INSTRUCTION MANUAL
Ultra Tugger®
Cable Puller and Pulling
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99920751 © 2007 Greenlee Textron Inc. IM 1259 REV 22 11/07
Packages
with Serial Code ABJ
Table of Contents
Ultra Tugger® Cable Puller and Pulling Packages
Description .................................................................... 3
Purpose ......................................................................... 3
Important Safety Information ..................................... 4-7
Grounding Instructions .................................................. 8
Identication ............................................................. 9-10
Specications .............................................................. 11
Cable Pulling Glossary ................................................ 12
Cable Pulling Principles:
Cable Pulling Systems ............................................. 13
Pulling Theory .......................................................... 14
Cable Pulling Forces:
At the Cable Puller Anchoring System ................. 15
At the Capstan ..................................................... 16
At the Pulling Rope .............................................. 17
At the Connectors ................................................ 18
At the Sheaves ..................................................... 19
Tailing the Rope:
Control of the Pull ................................................ 20
Amount of Tailing Force ....................................... 20
Number of Wraps of Rope around the Capstan .. 20
Preventing Rope Overlap ..................................... 20
Summary of Cable Pulling Principles....................... 21
Planning the Pull .......................................................... 21
Typical Setups:
Pipe Adapter ............................................................ 22
Chain Mount ............................................................ 22
Floor Mount ............................................................. 22
T-Stand .................................................................... 23
Wheeled Carriage .................................................... 24
Setup:
Pipe Adapter ....................................................... 25-27
T-Stand .................................................................... 28
Wheeled Carriage .................................................... 29
Mounting Components:
Boom with Nose Unit ........................................... 30
Booms with Elbow Unit and Nose Unit ................ 31
Slip-in Coupler ..................................................... 32
Straddling the Conduit with Slip-in Coupler ........ 32
Chain Mount ....................................................... 33-34
Floor Mount ............................................................. 35
Installation ................................................................ 35
Operation ..................................................................... 36
Removing Cable .......................................................... 37
Maintenance ........................................................... 38-39
Exploded Views / Parts Lists:
Ultra Tugger (with wiring diagram) ...................... 40-41
Gearmotor (50006460) ........................................ 42-43
Motor (50006649) .................................................... 44
Force Gauge ............................................................ 45
Accessories ............................................................ 46-52
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Ultra Tugger® Cable Puller and Pulling Packages
Description
The Greenlee Ultra Tugger® cable puller is intended
to be used to pull cable through conduit and in tray.
The Ultra Tugger will develop 35.6 kilo-Newtons
(8000 lb) of pulling force. See 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 tools provide information for
avoiding hazards and unsafe practices related to use of
this tool. Observe all of the safety information provided.
Purpose
This manual is intended to familiarize all personnel with
Greenlee 6800-series Ultra Tugger cable pullers.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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.
Ultra Tugger is a registered trademark of Greenlee Textron Inc.
Versi-Boom is a trademark of Greenlee Textron Inc.
Loctite and 242 are registered trademarks of Loctite Corporation.
Texaco is a registered trademark of Texaco Inc.
KEEP THIS MANUAL
3
Ultra Tugger® Cable Puller and Pulling Packages
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.
Immediate hazards which, if not avoided, WILL 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.
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.
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 before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
Ultra Tugger® Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
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 characteristics:
Maximum Rated Capacity:
•
at least 35.6 kN (8000 lb)
Average Breaking Strength:
•
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
5
Ultra Tugger® Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
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.
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.
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 35.6 kN (8000 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.
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 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.
Do not operate without chain guards
in place.
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.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Always lock boom components
in place during assembly or disassembly. Adding and removing
components may change rotation.
Parts may strike nearby personnel.
6
Ultra Tugger® Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
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
Ultra Tugger:
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Ultra Tugger® Cable Puller and Pulling Packages
ReceptaclePlug
Grounding Instructions
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.
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.
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
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Identification
1
2
3
4
6
7
8
10
9
11
5
12
Ultra Tugger® Cable Puller and Pulling Packages
1. Motor
2. Circuit Breaker/Switch
3. Mounting Plates
4. Rope Tie-Off
5. Adjustable Sheave Bracket
6. Tapered Steel Capstan
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger Cable Puller
7. Right Angle Sheave
8. Rope Ramp
9. Hitch Clip
10. Gearbox
11. Mounting Pin
12. Force Gauge with
Remote ON/OFF Switch
9
Identification (cont’d)
7
1
14
11
13
12
10
2
3
5
9
6
4
15
8
Ultra Tugger® Cable Puller and Pulling Packages
1. Elbow Unit
2. Sight Hole
3. 4' Boom Tube
4. Sight Hole
5. Boom Mount
6. T-Stand
7. Puller
8. Force Gauge
Versi-Boom™ Components
9. Wheeled Carriage
10. Slip-in Coupler
11. Nose Unit
12. Mounting Pins
13. Hitch Pin Clips
14. 3' Boom Tube
15. Long Pin
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Specifications
Weight ........................................................................................................ 38 kg (84 lb)
Dimensions:
Length ................................................................................................. 29 cm (11.5")
Width ....................................................................................................... 66 cm (26")
Height ................................................................................................... 17 cm (6.75")
Motor:
Voltage ................................................................. 120 VAC, 50/60 Hz, Single Phase
Current Draw at Full Load ........................................................................... 15 Amps
Sound Level ................................................................................... 75 dB at 1 meter
Power Source ................................................ 120 VAC, 60 Hz, 20 Amps, Single Phase
Speed:
No Load................................................................................... 2.74 m/min (9 ft/min)
8900 Newtons (2000 lb) .......................................................... 2.44 m/min (8 ft/min)
17.8 kN (4000 lb) .................................................................. 2.29 m/min (7.5 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)
Pulling Force:
0 - 28.9 kN (0 - 6500 lb) ......................................................... Continuous Operation
28.9 kN - 35.6 kN (6500 - 8000 lb) ............................15 minutes on / 15 minutes off
Pulling Rope:
Required Rope ....................... 7/8" diameter, double-braided, polyester composite
Average Breaking Strength .......................................... 143 kN (32,000 lb) minimum
Ultra Tugger® Cable Puller and Pulling Packages
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Cable Pulling Glossary
Ultra Tugger® Cable Puller and Pulling Packages
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 kilo-Newtons (metric)
or pounds; the maximum rated capacity of every
component must meet or exceed the maximum pulling
force of the cable puller
Newton
a metric unit of force, equivalent to .225 pounds of force
pipe adapter sheave
attaches to conduit for pulling or feeding cable
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—see the
complete explanation under Principles of Cable Pulling
pulling grip
connects the rope to the cable; consists of a wire mesh
basket that slides over the cable and grips the insulation
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
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
wire grip
connects the rope to the cable; some use a set screw to
clamp onto the conductors of the cable
12
Cable Pulling Principles
Ultra Tugger® Cable Puller and Pulling Packages
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.
