this warning could
result in severe injury or death.
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.
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Always lock boom components
in place during assembly or disassembly. Adding and removing
components may cause rotation.
Parts may strike nearby personnel.
Failure to observe this warning could
result in severe injury or death.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
SPECIFIC SAFETY RULES AND SYMBOLS
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
sufcient force to cause severe injury or death.
Entanglement hazard:
• Do not operate the cable puller while wearing
loose-tting clothing.
• Retain long hair.
Failure to observe this warning could result in severe
injury or death.
Wear eye protection when using this
tool. Failure to wear eye protection
could result in severe eye injury from
ying debris.
When using the wheeled carriage to transport the
UT10:
• Keep personnel out of the path of transport.
• Evaluate the terrain 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.
15°
Grounding Instructions
Electric shock hazard:
Connect this tool to a grounded
receptacle on a 20 amp GFCIprotected circuit.
Failure to observe this warning could
result in severe injury or death.
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. This path of
least resistance is intended to reduce the risk of electric
shock to the operator.
Note: Keep all decals clean and legible, and replace
when necessary.
This tool’s electric cord has a grounding conductor and
a grounding plug as shown. Do not modify the plug.
Connect the plug to receptacle that is properly installed
and grounded in accordance with all national and local
codes and ordinances. Do not use an adapter.
20 Amp / 115 Volt
Plug and Grounded Receptacle
ReceptaclePlug
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
FUNCTIONAL DESCRIPTION
Identification
4
3
5
6
7
8
9
2
1
13
12
1. Motor
2. Circuit Breaker/Switch
3. Power Cord
4. Force Gauge
5. Foot Switch
6. Adjustable Sheave
Bracket
10
11
UT10 Cable Puller
7. Hitch Clip
8. Rope Tie-Off
9. Right Angle Sheave
10. Tapered Steel Capstan
11. Rope Ramp
12. Mounting Plates
13. Gearbox
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Identification (cont’d)
Mobile Carriage
and Boom
1. Puller
2. Elbow
3. Nose
4. Back Boom
5. Forward Boom
6. Detent Pin
7. Crank
8. Conduit Adapter
Couplings
9. Adapter Storage
Hanger
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
7
1
9
15
8
15
5
4
14
2
6
3
15
16
13
12
10
11
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Specifications
Weight ........................................................................................................ 38 kg (84 lb)
Dimensions
Length ................................................................................................. 29 cm (11.5")
Width ....................................................................................................... 66 cm (26")
Height ................................................................................................... 17 cm (6.75")
Motor
Voltage ...........................................................120/230 VAC, 50/60 Hz, single phase
Current Draw at Full Load ................................... 20 amps (120 V), 12 amps (230 V)
Sound Level ................................................................................... 75 dB at 1 meter
Power Source ................................................. 120 VAC, 60 Hz, 20 amps, single phase
Speed LOW HIGH
No Load ....................................... 2.74 m/min (9 ft/min) 4.88 m/min (16 ft/min)
8900 N (2000 lb) ........................... 2.44 m/min (8 ft/min) 4.27 m/min (14 ft/min)
17.8 kN (4000 lb) .......................... 2.29 m/min (7.5 ft/min) 3.66 m/min (12 ft/min)
26.7 kN (6000 lb) .......................... 2.13 m/min (7 ft/min) —
35.6 kN (8000 lb) .......................... 1.83 m/min (6 ft/min) —
230 VAC, 50 Hz, 12 amps, single phase
Pulling Force
0 kN to 28.9 kN (0 lb to 6500 lb) .............................................Continuous operation
28.9 kN to 35.6 kN (6500 lb to 8000 lb) ........................5 minutes on / 5 minutes off
35.6 kN to 44.5 kN (8000 lb to 10,000 lb) ............................................... Momentary
Pulling Rope
Required Rope ....................... 7/8" diameter, double-braided, polyester composite
Average Breaking Strength .......................................... 143 kN (32,000 lb) minimum
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Glossary
anchoring system
any item or group of items that keeps a cable pulling
component in place during the cable pull
capstan
the hollow cylinder of the cable puller that acts on the
pulling rope to generate pulling force
coefficient of friction
the ratio that compares two amounts of force:
(1) the force needed to move an object over a surface
and (2) the force holding the object against the surface
This ratio is used to describe how the capstan and the
rope work together.
