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G3 Tugger

®

 System

Greenlee / A Textron Company

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

3

GENERAL SAFETY RULES

WARNING! Read and understand all instructions.

 

Failure to follow all instructions listed below may result 

in electric shock, fire, and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA SAFETY
Keep your work area clean and well lit. 

Cluttered 

benches and dark areas invite accidents.

Do not operate power tools in explosive atmo-

spheres, such as in the presence of flammable 

liquids, gases, or dust. 

Power tools create sparks 

which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while 

operating a power tool. 

Distractions can cause you to 

lose control.

ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet prop-

erly installed and grounded in accordance with all 

codes and ordinances. Never remove the grounding 

prong or modify the plug in any way. Do not use any 

adapter plugs. Check with a qualified electrician if 

you are in doubt as to whether the outlet is properly 

grounded. 

If the tools should electrically malfunction or 

break down, grounding provides a low resistance path 

to carry electricity away from the user.

Avoid body contact with grounded surfaces such 

as pipes, radiators, ranges, and refrigerators. 

There 

is an increased risk of electric shock if your body is 

grounded.

Do not expose power tools to rain or wet conditions. 

Water entering a power tool will increase the risk of 

electric shock.

Do not abuse the cord. Never use the cord to carry 

the tools or pull the plug from an outlet. Keep cord 

away from heat, oil, sharp edges or moving parts. 

Replace damaged cords immediately. 

Damaged 

cords increase the risk of electric shock.

When operating a power tool outside, use an 

outdoor extension cord marked “W-A” or “W.” 

These 

cords are rated for outdoor use and reduce the risk of 

electric shock.

PERSONAL SAFETY
Stay alert, watch what you are doing and use 

common sense when operating a power tool. Do not 

use tool while tired or under the influence of drugs, 

alcohol, or medication. 

A moment of inattention while 

operating power tools may result in serious personal 

injury.

Dress properly. Do not wear loose clothing or 

jewelry. Contain long hair. Keep your hair, clothing, 

and gloves away from moving parts. 

Loose clothes, 

jewelry, or long hair can be caught in moving parts.

Avoid accidental starting. Be sure switch is off 

before plugging in. 

Carrying tools with your finger on 

the switch or plugging in tools that have the switch on 

invites accidents.

Remove adjusting keys or switches before turning 

the tool on. 

A wrench or a key that is left attached to a 

rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance 

at all times. 

Proper footing and balance enables better 

control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection. 

Dust mask, non-skid safety shoes, hard hat, or hearing 

protection must be used for appropriate conditions.

TOOL USE AND CARE
Use clamps or other practical way to secure and 

support the workpiece to a stable platform.

 Holding 

the work by hand or against your body is unstable and 

may lead to loss of control.

Do not force tool. Use the correct tool for your appli-

cation. 

The correct tool will do the job better and safer 

at the rate for which it was designed.

Do not use tool if switch does not turn it on and off. 

Any tool that cannot be controlled with the switch is 

dangerous and must be repaired.

Disconnect the plug from the power source before 

making any adjustments, changing accessories, 

or storing the tool.

 Such preventive safety measures 

reduce the risk of starting the tool accidentally.

Store idle tools out of reach of children and other 

untrained persons. 

Tools are dangerous in the hands of 

untrained users.

Maintain tools with care. Keep cutting tools sharp 

and clean. 

Properly maintained tools, with sharp cutting 

edges, are less likely to bind and are easier to control.

Check for misalignment or binding of moving parts, 

breakage of parts, and any other condition that may 

affect the tool’s operation. If damaged, have the tool 

serviced before using. 

Many accidents are caused by 

poorly maintained tools.

Use only accessories that are recommended by the 

manufacturer for your model. 

Accessories that may 

be suitable for one tool may become hazardous when 

used on another tool.

SERVICE
Tool service must be performed only by qualified 

repair personnel.

 Service or maintenance performed by 

unqualified personnel could result in a risk of injury.

When servicing a tool, use only identical replace-

ment parts. Follow instructions in the “Maintenance” 

section of this manual.

 Use of unauthorized parts or 

failure to follow maintenance instructions may create a 

risk of electric shock or injury.

Summary of Contents for Greenlee G3 Tugger

Page 1: ...d and understand all of the instructions and safety information in this manual before operating or servicing this tool Register this product at www greenlee com 52063472 REV 3 2013 Greenlee Textron Inc 8 13 G3 Tugger System ...

Page 2: ...fications 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 Tugger is a registered trademark of Textron Innovations Inc Registered The color green for cable pulling equipment is a registered trademark of Textron Innovations Inc KEEP THIS MANUAL Table of Contents Description 2 Safety 2...

Page 3: ...es jewelry or long hair can be caught in moving parts Avoid accidental starting Be sure switch is off before plugging in Carrying tools with your finger on the switch or plugging in tools that have the switch on invites accidents Remove adjusting keys or switches before turning the tool on A wrench or a key that is left attached to a rotating part of the tool may result in personal injury Do not o...

Page 4: ...e to observe this warning will result in severe injury or death Do not operate the cable puller in a hazardous environment Hazards include flammable 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 source before servicing Failure to observe this warning could result in severe injury or death Att...

Page 5: ...t off fingers Failure to observe this warning could result in severe injury or death Keep hands away from the capstan Rope at the capstan can crush a hand Failure to observe this warning could result in severe injury or death Do not wrap rope around hands arms waist or other body parts Do not stand in spent coils or tailed rope Hold rope so that it may be released quickly Failure to observe this w...