Typical Cable Pulling System
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
Ultra Tugger® Cable Puller and Pulling Packages
Gravity
Weight
of Cable
Conduit
Friction
Tailing
Force
Pulling Force
35.6 kN
(8000 lb)
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.
Cable Pulling Theory Illustrated
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
Ultra Tugger® Cable Puller and Pulling Packages
35.6 kN
(8000 lb)
Maximum
35.6 kN
(8000 lb)
Maximum
Pulling Force
35.6 kN
(8000 lb)
Maximum Pulling Force
at Anchoring System
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.
Pulling Force at the Cable Puller’s Anchoring System
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. See the instruction manual provided with your
anchoring system for proper setup or installation.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
Ultra Tugger® Cable Puller and Pulling Packages
Pulling Force: 35.6 kN (8000 lb)
Tailing
Force
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
0.0175µø
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.
The following table is based on the formula above.
The input, or tailing force, is constant at 44.5 Newtons
(10 lb). Increasing the number of wraps increases
the pulling force.
Operator’s
Tailing Force
Number of
Wraps of Rope
Approximate
Pulling Force
1 93.4 N (21 lb)
2 213.5 N (48 lb)
3 474.9 N (106 lb)
44.5 N (10 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)
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.
The Capstan as a Force Multiplier
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Ultra Tugger® Cable Puller and Pulling Packages
Stored Energy
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)
energy (f x d), and may be measured in Newton-meters
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 50,000
Newton 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.
is
Stored Energy
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 Ultra Tugger cable
puller. Select a double-braided composite rope with
an average rated breaking strength of at least 143 kN
(32,000 lb).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
Ultra Tugger® Cable Puller and Pulling Packages
Maximum
Pulling Force
35.6 kN
(8000 lb)
Maximum
Pulling Force
35.6 kN
(8000 lb)
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.
A Typical Grip Setup—Clevis and Wire Grip
A Typical Grip Setup—Swivel and Pulling Grip
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. See 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
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
Ultra Tugger® Cable Puller and Pulling Packages
Resultant Force=
27.4 kN (6160 lb)
135°
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, see IM 1363 (99929988).
Resultant Force Table for the Ultra Tugger
(35.6 kN or 8,000 lb Maximum Pulling Force)
Illustration
Angle of Change
in Direction
180° 0 (0)
150°
135°
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)
18.5 (4160)
27.4 (6160)
Typical Resultant Force at Sheave
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Ultra Tugger® Cable Puller and Pulling Packages
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 will 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. See 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!
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
20
Ultra Tugger® Cable Puller and Pulling Packages
Cable Pulling Principles (cont’d)
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 resis-
•
tance: 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.
•
Planning the Pull
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
21
Ultra Tugger® Cable Puller and Pulling Packages
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.
Chain Mount
Secured to Steel Conduit or Pipe
Floor Mount
Secured to a Concrete Floor
Locked and folded for transport
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
22
Ultra Tugger® Cable Puller and Pulling Packages
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.
T-Stand
Pulling Horizontally Using One Boom Tube,
Nose Unit and Slip-in Coupler
T-Stand
Pulling Up Using One Boom Tube, Nose Unit and Slip-in Coupler
T-Stand
Pulling Horizontally Using Two Boom Tubes, Nose Unit,
Elbow Unit and Slip-in Coupler
Down-pull using boom with threaded coupler
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
23
Ultra Tugger® Cable Puller and Pulling Packages
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.
Wheeled Carriage
Pulling Up Using One Boom, Nose Unit and Slip-in Coupler
Wheeled Carriage
Pulling Horizontally in Manhole Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler
Wheeled Carriage
Pulling Up Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler
Wheeled Carriage
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
24
Ultra Tugger® Cable Puller and Pulling Packages
NO
NO
Sheave
Sheave Shaft
Hitch Pin Clip
Frame
Setup—Pipe Adapter
As of 2006, the pipe adapter has been discontinued and replaced by the 11147 boom adapter.