connector
any item, such as a wire grip, clevis, swivel, or pulling
grip, that connects the rope to the cable
direct line of pull
the areas next to the pulling rope and along its path;
this includes the areas in front of, in back of, and
underneath the rope
maximum rated capacity
the amount of pulling tension that any component
can safely withstand, rated in kilonewtons (metric)
or pounds; the maximum rated capacity of every
component must meet or exceed the maximum pulling
force of the cable puller
Newton (N)
a metric unit of force, equivalent to 0.225 pounds of
force
pipe adapter sheave
attaches to conduit for pulling or feeding cable
pulling grip
connects the rope to the cable; consists of a wire mesh
basket that slides over the cable and grips the insulation
resultant force
any force that is produced when two or more forces act
on an object; applies to the sheaves of a cable pulling
system
rope ramp
a device that works with a tapered capstan; guides the
rope onto the capstan to prevent rope overlap
sheave
a pulley that changes the direction of the rope and cable
stored energy
the energy that accumulates in the pulling rope as it
stretches, described in newton-meters (metric) or
foot-pounds
support structure
any stationary object that a cable pulling system
component is anchored to, such as a concrete oor
(for the oor mount) or an I-beam (for a sheave)
tactile feedback
the way the rope feels as it feeds off of the capstan; the
feel of the rope provides information about the progress
of the pull to the operator
tail
the portion of the rope that the operator applies force
to; this is the rope coming off of the capstan, and is not
under the tension of the pull
tailing the rope
the operator’s main function; this is the process of
applying force to the tail of the pulling rope—refer to the
complete explanation under “Cable Pulling Principles”
wire grip
connects the rope to the cable; some use a set screw to
clamp onto the conductors of the cable
pulling force
the amount of pulling tension developed by the cable
puller, rated in newtons (metric) or pounds; a cable
puller is usually described by the maximum pulling force
that it can develop
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles
Pulling cable is a complex process. This section of
the manual describes and explains four main topics of
pulling cable:
• Each cable pulling system component
• How these components work together
• Forces that are generated
• Procedures for the cable puller operator to follow
While reading through this section of the manual, look
for components that are shaded in the illustrations. 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.
Cable Pulling Systems
Pulling cable requires a system of components. At a
minimum, a cable pulling system will include a cable
puller, a cable pulling rope, and connectors to join the
rope to the cable. Most systems will also include, but
are not limited to, a cable puller anchoring system,
pulling sheaves, and sheave anchoring systems.
The cable puller has a maximum amount of pulling
force, which is the amount of pulling tension that it
develops. Every other component of the pulling system
has a maximum rated capacity, which is the amount
of pulling tension that it can withstand. The maximum
rated capacity of every component must meet or
exceed the cable puller’s maximum pulling force.
Typical Cable Pulling System
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Pulling Theory
This section introduces the main ideas involved with
pulling cable.
Pulling Resistance
The cable puller must overcome two types of resistance:
gravity and friction.
Gravity constantly exerts its force on the vertical
portions of the run. When the pulling force is relaxed,
gravity attempts to pull the cable downward. Friction
develops where the cable contacts the sheaves,
conduit, and tray. Friction resists any movement,
forward or backward, and tends to hold the cables in
place.
To accomplish a cable pull, the cable pulling system
must develop more force than the combination of
gravity and friction.
Generating Pulling Force
To generate pulling force, the capstan works as a
force multiplier. The operator exerts a small amount
of force on the rope. The cable puller multiplies this
and generates the pulling force.
This pulling force is applied to the rope, connectors,
and cable in order to accomplish the pull. The direction of force is changed, where necessary, with pulling
sheaves.
Gravity
Friction
Pulling Force
35.6 kN
(8000 lb)
Conduit
Weight
of Cable
Tailing
Force
Cable Pulling Theory Illustrated
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Ultra Tugger® 10 Cable Puller and Pulling Packages
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Cable Pulling Principles (cont’d)
Cable Pulling Forces
This section provides detailed explanations and illustrations of the forces that are generated during the cable
pull. These explanations are based on the concepts
presented in the last section, “Pulling Theory.”
At the Cable Puller Anchoring System
The cable puller will exert its maximum pulling force on
cable puller’s anchoring system. It is extremely important the anchoring system can withstand this amount of
force. Refer to the instruction manual provided with your
anchoring system for proper setup or installation.
Pulling Force
44.5 kN
(10,000 lb)
44.5 kN
(10,000 lb)
Maximum
Maximum Pulling Force
at Anchoring System
Pulling Force at the Cable Puller’s Anchoring System
44.5 kN
(10,000 lb)
Maximum
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Cable Pulling Forces (cont’d)
At the Capstan
The capstan acts as a force multiplier. The operator
exerts a small amount of tension, or tailing force, on the
rope; the capstan multiplies this force to pull the cable.
The resultant force depends upon the number of times
the rope is wrapped around the capstan, as shown in
the formula below.
Pulling Force = Tailing Force x e
Where:
e = the natural logarithm, or 2.7183
µ = the coefcient of friction between the
rope and the capstan*
ø = the number of degrees of wrap of rope
around the capstan
* The average value for the coefcient of friction when
double-braided composite rope is pulled over a
clean dry capstan is 0.125.
0.0175µø
The following table is based on the formula above.
The input, or tailing force, is constant at 44.5 N (10 lb).
Increasing the number of wraps increases the pulling
force.
Operator’s
Tailing Force
44.5 N (10 lb)
Number of
Wraps of Rope
1 93.4 N (21 lb)
2 213.5 N (48 lb)
3 474.9 N (106 lb)
4 1043.8 N (233 lb)
5 2293.7 N (512 lb)
6 5048.9 N (1127 lb)
7 11.1 kN (2478 lb)
Approximate
Pulling Force
This table shows how the capstan acts as a force
multiplier. Because the coefcient of friction depends
upon the condition of the rope and capstan, this formula
cannot determine an exact amount of pulling force.
Pulling Force
44.5 kN (10,000 lb)
The Capstan as a Force Multiplier
Tailing
Force
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Cable Pulling Forces (cont’d)
At the Pulling Rope
The product of a force (f) moving through a distance
(d) is energy (f x d), and may be measured in newtonmeters or ft-lb. Energy is stored in a rope when the rope
is stretched. This is similar to the way energy is stored in
a rubber band when it is stretched. Failure of the rope or
any other component of the pulling system can cause a
sudden uncontrolled release of the energy stored in the
rope.
