Ultra Tugger
®
Cable Puller and Pulling Packages
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
42
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 rectifier.
4. Unscrew the green ground wire from the motor.
5. Remove switchbox.
Switchbox Assembly Notes
1. If replacing the rectifier, use a heat conductive paste
between the rectifier and the switchbox.
2. Connect the white motor lead to the positive (+)
terminal on the rectifier. Connect the black motor
lead to the negative (–) terminal.
The first 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.
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Motor Removal
See Exploded View – Motor.
1. Remove switchbox.
2. Push in and pull out the tab to release the com-
mutator 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 first reduction hub will be damaged if the leads
are reversed.
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.