This information is reference for existing units.
Requires: Exposed metallic pull conduit of least
63.5 mm (2-1/2") diameter
Do not mount the pipe adapter to
the following:
steel conduit less than 65 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.
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. 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.
1. Remove the sheave from the frame.
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
25
Ultra Tugger® Cable Puller and Pulling Packages
Positioner
Positioning
Block
(not shown)
Chain
Pockets
(not shown)
Sheave Shaft
Hitch Pin Clip
Frame
Sheave
Adapter
Mounting
Plates
Puller
Mounting
Plates
Gearbox
Cradle
Setup—Pipe Adapter (cont’d)
Install the vise chains properly.
Follow the vise chain tightening instructions care-
•
fully. 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.
3. 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. Insert the chain into the slot in the frame. Wrap
the chain around the conduit, pipe sheave
adapter, or structural element.
c. Set the positioner against the positioning
blocks that protrude from the frame.
d. Pull the vise chain tight and insert the chain
pins into the chain pockets, or recesses.
e. Turn the handle clockwise to slightly tighten the
chain.
4. Rotate the vise chain handles, by hand, clockwise
to tighten the chain. Do not use tools, extensions or
“cheaters.”
5. Put the sheave back onto the frame. Install the pin
and hitch pin clip.
Note: If the 18" sheave interferes with existing
structures, install a 12" sheave (Greenlee 00843).
6. Align the puller so that the gearbox will t into the
cradle of the pipe adapter AND the puller mounting
plates straddle the pipe adapter mounting plates.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
26
Ultra Tugger® Cable Puller and Pulling Packages
Install Hitch Pins
from Motor Side
Install Hitch
Pin Clips on
Capstan Side
Boom Mount
Plates
Boom Mount
Cradle
Gearbox
Puller
Mounting
Plates
Install Hitch Pin Clips
on Capstan Side
Install Hitch Pins
from Motor Side
T-Stand
Insert
Pins Here
Setup—Pipe Adapter (cont’d)
7. Install two pins from the motor side. Secure the pins
with two hitch pin clips.
Setup—T-Stand
Requires: Adequate clearance. See Typical Setups
Illustrated
1. Set the puller on the oor with the mounting holes
upward.
2. Position the boom mount so that the puller gearbox
will t into the cradle of the boom mount and the puller
mounting plates straddle the boom mount plates.
3. Mount the boom mount to the puller.
4. 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
5. Align the two sets of holes in the T-stand with the
two sets of holes in the boom mount.
6. Install two pins. Secure the pins with hitch pin clips.
7. Continue with Setup: Mounting Components later
in this manual.
27
Setup—Wheeled Carriage
Removable Pin
Ultra Tugger® Cable Puller and Pulling Packages
Requires: Adequate clearance. See Typical Setups
Illustrated
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 boom mount and wheeled carriage.
Secure the pin with a hitch pin clip.
3. Check the right angle sheave support tube to be
sure it is fastened with the pin.
4. Rotate the puller and boom mount as shown. When
the second hole in the boom mount is aligned with
the second hole in the wheeled carriage, install a
pin. Secure the pin with a hitch pin clip.
2. Position the puller’s gearbox above the boom mount
cradle. Align the puller so that the puller mounting
plates straddle the boom mount plates. Lower the
puller onto the boom mount. Install two pins from
the motor side. Secure the pins with two hitch pin
clips.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
28
Ultra Tugger® Cable Puller and Pulling Packages
STRAIGHT EDGE
Sight Hole
Sight Hole
Setup—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.
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 Ultra Tugger
•
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
29
Ultra Tugger® Cable Puller and Pulling Packages
STRAIGHT EDGE
Sight Hole
Sight Hole
Sight Hole
Setup—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.
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 Ultra Tugger
•
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
30
Ultra Tugger® Cable Puller and Pulling Packages
Setup—Versi-Boom™ System: Using Couplers
Choosing Couplers
There are three choices available for coupling the boom to the conduit. Use the chart below to determine which
method of mounting to the conduit best suits your requirements:
Screw-On Couplers
Sizes: 2-1/2" – 4"
Advantages:
Will support weight of boom when pulling from ceiling.
No reduction of conduit opening.
Only one pin required to attach to boom.
Slip-In Couplers
Sizes: 2-1/2" – 5"
Advantages:
Easiest to set up.
Only one part per size.
Only one pin needed to attach to boom.
Straddling Conduit Using Slip-In Couplers
Sizes: Up to 4"
Disadvantages:
Hardest to set up.
Most loose pieces.
Pull conduit must have exposed threads.
Requires clearance around pull conduit to mount
properly.
Disadvantages:
Reduces conduit opening by 1/2”.
Can not be used if pulling down from ceiling.
Requires clearance around the conduit to seat properly.
Advantages:
Easy to set up.
Only one part per size.
Can be used for sizes below 2-1/2".
Can clear obstructions around conduit (other conduit,
pull box, door edges, etc.).
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Disadvantages:
Will only t over the threads of 4” and won’t t over 5”
conduit.
Must use external support to hold weight of boom if
pulling from ceiling.
Must be seated against support structure capable of
supporting 8000 pounds.
Requires two pins to attach to boom.