For example, a 100 meter nylon rope with a
50,000newton average breaking strength could stretch
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.
A similar double-braided composite rope could store
approximately 300,000 joules of energy. This could
throw the same object only 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.
Double-braided composite rope is the only type of rope
recommended for use with the UT10 cable puller. Select
a double-braided composite rope with an average rated
breaking strength of at least 143 kN (32,000 lb).
Stored Energy
Stored Energy
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Cable Pulling Forces (cont’d)
At the Connectors
The connectors will be subjected to the cable puller’s
maximum pulling force.
Several types of rope connectors—clevises, swivels,
and rope-to-swivel connectors—are available. Follow
the instructions provided with each to provide a good
connection.
Two types of wire connectors—wire grips and pulling
grips—are available. The wire grip uses a set screw
to clamp onto the conductors of the cable. The pulling
grip consists of a wire mesh basket that slides over
the cable and grips the insulation.
Maximum
Pulling Force
44.5 kN
(10,000 lb)
A Typical Grip Setup—Clevis and Wire Grip
Maximum
Pulling Force
44.5 kN
(10,000 lb)
When selecting a pulling grip, it is extremely important
to select a grip of the correct (1) type, (2) size, and
(3)maximum rated capacity.
1. Select the correct type based on the descriptions
of each type in the Greenlee catalog.
2. Measure the circumference of the wire bundle.
(To do this accurately, fasten a tie strap around the
bundle. Cut off and discard the tail. Then cut the tie
strap and measure its length.). Use the table provided to nd the correct size.
3. Refer to the maximum rated capacities in the
Greenlee catalog.
Pulling Grip Size Table
Circumference Range Required Grip Diameter
inches mm inches mm
1.57–1.95 39.9–49.5 0.50–0.61 12.7–15.5
1.95–2.36 49.5–59.9 0.62–0.74 15.8–18.8
2.36–3.14 59.9–79.8 0.75–0.99 19.1–25.1
3.14–3.93 79.8–99.8 1.00–1.24 25.4–31.5
3.93–4.71 99.8–119.6 1.25–1.49 31.8–37.8
4.71–5.50 119.6–139.7 1.50–1.74 38.1–44.2
5.50–6.28 139.7–159.5 1.75–1.99 44.5–50.5
6.28–7.85 159.5–199.4 2.00–2.49 50.8–63.2
7.85–9.42 199.4–239.3 2.50–2.99 63.5–75.9
9.42–11.00 239.3–279.4 3.00–3.49 76.2–88.6
11.00–12.57 279.4–319.3 3.50–3.99 88.9–101.3
12.57–14.14 319.3–359.2 4.00–4.49 101.6–114.0
14.14–15.71 359.2–399.0 4.50–4.99 114.3–126.7
A Typical Grip Setup—Swivel and Pulling Grip
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Cable Pulling Forces (cont’d)
At the Sheaves
Sheaves are used to change the direction of the pull.
A change in direction creates a new resultant force
that may be greater than the cable puller’s maximum
pulling force. This new resultant force exerts itself on the
sheaves, sheave anchoring system, and support structures illustrated.
The resultant amount of force depends on the angle of
the change in direction. A brief table is provided here;
For details on calculating the resultant force for any
angle, refer to IM 1363 (99929988).
Resultant Force Table
(35.6 kN or 8,000 lb Pulling Force)
Illustration
Angle of Change
in Direction
180° 0 (0)
150° 18.5 (4160)
135° 27.4 (6160)
120° 35.6 (8000)
90° 50.2 (11,300)
60° 61.6 (13,800)
45° 65.8 (14,800)
30° 68.7 (15,400)
0° 71.2 (16,000)
Resultant Force
in kN (lb)
135°
Resultant Force
27.4 kN (6160 lb)
Typical Resultant Force at Sheave
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Page 19
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Tailing the Rope
The rope must be pulled off of the capstan as the pull
progresses. The rope that has left the capstan is the
“tail.” The process of pulling the rope off of the capstan
is called tailing the rope.
The resistance of the cable varies throughout the duration of the cable pull. Changes in resistance are
due to characteristics of the rope, changes in conduit
direction, and changes in the amount of friction. The
“feel” of the rope provides this information about the
pull. This is called tactile feedback. Adjust the tailing
force as necessary to compensate for these changes.
Control of the Pull
Decreasing the tailing force will decrease the pulling
force, until the rope slips on the capstan and the pull
stops. This provides a high level of control over the
progress of the cable pull.
Do not allow the rope to slip on the capstan for more
than a few moments. If it becomes necessary to completely stop a pull, shut off the puller and maintain
enough tailing force to hold cable in place. Tie the rope
off to hold it in place.
Amount of Tailing Force
While the rope and cable are under tension, it is important to maintain the proper amount of tailing force.
Too little tailing force will allow the rope to slip on the
capstan. This will build up excessive heat and accelerate rope wear, increasing the possibility of breaking the
rope.
The proper amount of tailing force will stop the rope
from slipping on the capstan and produce a sufcient
amount of pulling force to pull in the rope and cable.
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.
Number of Wraps of Rope Around the Capstan
An experienced operator should choose the number
times the rope is wrapped around the capstan.
The proper number of wraps allows the operator to
control the progress of the pull with a comfortable
amount of effort.