Page 6: ...n using this tool Failure to wear eye protection could result in severe eye injury from flying debris Grounding Instructions Electric shock hazard Do not modify the plug provided with the tool Connect this tool to a grounded receptacle on a 15 amp GFCI protected circuit Failure to observe these warnings could result in severe injury or death This tool must be grounded In the event of a malfunc tio...

Page 7: ...g Pull Detent Pin 3 Handle 4 Clamp Assembly 5 Sheave 6 Detent Pin 7 Top Extension Boom Tube 8 Mid Extension Boom Tube 9 Ring Pull Detent Pin 10 Motor Adapter Assembly 11 Hitch Clip 12 Motor Assembly 13 Power Cord 14 Motor 15 Circuit Breaker and Switch 16 Dolly Base Assembly 17 Two Speed Capstan 18 Motor Attachment 19 Right Angle Sheave 1 10 11 12 13 14 15 18 19 7 8 17 16 9 2 3 6 5 4 ...

Page 8: ... High Speed 4 wraps Pulling Rope 1 2 double braided composite rope 10 000 lb average breaking strength 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 t...

Page 9: ... sion and top extension boom tubes as shown in Figure 3 Make sure all the ring pull detent pins engage with the other tubes 4 Slide the nose unit into the top extension boom tube using the ring pull detent pin 5 Finally attach the motor assembly unit to the motor adapter assembly as shown in Figure 5 using two clevis pins to lock it in place Tip Lay the entire assembly on the ground to make it eas...

Page 10: ...nduit and lock it in place with long detent pin 3 Butt nose up against conduit threads and conduit locking nut Place clamping plate inside of conduit and tighten knurled nut Take lock nut off temporar ily for more thread engagement if needed 4 If the conduit is free standing or without threads position the nose so that the conduit will butt up against the flats of the clamping plate ...

Page 11: ...Tugger System Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 11 Boom Setup cont d Typical Setup for a Side Pull Typical Setup for an Up Pull Typical Setup for a Down Pull ...

Page 12: ...to the correct height 5 Make sure the ring pull detent pins 2 3 are engaged with the boom tubes Lowering the Boom 1 Hold the boom tube with one hand Be aware of the weight 2 Lift up the boom tube slightly and pull out the ring pull detent pin 3 Move the boom tube to the correct height while pulling the ring pull detent pin DO NOT allow the boom tube to drop freely 4 When the correct height is reac...

Page 13: ...e locked in place by a detent pin set located between the sheave and the end of the boom tube receptacle To pivot squeeze the grips on the detent pins fully inward Squeeze Grips Make sure the detent pins on both sides are fully retracted before trying to pivot Release the grips when the desired pivot angle is reached and pivot slightly more to allow both detents to engage in the closest holes When...

Page 14: ...ed High Speed When ready to start pulling cable use only a few wraps of rope on the capstan at first Using too many wraps will reduce your ability to control the rope on the capstan Use the right angle sheave to position yourself so you are not in line with the high tension rope in case it the cable or the connector breaks Turn on the puller and gradually apply a tailing force to the free end of t...

Page 15: ...lways replace the entire chain including the connecting link as a whole unit Lubrication Lubricate the drive chains after every 40 hours of operation Lubricate between the chain plates from the inside of the loop with any high quality chain lube or an 80W 90W gear oil Adjustment Loosen the 4 screws securing the motor Push the motor away from the capstan while retightening the motor screws Capstan ...

Page 16: ...sembly 1 2 52066725 Tube extension top weldment painted 1 3 52066726 Tube extension middle assembly 1 4 52066727 Motor adapter assembly 1 5 Dolly base assembly 1 6 Motor assembly 1 7 Clip hitch pin 3 8 Pin clevis 3 52066173 Dolly assembly kit includes 5 7 1 8 1 52066174 Motor assembly kit includes 6 7 2 8 2 Key Part No Description Qty G3 Tugger Cable Pulling System ...

Page 17: ...de 1 8 Detent black oxide 2 9 Grip detent 0 187 4 10 Pin clevis ø 1 2 x 4 2 11 Spring compression 177 ID x 329 OD x 1 410 1 420 L 1 Key Part No Description Qty Key Part No Description Qty Key Part No Description Qty Mobile Carriage Head Assembly 3 2 1 13 1 3 4 5 6 9 8 15 14 10 16 17 18 2 11 12 7 12 Grip 2 13 52066741 Sheave 2 14 Rollpin 187 x 2 00 2 15 Clip hitch pin ø 12 x 2 56 2 16 Plunger 3 17 ...

Page 18: ...m Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 18 15 6 7 8 9 11 10 17 24 16 13 12 18 14 21 20 19 1 2 23 4 5 3 22 25 ILLUSTRATIONS AND PARTS LISTS cont d Motor Assembly Illustration ...

Page 19: ...Washer thrust 2 Key Part No Description Qty Key Part No Description Qty 17 Washer flat 1 00 x 1 50 x 031 fiber 1 18 Screw cap 1 4 20 x 625 hex hd 4 19 Screw cap 1 4 20 x 500 skt hd 1 20 Ring retaining 500 Truarc 5100 EX 1 21 Pawl 1 22 Spring torsion 1 23 Screw slftpg phll hd 10 16 x 250 6 24 Washer shim ø 5 ID x ø 75 OD x 031 2 25 Nut hex 1 4 20 1 52066182 Motor guard assembly kit includes 2 3 23 ...

Page 20: ...88 USA 815 397 7070 An ISO 9001 Company Greenlee Textron Inc is a subsidiary of Textron Inc USA Tel 800 435 0786 Fax 800 451 2632 Canada Tel 800 435 0786 Fax 800 524 2853 International Tel 1 815 397 7070 Fax 1 815 397 9247 www greenlee com ...

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