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Ultra Tugger

Cable Puller and Pulling Packages

Greenlee / A Textron Company

4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Accessories

Slip-in Couplers

Screw-on Couplers

Boom Tubes

Key

Part No.

Description

Qty

50008048

Slip-in coupler for 2-1/2" conduit (EMT, IMC or Rigid) ............................. 1

50008110

Slip-in coupler for 3" conduit (EMT, IMC or Rigid) .................................... 1

50008153

Slip-in coupler for 3-1/2" conduit (EMT, IMC or Rigid) ............................. 1

50008200

Slip-in coupler for 4" conduit (EMT, IMC or Rigid) .................................... 1

50008277

Slip-in coupler for 5" conduit (EMT, IMC or Rigid) .................................... 1

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)

50036610

Screw-on coupler for 2" IMC or Rigid only ............................................... 1

50007815

Screw-on coupler for 2-1/2" IMC or Rigid only ....................................... 1

50007823

Screw-on coupler for 3" IMC or Rigid only ............................................... 1

50007831

Screw-on coupler for 3-1/2" IMC or Rigid only ....................................... 1

50007840

Screw-on coupler for 4" IMC or Rigid only ............................................... 1

50007998

Adapter for screw-on IMC or Rigid only ................................................... 1

50008773

Screw assembly (includes items 5, 6 and 7) ............................................. 2

50007955

Screw..................................................................................................... 1

50007963

Handle ................................................................................................... 1

90527178

Roll pin................................................................................................... 1

Key

Part No.

Description

Qty

50008358

3' Boom tube ............................................................................................ 1

50007912

4' Boom tube ............................................................................................ 1

Summary of Contents for Ultra Tugger

Page 1: ...Cable Puller and Pulling Packages 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 R...

Page 2: ...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 Pi...

Page 3: ...e 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 I...

Page 4: ...ult 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 unde...

Page 5: ...earby per sonnel with great force 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...

Page 6: ...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 Rop...

Page 7: ...rate the cable puller while wearing loose fitting 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 w...

Page 8: ...the event of a malfunc tion 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 sho...

Page 9: ...A 815 397 7070 Identification Ultra Tugger Cable Puller 1 Motor 2 Circuit Breaker Switch 3 Mounting Plates 4 Rope Tie Off 5 Adjustable Sheave Bracket 6 Tapered Steel Capstan 7 Right Angle Sheave 8 Rop...

Page 10: ...USA 815 397 7070 10 Identification cont d 7 1 14 11 13 12 10 2 3 5 9 6 4 15 8 1 Elbow Unit 2 Sight Hole 3 4 Boom Tube 4 Sight Hole 5 Boom Mount 6 T Stand 7 Puller 8 Force Gauge 9 Wheeled Carriage 10 S...

Page 11: ...ps 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...

Page 12: ...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 pou...

Page 13: ...ommends that each member of the cable pulling crew review this section of the manual before each cable pull Cable Pulling Systems Pulling cable requires a system of components At a minimum a cable pul...

Page 14: ...the sheaves conduit and tray Friction resists any movement forward or backward and tends to hold the cables in place To accomplish a cable pull the cable pulling system must develop more force than th...

Page 15: ...uring the cable pull These explanations are based on the concepts presented in the last section Pulling Theory At the Cable Puller Anchoring System The cable puller will exert its maximum pulling forc...

Page 16: ...r of degrees of wrap of rope around the capstan The average value for the coefficient of friction when double braided composite rope is pulled over a clean dry capstan is 0 125 The following table is...

Page 17: ...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 t...

Page 18: ...eenlee 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...

Page 19: ...is new resultant force exerts itself on the sheaves sheave anchoring system and support struc tures illustrated The resultant amount of force depends on the angle of the change in direction A brief ta...

Page 20: ...es 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 ta...

Page 21: ...upport 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 d...

Page 22: ...2988 USA 815 397 7070 22 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 Mou...

Page 23: ...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...

Page 24: ...g 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 Wheeled Carriage Pulling Horizontally in...

Page 25: ...ill not support the loads imposed by the puller Failure to observe this warning could result in severe injury or death NO NO When setting up the pipe adapter do not use the vise chains on a structural...

Page 26: ...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 tig...

Page 27: ...Position the boom mount so that the puller gearbox will fit into the cradle of the boom mount and the puller mounting plates straddle the boom mount plates Boom Mount Plates Boom Mount Cradle Gearbox...

Page 28: ...d carriage 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...

Page 29: ...p 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...

Page 30: ...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...

Page 31: ...duction of conduit opening Only one pin required to attach to boom Advantages Easiest to set up Only one part per size Only one pin needed to attach to boom Disadvantages Reduces conduit opening by 1...

Page 32: ...nduit until tight and then back it off until the flat plate faces the puller 3 Slide the coupler adapter onto the coupler Make sure the flat plate is trapped by the keepers on the adapter 4 Lock in pl...

Page 33: ...ecure the pin with a hitch pin clip Note If possible add a second pin and hitch pin clip Nose Unit Coupler Pin secured with Hitch Pin Clip Straddling the Conduit with Slip in Coupler Requires Two pins...

Page 34: ...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...

Page 35: ...l 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 Th...

Page 36: ...stock 3 and 4 boom tubes are used the unit may not balance on all four wheels Break down long boom sections before moving SECURE SECOND PIN If this boom section is longer than the stock boom tube the...

Page 37: ...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...

Page 38: ...ounterclockwise 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...

Page 39: ...2 Set the floor mount in the desired location Use the floor 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...

Page 40: ...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...

Page 41: ...ng 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 ca...

Page 42: ...not contact the commutator 4 Position the switchbox and clamp so that the vent holes are towards the rear of the motor Motor Removal See Exploded View Motor 1 Remove switchbox 2 Push in and pull out t...

Page 43: ...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 mou...

Page 44: ...ron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 44 Exploded View and Wiring Diagram Ultra Tugger 23 25 26 27 BLACK BLACK BLACK BLACK RED RED WHITE WIRING DIAGRAM MOTOR 10 1 2 3 4 5...

Page 45: ...und 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...

Page 46: ...Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 46 Exploded View Gearmotor 50006460 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 2...

Page 47: ...tor 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...

Page 48: ...49 1 2 3 6 7 8 5 4 10 10 9 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...

Page 49: ...0539346 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 Scre...

Page 50: ...pler for 5 conduit EMT IMC or Rigid 1 3 2 5 4 7 6 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 o...

Page 51: ...y 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...

Page 52: ...y 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 idle...

Page 53: ...0008323 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 0...

Page 54: ...ot 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 9054838...

Page 55: ...es Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 55 Accessories cont d Floor Mount 50008650 3 1 2 Key Part No Description Qty 1 50007890 Frame 1 2 50356070 Anchor w...

Page 56: ...le unit vise chain 2 5 50256615 Screw unit vise chain 2 6 50007734 Block pivot 2 50010514 Decal warning not shown 1 USA 800 435 0786 Fax 800 451 2632 815 397 7070 Fax 815 397 1865 Canada 800 435 0786...

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