Using too few wraps requires a large tailing force to
accomplish the pull. Using too few wraps also makes
the rope more likely to slip on the capstan. This builds
up heat and accelerates rope wear.
Using too many wraps causes the rope to grab the
capstan tighter. This accelerates rope wear, wastes
power, and increases the possibility of a rope overlap.
Using too many wraps also reduces tactile feedback,
so you receive less information about the pull. You
cannot quickly relax the tailing force when there are too
many wraps.
If the rope becomes difcult to tail, add another wrap
of rope. Turn off the puller and release all of the tension
in the rope. Add a wrap and resume pulling. Be aware,
however, that some pulls will require tension to hold
the cables in place. In these cases, do not attempt to
release all of the tension and add a wrap of rope. You
will need to anticipate the number of wraps before starting the pull.
Preventing Rope Overlap
Do not allow the rope to become overlapped on the
capstan during a pull.
A rope overlap will make it impossible to continue
or back out of the pull.
If the rope becomes overlapped, you will lose control
of the pull —the rope will advance with no tailing force
and will not feed off of the capstan. The capstan will not
allow you to reverse the direction of the rope, so you
cannot back out of an overlap.
Set up the puller properly. The rope ramp and tapered
capstan are intended to prevent rope overlap. Refer
to the instructions in the “Operation” section of this
manual.
Every wrap of the rope must remain in direct contact
with the capstan. During the pull, take great care to
prevent the incoming rope from riding up and overlapping the next wrap. If an overlap begins to develop,
immediately relax the tailing force on the rope so that
the rope can feed back toward the conduit or tray.
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!
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Cable Pulling Principles (cont’d)
Planning the Pull
Summary of Cable Pulling Principles
• A cable pulling system consists of many components
that work together to accomplish a pull.
• The cable puller is rated by its maximum pulling
force; every other component is rated by its maximum
rated capacity. The maximum rated capacity of every
component must meet or exceed the maximum
pulling force of the cable puller.
• The cable puller must overcome two types of resistance: gravity and friction. The puller’s capstan, the
pulling rope, and the operator tailing the rope work
together to produce pulling force.
• The cable puller exerts force on every component
of the cable pulling system, including the anchoring
systems and the support structures.
• Energy is stored in a rope when the load causes
the rope to stretch. Failure of the rope or any other
component can cause a sudden release of energy.
Replace any rope that is worn or damaged.
• Carefully select the number or wraps of rope around
the capstan before starting the pull.
• 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.
• Pull in a direction that will require the lowest amount
of pulling force.
• Plan several shorter pulls rather than fewer longer
pulls.
• Locate the puller as close to the end of the conduit
as possible to minimize the amount of exposed rope
under tension.
• Place each component so that the pulling forces are
used effectively.
• Select an anchoring system: adapter sheaves, which
are preferred, or the oor mount.
• Verify that each component has the proper load
rating.
• Inspect the structural supports. Verify that they have
enough strength to withstand the maximum forces
that may be generated.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
ASSEMBLY
Boom Assembly/Disassembly
Under normal circumstances, there is no need to disassemble the boom assembly. However, it can be disassembled in order to t into a small truck, mount the
puller head remotely on a oor mount, alter the boom
lengths, etc.
To disassemble, follow this procedure:
1. Lock the swivel caster brakes.
2. Pivot the elbow until the forward boom is clear of
the carriage.
3. Grab the nose by the hole at the end of the boom
tube, and lift up to relieve the preload on the detent
pins.
Ring Pull
Detent Pin
4. Pull out on the detent ring that locks the boom tube,
and twist the nose slightly so the hole in the boom
tube and detent pin are misaligned.
Ring Pull
Detent Pin
5. Release the detent ring, and pull the nose and
forward boom from the elbow.
6. Repeat this process to remove the back boom
and elbow. Raise or lower the boom(s) as desired
beforehand to gain a comfortable position.
7. Turn the crank clockwise until the puller head is as
high as it will go.
8. Remove the clips and pull out the pins that mount
the puller head.
Grab
Point
9. Lift the puller head off the boom mount using as
many people as needed to lift 45 kg (100 lb).
Aside from detaching the other end of the two boom
tubes, this is as far as the unit breaks down. Assemble
in the reverse order, making sure that all detent pins are
fully seated before releasing your hold.
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Puller
Mounting
Pins
Page 22
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Boom Setup
Up Pull Starting from Teepee Position
1. Set the brakes.
2. Raise the forward boom as described under “Boom
Operation” until it is close to the angle desired for
the pull setup,
or
a. Lock the elbow detent pins in the fully inward
position.
b. Lower the boom (turn crank CW) until the nose
hits the oor.
c. Release the brakes and continue to lower the
boom while walking the carriage backwards
until the elbow is at the desired angle and lock it
in place.
To use slip-in couplings:
a. Insert the appropriate slip-in conduit adapter
coupling into the nose.
b. Pivot the nose until the coupling is aligned with
the conduit and lock in position.
c. Raise the boom until the bottom of the coupling
clears the conduit.
d. Release the brakes if not already released.
e. Roll the carriage forward until the coupling is
over the conduit and lower it into the conduit.
To use screw-on couplings:
a. Screw the appropriate screw-on adapter cou-
pling fully onto the conduit.
b. Pivot the nose until it is aligned with the cou-
pling and lock in position.
c. Raise the boom until the bottom of the coupling
clears the conduit.
d. Release the brakes if not already released.
e. Roll the carriage forward until the nose is over
the coupling, pull the detent ring, and lower the
nose onto the coupling.