31
Ultra Tugger® Cable Puller and Pulling Packages
COUPLER
ADAPTER
PULL
CONDUIT
SCREW-ON
COUPLER
LOCKING
SCREWS
SCREW-ON
COUPLER
COUPLER
ADAPTER
KEEPERS
LOCKING
SCREWS
Setup—Versi-Boom™ System: Using Couplers (cont’d)
Screw-On Couplers and Coupler Adapters
1. Choose the coupler that best ts the conduit.
2. Screw it onto the conduit until tight and then back it
off until the at plate faces the puller.
3. Slide the coupler adapter onto the coupler. Make
sure the at plate is trapped by the keepers on the
adapter.
4. Lock in place with the locking screws.
Check the condition of pull conduit threads. Pull
conduit must have a minimum of 3 full threads in
good condition to support the pulling loads.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
32
Ultra Tugger® Cable Puller and Pulling Packages
Pull
Conduit
Coupler
Coupler must seat
on the Conduit here
Nose Unit
Coupler
Pin secured with
Hitch Pin Clip
Pull
Conduit
Coupler
Conduit must
not protrude
past here
Support
Structure
Pull Conduit
Coupler
Conduit must not
protrude past here
Support
Structure
Setup—Versi-Boom™ System: Using Couplers (cont’d)
Slip-in Couplers
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 doesn’t seat on the conduit,
see Straddling the Conduit with a Slip-In Coupler.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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.
33
Ultra Tugger® Cable Puller and Pulling Packages
INSERT PIN HERE
NOSE
COUPLER
CONDUIT
FIND 2 SETS OF HOLES
THAT MOST CLOSELY LINE UP
WITH COUPLER HOLES
STRAIGHT EDGE
Setup—Versi-Boom™ System: Assembling Boom Components
Using Double Boom, Elbow and Nose Units:
Use only Greenlee supplied boom tubes, 3" rigid steel
conduit or 3" schedule 40 steel pipe (less than 10') with
the Versi-Boom™ systems.
1. Place boom tube into receptacle of boom mount.
Boom tube must slide completely into boom mount.
Make sure the boom tube can be seen through the
sight holes.
2. Tighten the set screws.
3. Adjust elbow to an appropriate angle and lock in
place with long pin and hitch clip.
4. Slide either end of elbow over boom tube. Boom
tube must slide completely into elbow unit. Make
sure the boom tube can be seen through the sight
holes.
5. Tighten set screws.
6. Slide second boom tube into elbow unit. Boom tube
must slide completely into elbow unit. Make sure
the boom tube can be seen through the sight holes.
7. Tighten set screws.
8. Slip nose unit onto boom tube. Nose unit should
t completely over the boom tube. Make sure the
boom tube can be seen in the sight holes.
9. Tighten set screws.
Note: The nose unit of the boom should attach to the
coupler so that the cable being pulled will pass directly
onto the sheave without dragging over the edges of
the coupler. The boom nose unit has been designed so
that the sheave is in perfect alignment with the conduit
whenever any two sets of holes from the nose unit and
coupler line up.
10. Raise the boom assembly and slide the nose unit
over the coupler (see Using Couplers). BOTH
mounting plates of the nose unit should be
OUTSIDE the mounting plates of the coupler.
11. Find two sets of holes on the nose unit that most
closely line up with coupler holes.
12. Insert short pin through holes closest to the conduit.
Lock in place with a hitch clip. Use two pins whenever possible.
Note: If a slip-in coupler is being used to straddle the
conduit (see Using Couplers), two pins MUST be used
to connect nose unit and coupler. Some extra adjustment may be required to install second pin.
Two pins must be used if coupler is not fully inserted
or attached to conduit. Nose unit may collapse,
causing serious injury or death.
Shear Point:
Never put ngers through holes
in boom components. Pivoting of
mating parts may cut off ngers.
Always keep elbow unit locked with
pivot pin except while adjusting.
Proper assembly of elbow unit
must be maintained. If elbow is disassembled, it must be reassembled
with the proper orientation as shown.
Improper assembly could result in
collapse of boom.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
34
Ultra Tugger® Cable Puller and Pulling Packages
IDLER
WHEEL
Setup—Versi-Boom™ System: Special Situations
Down Pulls:
The idler wheel on the boom mount must be used
during down pulls. In down pulls the pull rope will pass
underneath the boom nose sheave. The idler wheel
must be used as shown to get the rope from underneath
the boom to the top of the capstan.
Down Pulls/Elbow Unit:
If the pull rope passes OVER the nose unit sheave then
it must pass OVER the elbow unit sheave. The idler
wheel is not used.
If the pull rope passes UNDER the nose unit sheave
then it must pass UNDER the elbow unit sheave. The
rope must then pass under the idler wheel and on to the
capstan. (See Down Pull with Threaded Coupler, page 16.)
Rotating Boom Nose and Elbow:
Keep nose, elbow and puller in line whenever possible.
Do not use the nose or elbow at an angles which make
the rope twist or wrap around the boom. Rope wear
may occur.
Couplers may break if the weight of the puller is
not properly supported. Do not allow the puller and
boom to hang from slip-in or screw-in couplers.
Damage to the coupler and rope may result. Use the
wheeled carriage or T-stand to support the weight of
the puller at the motor and capstan.
Idler Wheel
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Rotating Boom Nose and Elbow
35
Ultra Tugger® Cable Puller and Pulling Packages
SECURE
SECOND PIN
Setup—Versi-Boom™ System: Moving the Wheeled Carriage
Moving the Puller and Boom:
Lock the boom mount to the wheeled carriage before
moving. Align both sets of boom mount holes with both
sets of holes on carriage. Insert short pins and lock with
hitch clips. If elbow is used, fold it back against top as
shown.
