Ultra Tugger
®
10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
32
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 mount-
ing 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.
Gearbox Assembly Notes
1. Clean all ring mating surfaces. Apply a flange
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 fit 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.
Disassembly of Planet Gear Carriers
1. Remove the flat 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 flat
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 counter-
clockwise (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 flat head screws (items 35 and 36 on the
gearmotor). Follow the manufacturer’s instructions
for curing.