Position Elbow to Desired Angle
3. Raise or lower the boom until the nose is just above
the conduit to be pulled from.
Conduit
Position Nose Higher than Conduit
Insert Conduit Adapter and Raise above Conduit
Lower into Conduit
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Boom Setup (cont’d)
Down Pull Starting from Teepee Position
1. Set the brakes.
2. Pivot the elbow one or two detent positions
outward. Lift up on the nose to release any preload
on the detent pin securing the back boom to the
elbow.
3. While holding the detent out, rotate the elbow
on the back boom 180° by walking it around the
carriage.
Rotate 180°
4. Lower the entire boom until the forward boom is
close to vertical.
5. Lower the forward boom until the elbow is close to
the angle desired for the pull setup.
6. Raise or lower the boom until the nose is just below
the conduit to be pulled from.
To use slip-in couplings:
a. Insert the appropriate slip-in conduit adapter
coupling into the nose.
b. Pivot the nose until the coupling is aligned with
the conduit and lock in position.
c. Lower the boom until the coupling clears the
conduit.
d. Release the brakes.
e. Roll the carriage forward until the coupling is
under the conduit and raise it.
To use screw-on couplings:
a. Screw the appropriate screw-on adapter cou-
pling fully onto the conduit.
b. Pivot the nose until it is aligned with the cou-
pling and lock in position.
c. Lower the boom until the coupling clears the
conduit.
d. Release the brakes.
e. 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
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Boom Setup (cont’d)
Horizontal Pull
Horizontal pulls are essentially the same as an up pull or
a down pull.
• If the conduit is above the puller, follow the up pull
instructions.
• If the conduit is below the puller, follow the down pull
instructions.
The only difference is in the horizontal alignment of the
coupling with the conduit and using the carriage to walk
the coupling into the conduit (or the nose into the coupling for the screw-on adapters).
Single Boom Pull
All of the previous boom setup instructions assume that
two booms are used. While using two booms can be
useful for working around obstructions, keeping angles
over sheaves to a minimum, and pulling out extra tail,
it is not always necessary. A single 3', 4', or 3" rigid
conduit up to 10' long can be used to keep setups even
simpler.
Horizontal Pull in Underground Vault
Single Boom Setup
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Page 25
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Boom Setup (cont’d)
Boom Components
• Use only Greenlee supplied booms or 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.
If the elbow/nose unit is disassembled, reassemble 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 UT10
• 3" rigid steel conduit (3 m or 10' maximum)
• 3" Schedule 40 pipe (3 m or 10' maximum)
If using 3" rigid conduit in place of the standard booms:
1. Insert the conduit while pulling out the detent rings.
2. Slide the conduit fully in and verify it is seated
through the sight holes.
3. Use 1/2"-13 screws (not supplied) in the weld nuts
to lock the conduit in place.
Sight Holes
Shear point:
Never put ngers through holes
in boom components. Pivoting of
mating arts may cut off ngers.
Always keep elbow unit locked with
pivot pin except while adjusting.
Failure to observe this warning could
result in severe injury or death.
Detent Rings
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Transporting the Boom
Wheeling
1. If the unit had been set up for an up pull:
a. Lower the nose to the oor to get to the Teepee
transport position.
b. Lock the elbow pivot detents in the inward
position.
c. Raise the boom by cranking until the nose is off
the oor, and release the detents.
If the unit had been set up for a down pull:
a. Release the elbow pivot detents, fold the
forward boom back to the next to last position,
and lock the elbow.
b. Raise the boom all the way up until it hits the
stop.
c. Release the ring pull detent that locks the back
boom to the elbow, and rotate the elbow 180°
into its Teepee position.
2. Lift the push/pull handle up until it contacts the
boom mount to push the carriage. Use the same
handle to pull the unit.
Handle raised
for pushing
Lifting
1. Connect a lifting sling to the top puller head mounting pin.
2. Feed the sling up between the sheave and frame of
the elbow so that it is trapped.
3. Lift the sling from above the elbow.
Sling
Handle Position for Pushing
Handle raised
for pulling
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.
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Page 27
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
OPERATION
Boom Operation
Raising and Lowering
The boom can be raised and lowered using the crank
in front of the puller. Turn the crank counterclockwise to
raise the boom, and clockwise to lower it. When starting from the Teepee position, unlock the elbow before
lowering to prevent the boom from crashing against the
carriage.
Pivoting the Elbow and Nose Units
The elbow and nose units are physically identical and
can be used interchangeably. For the sake of clarity, in
this manual:
• “Nose” refers to the unit that attaches to the conduit
via couplers.
• “Elbow” refers to the unit that connects the two boom
tubes.
The elbow/nose units pivot and lock at various degrees
of rotation. They are locked in place by a detent pin set
located between the sheave and the end of the boom
tube receptacle. To pivot, squeeze the grips on the
detent pins fully inward.
Squeeze
Grips
Teepee Position
Make sure the detent pins on both sides are fully
retracted before trying to pivot. Release the grips when
the desired pivot angle is reached, and pivot slightly
more to allow both detents to engage in the closest
holes.
When the detent pins are squeezed to the fully inward
position, they can be locked in place by twisting them
counterclockwise.