Note: If boom sections longer than the stock 3' and 4'
boom tubes are used, the unit may not balance on all
four wheels. Break down long boom sections before
moving.
Wheeled carriage with boom is heavy and may be
unstable over some terrain.
Keep personnel out of path of transport.
•
Evaluate the terrain over which the carriage is to
•
move. If in doubt, obtain additional help and move
unit cautiously.
If this boom section is longer
than the stock boom tube the
puller and carriage will tip
forward on the front wheels.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15°
Do not transport over inclines greater than 15°.
Do not transport with boom tubes longer than the
stock 3' and 4' lengths.
Improper transport may result in tipping causing
serious injury.
36
Ultra Tugger® Cable Puller and Pulling Packages
NO
NO
12
O’CLOCK
1
2
3
11
10
9
6
O’CLOCK
PULLING
ROPE
PULL
LOAD
TAILING
ROPE
VISE CHAINS
SUPPORT
Setup—Chain Mount
Requires: Exposed metallic conduit with the following
characteristics:
63.5 – 254 mm (2-1/2" – 10") in diameter
•
capable of withstanding at least 35.6 kN (8000 lb)
•
of force
Do not mount the pipe adapter 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.
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.
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.
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.
Install the vise chains properly.
Follow the vise chain tightening instructions care-
•
fully. 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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
37
Ultra Tugger® Cable Puller and Pulling Packages
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 slightly tighten the
chain.
2. Set the puller into the cradle of the chain mount.
3. Install two pins from the motor side. Secure the pins
with two hitch pin clips.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
38
Setup—Floor Mount
at least
152 mm (6")
90°
at least
152 mm (6")
at least
152 mm (6")
Top of
Anchor
Nut
Washer
Ultra Tugger® Cable Puller and Pulling Packages
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.
2. Insertthefouranchorsthroughtheoormountand
intotheholesintheoor.
3. Hammertheanchorsinuntilthewasherisinrm
contactwiththeoormount.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4. Expand the anchors by torquing the nuts to 122 to
128 Newton-meters (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.
39
Operation
90° (±5°)
Surface A
Pull Side
Ultra Tugger® Cable Puller and Pulling Packages
1. Fish the rope through the conduit.
2. Set up the cable puller. See Typical Setups illustrations and instructions in this manual.
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.
3. Set the rope ramp as follows:
4. Check the ON/OFF switch on the puller to be sure
it is OFF. Plug the puller into the receptacle of the
standard force gauge.
5. Connect the force gauge to an appropriate power
supply (see Grounding Instructions in this manual).
Note: If using an extension cord, it must be rated
for 20 amps. Use the shortest cord possible. Longer
cords reduce puller speed.
6. Position the force gauge so that it can be monitored
by the puller operator.
Color Band
on Meter
Green 0 - 6500 OFF continuous
Yellow 6500 - 8000 ON 15 ON / 15 OFF
Red over 8000 ON puller will stop
7. Turn the circuit breaker in the force gauge ON.
8. Grasp the tailing end of the rope. Apply a slight
amount of tailing force.
9. Turn the puller ON.
10. Tail the rope, allowing the spent rope to accumulate
on the oor between the operator and the puller.
11. When the pull is complete, turn the puller OFF.
Tie off the rope and anchor the cable.
Pounds of
Pulling Force
Alarm
Duty Cycle
(in minutes)
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
40
Removing Cable
Ultra Tugger® Cable Puller and Pulling Packages
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.
Using a Force Gauge
When pulling old cable out of a conduit, the pulling force
will be highest when starting the pull. Select a cable
puller and pulling components to meet or exceed the
estimated amount of pulling force necessary to remove
the old cable. Because breaking the cable free will
require the largest amount of pulling force, it is necessary to use a force gauge to prevent overloading the
system components. Select either the 01069 Standard
Force Gauge or the 00967 Deluxe Force Gauge.
Carefully monitor the pulling force at the force gauge;
if the puller is not able to begin the pull, shut off the
puller and disassemble the setup. Start over with a
puller and components of a higher force rating.
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.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
41
Ultra Tugger® Cable Puller and Pulling Packages
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
•
0.15 mm (1/16").
The puller should not require any lubrication
•
during its normal service life.
Switchbox Removal
1. Remove the four hex head cap screws (12) and nuts
(13) that secure the clamp (6) to the switchbox (5).
2. Remove the clamp and pull switchbox from the
motor.
3. Disconnect the white and black motor leads from
the rectier.
4. Unscrew the green ground wire from the motor.
5. Remove switchbox.
Switchbox Assembly Notes
1. Ifreplacingtherectier,useaheatconductivepaste
betweentherectierandtheswitchbox.
2. Connectthewhitemotorleadtothepositive(+)
terminalontherectier.Connecttheblackmotor
leadtothenegative(–)terminal.
Motor Removal
See Exploded View – Motor.
1. Remove switchbox.
2. Push in and pull out the tab to release the commutator brush springs.
3. Use a 7/16" socket to remove nuts and washers at
rear of motor.
4. Pull the motor off of the tail housing (3).
5. Pull off commutator brush assembly (1, 2 and 4).
6. Pull off magnet housing (5).
7. Pull out armature (6).
8.
Remove screw holding the air vent protective screen.