Twist to lock.
Never pull cable with the detent pins locked inward;
both the elbow and nose must be locked from pivoting
before pulling.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Boom Operation (cont’d)
Boom Tubes
The pulling system comes standard with a 4' and 3' long
boom. The default setup is with the 3' boom between
the puller and elbow, and the 4' tube between the elbow
and nose. This setup can be reversed at the user’s discretion. The boom tubes are held in place by detent pins
with pull rings.
In addition, 3" rigid conduit up to 10' long can be substituted for either or both of the boom tubes. If 3" rigid
conduit is used, two conditions must be accounted for:
• Because the detents will not hold the conduit in place
in the receptacles, the conduit must be clamped in
place opposite the detent pins using 1/2"-13 screws
(not supplied).
• Because the weight will be too great to use the
crank to raise and lower the boom, manual assist is
required.
Conduit Adapter Couplings
Couplings to attach the puller system to the conduit are
available in 2", 2-1/2", 3", 3-1/2", 4", and 5" sizes.
There are two types: slip-in and screw-on:
• Slip-in couplings are the easiest to use but do intrude
on the ID of the conduit.
• Screw-on couplings do not decrease the effective ID
of the conduit, but take longer to set up.
If longer than standard booms are being used, screw-on
couplings may be necessary to support the boom and
prevent it from falling. The conduit adapter couplings t
into the same receptacles as the boom tubes and are
retained by the same ring pull detent pins.
Ring Pull
Detent Pin
Slip-in
Coupling
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Puller Operation
1. Fish the rope through the conduit.
2. Set up the cable puller. Refer to the illustrations and
instructions in the “Typical Setups” section.
Set up the cable puller so that the rope will approach
the capstan at an angle of 90° (±5°). Angles outside
of this range may cause the rope to overlap.
90° (±5°)
3. Set the rope ramp as follows:
Pull Side
6. After the foot switch is depressed, the green light
indicating 0 lb will be lit. As the force climbs, an
additional light illuminates for every 1000 lb increase
in pulling force.
• If the continuous operating limit of the puller is
exceeded in high speed mode, the green lights
start to ash.
• If the continuous operating limit of the puller is
exceeded in low speed mode, the yellow lights
illuminate.
• The red light illuminates at 10,000 lb to indicate
that the maximum operating limit of the puller has
been reached. The circuit breaker (or current limiting) may shut down the puller before or shortly
after the red light illuminates.
7. Make sure all nearby personnel are not standing in
line with or close to the pull rope. The right angle
sheave on the UT10 should be used to allow the
operator to stand off to the side as required.
8. Position yourself so that you can see the force
gauge indicator lights. Refer to the table below.
Force Gauge Indicator Lights
State of
Force Lights
Green
Green ashing 3250–4000 (high) 15 ON/15 OFF
Yellow 6500–8000 (low)
Red Over 8000 STOP
Pulling Force (lb) Duty Cycle
0–6500 (low)
0–3250 (high)
Continuous
15 ON/
change to low
Surface A
a. Wind the rope several times around the
capstan.
b. Pull the ramp away from the mounting plate and
rotate it until Surface A contacts the rope.
c. Push the ramp toward the mounting plate and
rotate it counterclockwise until it locks into
place.
9. Grasp the tailing end of the rope. Apply a slight
amount of tailing force.
10. Start the puller by pressing and holding down the
foot switch.
11. Tail the rope, allowing the spent rope to accumulate
on the oor between the operator and the puller.
12. When the pull is complete, turn the puller OFF.
Tie off the rope and anchor the cable.
4. Plug the puller into a 20 amp grounded outlet.
Turnon the switch/circuit breaker.
5. The lights will cycle through a power up sequence
with only the “0” light remaining lit. The default
startup speed is high. The high speed light will be
lit. To change the speed to low, double tap the foot
switch. The low speed light will illuminate. Double
tap the foot switch again to change back to high
speed.
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Page 30
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Removing Cable
Removing old cable involves the same principles as
installing new cable. However, there are some important
differences.
Pulling Force
It is difcult to predict the amount of pulling force
necessary to remove an old cable. The cable may be
damaged, and it may break with an unexpectedly low
pulling force.
The required pulling forces may be very high:
• The cable has probably “taken a set.” Unlike the new
cable on a reel, cable in conduit has probably been in
the conduit for years, or perhaps decades. The cable
will resist bending and straightening as it is pulled
through the conduit.
• The pulling lubricant has probably hardened,
increasing pulling resistance.
• The insulation may be damaged and the cable may be
corroded.
• Dirt or other foreign matter may have entered the
conduit and may have cemented the cable in place.
Puller Placement
Pulling out old cable is generally accomplished with the
puller located some distance away from the end of the
conduit. This allows the pulling crew to pull out a long
section of cable before turning off the puller, cutting
off the cable, and reattaching the grip(s). Mounting the
cable puller a distance away from the end of the conduit
increases the amount of exposed rope, which greatly
increases the amount of violent whipping action which
would occur if the rope were to break.
To isolate the operator from the rope path:
• Locate the puller so that you will stand behind an
obstruction, such as a wall. Set up the puller so that
you will be able to maintain control of the pull. You
need a clear view of the rope as it feeds onto the
capstan, including several feet of the rope in front of
the capstan. You must be able to turn off the puller
before the pulling grip, connector, or swivel contacts
the capstan.