Remove protective screen.
Motor Assembly Notes
1. Apply gasket sealant between gearbox housing and
the outside of the front armature housing.
2. If the armature does not turn freely after installation,
the wrong gear teeth were engaged.
3. Hold armature in place when installing the magnet
housing. Position magnet housing with the roll pin
outward and pointed towards 8 o’clock. The square
hole of the mounting plate should be positioned at
10 o’clock.
4. Install commutator brush assembly. Wires should be
at the 9 o’clock position.
5. Insert magnet housing roll pin into the recess on the
tail housing.
Capstan Removal
1. Use a 1-inch 18 point socket to remove capstan
retaining bolt (11) and washer (19).
2. Pull the capstan (2) 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.
The rst reduction hub will be damaged if the leads
are reversed.
The rst reduction hub will be damaged if the leads
are reversed.
3. Secure motor leads to motor using tie-wraps. Make
sure the wires will not contact the commutator.
4. Position the switchbox and clamp so that the vent
holes are towards the rear of the motor.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3. Remove key (24).
4. Remove rope ramp (3).
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.
42
Maintenance (cont’d)
Ultra Tugger® Cable Puller and Pulling Packages
Right Angle Sheave Bracket Removal
1. Remove detent pin (22).
2. Slide arm towards motor. Use a small punch to
remove the roll pin (20).
3. Remove bracket (4).
Gearbox Disassembly
1. Remove motor, capstan and right angle sheave
bracket.
2. Remove the screws (38) on the motor side of the
gearbox. Remove the mounting plate (20).
3. Remove the motor mounting housing (2).
4. Pull out the 1st reduction planet gear assembly and
thrust washer.
5. Pull out the center shaft (12).
6. Pull out the 2nd reduction planet gear assembly and
thrust washer.
7. Push out the output shaft/3rd reduction gear
assembly and thrust washer.
8. Remove the screws holding the ring gear (37).
9. Tap the bearing housing off the ring gear and dowel
pins. Do not mar the mating surface to the ring
gear.
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 Note
1. Clean all ring mating surfaces. Apply a ange
sealant (Loctite® 515 or equivalent) to all ring mating
surfaces.
2. Install center shaft with the small diameter towards
the motor.
3. 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.
4. Position mounting plates so the screw heads on
the capstan side t into the counterbores of the
mounting plates.
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
43
Ultra Tugger® Cable Puller and Pulling Packages
23
25
26
27
BLACK
BLACK
BLACK
BLACK
RED
RED
WHITE
WIRING DIAGRAM
MOTOR
10
1
2
3
4
5
6
7
8
9
11
12
13
15
16, 17
18
19
20
20
21
22
24
26
27
28, 29
14
Exploded View and Wiring Diagram – Ultra Tugger
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
44
Ultra Tugger® Cable Puller and Pulling Packages
Parts List—Ultra Tugger
Key Part No. Description Qty
1 50006460 Gearmotor ................................................................................................. 1
2 50007440 Capstan ..................................................................................................... 1
3 50007513 Ramp, rope ............................................................................................... 1
4 50007416 Bar, tie ....................................................................................................... 1
5 50007491 Switchbox ................................................................................................. 1
6 50007505 Clamp ........................................................................................................ 1
7 50353110 Sheave, right angle ................................................................................... 1
8* 50007432 Puller pin ................................................................................................... 2
9 50008757 Cord unit, power ....................................................................................... 1
10 50006690 Capacitor unit............................................................................................ 1
11 90548485 Screw, cap, 3/4 – 16 x 1.500" hex head, grade 5 ..................................... 1
12 90502787 Screw, cap, #6 – 32 x .500" socket head ................................................. 4
13 90548493 Nut, hex, #6 – 32 ....................................................................................... 4
14 90522036 Screw, machine, #6 – 32 x .250" round head ........................................... 2
15 90539214 Screw, shoulder, .5/8 x 1-3/4 x 1/2 – 13 ................................................... 1
16 90524918 Screw, machine, #10 – 24 x .750" round head ......................................... 1
17 90533453 Nut, hex, #10 – 24 lock, zinc-plated ......................................................... 1
18 90527941 Nut, hex, 1/2 – 13 zinc-plated ................................................................... 1
19 90548507 Washer, at, .780 x 2.000 x .250" ............................................................. 2
20* 90507002 Pin, roll, .187" x 1.50" ............................................................................... 3
21* 90503023 Clip, hitch pin, #8 ...................................................................................... 2
22 90548523 Hitch pin, Rein Leitzke #30 – 07 ............................................................... 1
23 90533305 Screw, machine, #8 – 32 x .328" hex head, green .................................... 1
24 90548515 Key, square, .375" x 1.88" ........................................................................ 1
25 50008765 Wire unit .................................................................................................... 1
26 91871328 Switch / circuit breaker ............................................................................. 1
27 91868130 Rectier, 50 amp, bridge ........................................................................... 1
28 90541243 Bushing, strain relief .................................................................................. 1
29 91862639 Nut, conduit, 1/2" lock .............................................................................. 1
Repair Kit
* 50061887 Kit, puller pin
(includes one each of the items marked with an asterisk) .................... 2
Decals
50010298 Decal, warning .......................................................................................... 1
50010590 Decal, read IM ........................................................................................... 1
99935767 Decal, technical assistance ....................................................................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
45
Ultra Tugger® Cable Puller and Pulling Packages
37
20
28
25
1
26
27
3
24
31
11
23
29
17
29
4
33
36
24
16
24
31
5
10
29
22
15
29
6
33
24
35
24
31
7
33
35
31
30
21
30
9
13
8
12
32
18
39
2
20
38
19
14
Exploded View—Gearmotor (50006460)
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
46
Ultra Tugger® Cable Puller and Pulling Packages
Parts List—Gearmotor (50006460)
Key Part No. Description Qty
1 50006657 Bearing housing ........................................................................................ 1
2 50006630 Motor mount ............................................................................................. 1