• Use an additional pulling sheave (if necessary)
to change the direction of the tailing rope. Anchor
the sheave so that you are close enough to maintain
control of the pull. You need a clear view of the rope
as it feeds onto the capstan, including several feet of
the rope in front of the capstan. You must be able to
turn off the puller before the pulling grip, connector, or
swivel contacts the capstan.
Note: Use the additional pulling sheave to change the
direction of the tailing rope (after the rope leaves the
capstan). Do not change the direction of the pulling
rope.
• Use a longer tailing rope than usual and stand away
from the puller. Stand as far from the puller as possible, while maintaining control of the pull. You need
a clear view of the rope as it feeds onto the capstan,
including several feet of the rope in front of the
capstan. You must be able to turn off the puller before
the pulling grip, connector, or swivel contacts the
capstan.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
SERVICE
Tool service must be performed only by qualified
repair personnel. Service or maintenance performed by
unqualied personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts. Follow instructions in the “Maintenance”
section of this manual. Use of unauthorized parts or
failure to follow maintenance instructions may create a
risk of electric shock or injury.
Maintenance
Maintenance should be performed by authorized
personnel only.
General Maintenance Notes
• Replace any part that is broken, cracked, or worn.
• Replace any bearings that don’t turn freely.
• Clean all mating surfaces before assembly.
• Replace gearbox grease with Sentinel SL-WPG
or equivalent.
Specific Service Notes
• Average brush life for commutator brushes is about
100 hours. Replace brushes if they are shorter than
9.5 mm (3/8").
• Replace rope ramp if it is grooved more than
6.5 mm (1/4").
• Replace the capstan if it is grooved more than
0.15mm (1/16").
• The puller should not require any lubrication during its
normal service life.
Control Box Removal and Disassembly
1. Remove the four hex head cap screws and nuts that
secure the clamp to the control box.
2. Loosen the motor and power cord strain reliefs.
Remove the six screws securing the cover to the
base plate.
3. Disconnect the white and black motor leads from
the circuit board.
4. Unscrew the green ground wire from the base plate.
5. Disconnect the ribbon cable.
6. Disconnect the power cord at the circuit board and
breaker.
7. Disconnect the foot switch plug.
8. Pull the control unit free.
Switchbox Assembly Notes
1. The ribbon cable has an arrow at the No. 1 pin
connection, which goes next to the foot switch
receptacle.
2. The foot switch plugs into the receptacle closest to
the ribbon cable.
3. The white motor lead connects to the tab closest to
the foot switch plug.
The rst reduction hub will be damaged if the leads
are reversed.
Motor Removal
1. Remove the control box.
2. Remove the black com mutator brush caps and pull
out the commutator brushes.
3. Use a 7/16" socket to remove nuts and washers at
rear of motor.
4. Pull the tail housing off the motor.
5. Pull off the magnet housing.
6. Pull out the armature.
Motor Assembly Notes
1. If the armature does not turn freely after installation,
the wrong gear teeth were engaged.
2. Hold armature in place when installing the magnet
housing.
3. Insert magnet housing roll pin into the recess on the
tail housing.
Capstan Removal
1. Use a 1-1/8" socket to remove capstan retaining
bolt and washers.
2. Pull the capstan off of the shaft.
If the capstan is stuck: Pull out the rope ramp.
Use two pry bars on opposite sides of the capstan
between the gear housing and the capstan.
3. Remove key.
4. Remove rope ramp.
Capstan Assembly Notes
1. Remove oxidation before assembling.
2. Do not hammer capstan onto shaft. Use a 65 mm
(2-1/2") or longer bolt to draw the capstan onto the
shaft.
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Page 32
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Maintenance (cont’d)
Right Angle Sheave Bracket Removal
1. Remove detent pin.
2. Slide arm towards motor. Use a small punch to
remove the roll pin.
3. Remove bracket.
Gearbox Disassembly
1. Remove control box, motor, capstan, and right
angle sheave bracket.
2. Remove the six screws securing the motor mounting plate.
3. Remove the motor mounting plate.
4. Remove the two additional screws still retaining the
intermediate housing (one inside and one outside).
5. Remove the intermediate housing.
6. Remove the reversing gear and shaft. Slide the high
and low gears off the planetary input shaft.
7. Remove the six screws securing the puller mounting
plate.
8. Remove the puller mounting plate and planetary
input plate.
9. Remove the 1st reduction sun gear and shaft with
bearing from the planetary input plate.
10. Pull out the 1st reduction gear cluster.
11. Pull out the 2nd reduction gear cluster and center
shaft.
12. Pull out the output shaft and 3rd reduction cluster.
13. Remove the six screws securing the remaining
puller mounting plate.
14. Remove the mounting plate and ring gear.
15. Remove dowels, washers, and keys, as necessary.
Disassembly of Planet Gear Carriers
1. Remove the at head screws.
2. Tap or pry off the hub plate from the hub and dowel
pins.
3. Remove the thrust washers, gears, thrust washers
and shaft.
4. Remove sun gear ONLY if replacement is required.
Planet Gear Carrier Assembly
1. Place the shafts in the hub. The end with the at
should face outward.
2. The 1st planet reduction gears must be positioned
with the gear end towards the capstan.
3. When replacing the 1st reduction gear bearing/
clutch, the locked arrow direction must be counterclockwise (when viewed from the gear end).
4. When replacing the ball bearing on the output
shaft, the thick side of the outer race must face
the capstan.
5. Use a removable thread-locking compound, such
as Loctite® 242® Threadlocker or equivalent, on the
#10–32 at head screws (items 35 and 36 on the
gearmotor). Follow the manufacturer’s instructions
for curing.
Gearbox Assembly Notes
1. Clean all ring mating surfaces. Apply a ange
sealant (Loctite® 515 or equivalent) to all ring mating
surfaces.
2. Install the mounting plates. When viewed from the
motor end, the motor mounting studs should be
positioned at 1 and 7 o’clock. The square hole in
the mounting plate should be between 10 and 11
o’clock.
3. Position mounting plates so the screw heads on
the capstan side t into the counterbores of the
mounting plates.
4. Assemble the high and low speed gears so that they
freewheel clockwise and lock counterclockwise as
viewed from the motor end.
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Page 33
Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
ACCESSORIES
Chain Mount—Secured to Steel Conduit or Pipe
Floor Mount—Secured to a Concrete Floor
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Setup—Chain Mount
Requires: Exposed metallic conduit with the following
characteristics:
• 63.5 mm to 254 mm (2-1/2" to 10") in diameter
• Capable of withstanding at least 44.5 kN (10,000 lb) of
force
Do not mount the chain mount to the
following:
• Steel conduit less than 63.5 mm
(2-1/2") in diameter
• PVC conduit of any size
These conduits will not support the
loads imposed by the puller.
Failure to observe this warning could
result in severe injury or death.
NO
When setting up the pipe adapter, do
not use the vise chains on a structural support that is less than 51 mm
(2") or more than 254 mm (10") wide.
NO
An oversized or undersized structural
support can allow the puller to slide
or break loose and strike nearby
personnel.
Failure to observe this warning could
result in severe injury or death.
Do not pull between the 10 o’clock and 2 o’clock
directions. Pulling between 10 o’clock and 2 o’clock
could damage the mounting conduit.
12
Pull
Load
O’CLOCK
10
11
Pulling
Rope
9
Support
Vise Chains
6
O’CLOCK
1
Tailing
Rope
2
3
Install the vise chains properly.
• Follow the vise chain tightening instructions carefully. Improperly tightened chains can allow the
puller to slide or break loose and strike nearby
personnel.
• Do not allow the vise chains to bind at the corners
when mounting the puller to a square or rectangular support. The vise chain must be uniformly tight
at all points.
Failure to observe this warning could result in severe
injury or death.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Setup—Chain Mount (cont’d)
1. On each vise chain unit:
a. Rotate the vise chain handle counterclockwise
to expose most of the threads. Leave only three
or four threads engaged in the handle.
b. Wrap the chain around the conduit.
c. Pull the vise chain tight and insert the chain pins
into the chain pockets, or recesses.
d. Turn the handle clockwise to tighten the chain.
Tighten as much as possible by hand. Do not
use a “cheater.”
2. Set the puller into the cradle of the chain mount, as
shown, so that the inside of the capstan is directly
over the mounting.
3. Install two pins from the motor side. Secure the pins
with two hitch pin clips.
Do not mount puller as shown above.
The chain mount could break away from the mounting, causing severe injury or death.
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Ultra Tugger® 10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
Setup—Floor Mount
Requires: A concrete oor with the following
characteristics:
• Fully cured structural-type concrete
• Minimum compressive strength of 211 kg/cm2
(3000 psi)
• Free of cracks, crumbling, or patchwork
Follow all oor mounting instructions carefully.
• An improperly attached oor mount can come
loose and strike nearby personnel.
• Do not attach the oor mount to masonry, brick,
or cinder block. These materials will not hold the
anchors securely.
Failure to observe this warning could result in severe
injury or death.
1. Determine the best position for locating the oor
mount. Locate the oor mount:
• on a at section
• at least 152 mm (6") from edge of concrete
• as close to the conduit as possible to reduce the
amount of exposed rope under tension
• so that the pull rope will approach the puller’s
capstan at a 90° (±5°) angle.
Installation
Greenlee recommends using Greenlee 35607 Wedge
Anchors. If another type of anchor is used, they must
have an ICBO (International Conference of Building
Ofcials) allowable tension and shear rating of 10.7 kN
(2400 lb) in 211 kg/cm2 (3000 psi) concrete.
1. Assemble the nut and washer to the anchor so the
top of the nut is ush with the top of the anchor,
as shown.
Top of
Anchor
Nut
Washer
2. Insert the four anchors through the oor mount and
into the holes in the oor.
3. Hammer the anchors in until the washer is in rm
contact with the oor mount.
at least
152 mm (6")
90°
at least
152 mm (6")
2. Set the oor mount in the desired location. Use the
oor mount as a template to drill four 5/8" holes at
least 152 mm (6") deep.
Note: Use a 5/8" carbide-tipped masonry bit
manufactured in accordance with ANSI standard
B94.12-77.
3. Vacuum the debris from the holes.
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at least
152 mm (6")
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4. Expand the anchors by torquing the nuts to 122 to
128 Nm (90 to 95 ft-lb).
If any of the four anchors spin before the minimum
torque is achieved, abandon the location and start
elsewhere. An improperly installed anchor can allow
the puller to break loose.
Failure to observe this warning could result in severe
injury or death.
5. Have the installation checked by a qualied
inspector.
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