3 50006576 Output hub ................................................................................................ 1
4 50006584 Output hub plate ....................................................................................... 1
5 50006622 2nd reduction hub ..................................................................................... 1
6 50006592 2nd reduction hub plate ............................................................................ 1
7 50006606 1st reduction hub ...................................................................................... 1
8 50006517 1st reduction hub plate ............................................................................. 1
9 50006487 1st reduction shaft .................................................................................... 2
10 50006495 2nd reduction shaft ................................................................................... 3
11 50006509 3rd reduction shaft .................................................................................... 4
12 50006479 Center shaft .............................................................................................. 1
13 50006525 1st reduction planet gear .......................................................................... 2
14 50006533 2nd reduction sun gear ............................................................................. 1
15 50006541 2nd reduction planet gear ......................................................................... 3
16 50006550 3rd reduction sun gear .............................................................................. 1
17 50006568 3rd reduction planet gear .......................................................................... 4
18 50006614 Ring gear ................................................................................................... 1
19 50006649 Motor ........................................................................................................ 1
20 50006665 Motor mounting plate................................................................................ 2
21 90548230 Clutch, Torrington #RCB-081214 .............................................................. 2
22 90548248 Bearing, Torrington #B-1210 ..................................................................... 3
23 90548256 Bearing, Torrington #B-128 ....................................................................... 8
24 90548264 Bearing, Torrington #B-46 ......................................................................... 5
25 90548272 Bearing, Torrington #BH-3316 .................................................................. 1
26 90548280 Inner race, Torrington #IR-2824 ................................................................ 1
27 90548299 Bearing, Fafnir #7209W ............................................................................ 1
28 90548302 Seal, Freudenberg-Nok #UF-0216E .......................................................... 1
29 90548329 Thrust washer, .760 x 1.25 x .020" ......................................................... 14
30 90548310 Thrust washer, .510 x 1.00 x .020" ........................................................... 4
31 90548337 Thrust washer, .260 x .50 x .030" ............................................................. 8
32 90534719 Dowel pin, .250 x 1.250" ........................................................................... 6
33 90541036 Dowel pin, .312 x .625" ............................................................................. 9
35 90548345 Screw, cap, #10–32 x .500", socket at head .......................................... 5
36 90548353 Screw, cap, #10–32 x .750", socket at head .......................................... 4
37 90548361 Screw, cap, 1/4 – 28 x 2.00", socket head ............................................... 6
38 90501535 Screw, cap, 1/4 – 28 x 1.500", socket head ............................................. 6
39 90521080 Nut, hex, 1/4 – 20 ...................................................................................... 2
Repair Kits
50022920 Gearmotor repair group #1
(includes 3, 4, 11, 17, 23, 24[2], 29[2], 33, 36)
50022954 Gearmotor repair group #2
(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
47
Ultra Tugger® Cable Puller and Pulling Packages
1
2
3
6
7
8
5
4
10
10
9
Exploded View—Motor (50006649)
Key Part No. Description Qty
50006649 Motor
1 91867053 Commutator brushes ................................................................................ 2
2 91867061 Commutator brush retention spring .......................................................... 1
3 91865590 Tail housing ............................................................................................... 1
4 91865603 Brush assembly plate ................................................................................ 1
5 91865611 Magnet housing ........................................................................................ 1
6 91865620 Armature ................................................................................................... 1
7 90543483 Belleville washers ...................................................................................... 2
8 91860717 Bearing ...................................................................................................... 1
9 91869218 Screen ....................................................................................................... 1
10 91869145 Threaded rod ............................................................................................. 2
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
48
Ultra Tugger® Cable Puller and Pulling Packages
11
876
3
12
2
14
16
15
5
17
FORCE INDICATOR
CONNECTOR
A
SWITCH
POWER CORD
BLACK
BLACKBLACK
GREEN
WHITE
4
10
19
18
1
13
14
9
Exploded View—Force Gauge (50010697)
Key Part No. Description Qty
1 50371088 Box, lower ................................................................................................. 1
2 50371070 Box, upper ................................................................................................ 1
3 50297082 Guard, switch ............................................................................................ 1
4 50010760 Meter ......................................................................................................... 1
5 50371703 Cord, power .............................................................................................. 1
6 50371622 Wire unit, 12 AWG x 3.00", black .............................................................. 1
7 50371630 Wire unit, 12 AWG x 7.00", black .............................................................. 1
8 50371649 Wire unit, 12 AWG x 4.00", green ............................................................. 1
9 90539346 Bumper, #8 – 32 machine screw, rubber .................................................. 4
10 90506332 Nut, hex, #8 – 32 ....................................................................................... 4
11 90531949 Screw, self-tapping, #10 – 16 x .250 Phillips head ................................... 6
12 90522036 Screw, machine, #6 – 32 x .25", slotted pan head ................................... 2
13 90514408 Screw, machine, #8 – 32 x .375", round head .......................................... 2
14 91866847 Receptacle, 20 amp female ...................................................................... 1
15 90541243 Bushing, strain relief .................................................................................. 1
16 91863830 Switch ....................................................................................................... 1
17 91862639 Nut, conduit, 1/2" lock .............................................................................. 1
18 90537254 Screw, cap, #6 – 32 x .750", socket button head ..................................... 3
19 90506324 Nut, hex, #6 – 32 ....................................................................................... 3
Decals
50303929 Decal, damp warning ................................................................................ 1
50010719 Decal, identication ................................................................................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
49
Ultra Tugger® Cable Puller and Pulling Packages
3
2
5
4
7
6
8
9
1
Accessories
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
Key Part No. Description Qty
— 50008684 Screw-on coupler set for 2-1/2", 3", 3-1/2" & 4"
conduit (includes items 2, 3, and 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, 6 and 7) ............................................. 2
5 50007955 Screw..................................................................................................... 1
6 50007963 Handle ................................................................................................... 1
7 90527178 Roll pin................................................................................................... 1
Boom Tubes
Key Part No. Description Qty
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
50
Accessories (cont’d)
8
4
8
4
3
1
2
8
8
4
4
9
6
5
7
T-Stand (50008676)
Wheeled Carriage (50008706)
Ultra Tugger® Cable Puller and Pulling Packages
Key Part No. Description Qty
1 50007700 Frame ........................................................................................................ 1
2 90548396 Wheel, 4.10/3.50 – 6 x 3/4 shaft, 3" hub length ........................................ 4
3 50007688 Axle ........................................................................................................... 2
4 50320262 Spacer, .824 x 1.05 x .750" ....................................................................... 4
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
Repair Kit
* 50061887 Kit, puller pin
(includes one each of the items marked with an asterisk) .................... 2
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
51
Accessories (cont’d)
1
9
6
3
3
8
7
2
4
3
4
5
Boom Mount (50008714)
Ultra Tugger® Cable Puller and Pulling Packages
Key Part No. Description Qty
1 50007610 Frame ........................................................................................................ 1
2 + 50007556 Shaft .......................................................................................................... 1
3* + 90507002 Pin, roll, .187 x 1.50" ................................................................................. 3
4* + 90503023 Clip, hitch pin #8 ....................................................................................... 3
5 90505301 Screw, cap, 3/8 – 16 x 1.000" hex head ................................................... 1
6* 50007432 Puller pin ................................................................................................... 2
7 50009206 Wheel unit, idler ........................................................................................ 1
8 50167987 Bushing ..................................................................................................... 2
9 50010310 Decal, warning .......................................................................................... 1
Repair Kits
* 50061887 Kit, puller pin
(includes one each of the items marked with an asterisk ) ................... 2
+ 50061917 Kit, shaft
(includes one each of the items marked with a plus sign)..................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
52
Accessories (cont’d)
8
2
1
9
4
5
6
3
5
7
Nose Unit (50008641)
Ultra Tugger® Cable Puller and Pulling Packages
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 90505301 Screw, cap, 3/8 – 16 x 1.000" hex head ................................................... 1
8 90548388 Bushing ..................................................................................................... 2
9 50010425 Decal, warning .......................................................................................... 1
Repair Kit
* 50061887 Kit, puller pin
(includes one each of the items marked with an asterisk) .................... 2
50061925 Kit, elbow shaft
(includes one of item 3 and two of item 5) ............................................ 2
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
53
Accessories (cont’d)
3
1
2
8
11
5
7
4
6
8
9
6
10
Elbow Unit (50008633)
Ultra Tugger® Cable Puller and Pulling Packages
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 90505301 Screw, cap, 3/8 – 16 x 1.000" hex head ................................................... 2
9 90548388 Bushing ..................................................................................................... 2
10 50013971 Lanyard ..................................................................................................... 1
11 50010328 Decal, warning .......................................................................................... 1
Repair Kits
* 50061941 Kit, elbow pins
(includes one each of the items marked with an asterisk) .................... 1
50061950 Kit, pivot pins
(includes one of item 4 and two of item 6) ............................................ 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
54
Accessories (cont’d)
3
1
2
Floor Mount (50008650)
Ultra Tugger® Cable Puller and Pulling Packages
Key Part No. Description Qty
1 50007890 Frame ........................................................................................................ 1
2 50356070 Anchor, wedge, .625 x 6.00" ..................................................................... 4
3 50010476 Decal, warning .......................................................................................... 1
Greenlee / A Textron Company 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
55
Accessories (cont’d)
1
2
3
4
6
5
USA 800-435-0786 Fax: 800-451-2632
815-397-7070 Fax: 815-397-1865
Canada 800-435-0786 Fax: 800-524-2853
International +1-815-397-7070 Fax: +1-815-397-9247
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
Printed in USA
Chain Mount (50028464)
Ultra Tugger® Cable Puller and Pulling Packages
Key Part No. Description Qty
1 50111639 Frame ........................................................................................................ 1
2 50296647 Foot ........................................................................................................... 4
3 90505794 Screw, cap, 1/4 – 20 x .500", socket head ............................................... 8
4 50296302 Handle unit, vise chain .............................................................................. 2
5 50256615 Screw unit, vise chain ............................................................................... 2
6 50007734 Block, pivot ............................................................................................... 2
50010514 Decal, warning (not shown) ....................................................................... 1
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