Textron GREENLEE Ultra Tugger 8 Instruction Manual Download Page 1

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INSTRUCTION MANUAL

Ultra Tugger

Cable Puller and

Pulling Packages

99920751

IM 1259 REV 27 8/12

Serial Code ABJ

Read

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

Summary of Contents for GREENLEE Ultra Tugger 8

Page 1: ... Pulling Packages 99920751 2012 Greenlee Textron Inc IM 1259 REV 27 8 12 Serial Code ABJ Read 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 ...

Page 2: ... 30 Setup Chain Mount 31 32 Setup Floor Mount 33 Operation 34 Removing Cable 35 Maintenance 36 37 Illustrations and Parts Lists 38 45 Ultra Tugger 8 38 39 Gearmotor 40 41 Motor 42 Force Gauge 43 Mobile Carriage and Boom 44 45 Accessories 46 Description The Greenlee Ultra Tugger 8 Cable Puller is intended to be used to pull cable through conduit and in tray The Ultra Tugger will develop 35 6 kN 800...

Page 3: ...ed 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 Do not operate the cable puller in a hazardous environment Hazards include fl...

Page 4: ...e nearby 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 to observe this warning could result in severe injury or death IMPORTANT SAFETY INFORMATION Locate the puller so that it is close to the conduit Rope cable or connectors can break under tension cau...

Page 5: ...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 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...

Page 6: ...valuate 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 Grounding Instructions Electric shock hazard Connect this tool to a grounded receptacle on a 20 amp GFCI protected circuit Failure to observe this...

Page 7: ...A 815 397 7070 7 Identification Ultra Tugger 8 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 Rope Ramp 9 Hitch Clip 10 Gearbox 11 Mounting Pin 12 Force Gauge with Remote ON OFF Switch 1 2 3 4 6 7 8 10 9 11 5 12 ...

Page 8: ...cont d Mobile Carriage and Boom 1 Puller 2 Elbow 3 Nose 4 Back Boom 5 Forward Boom 6 Detent Pin 7 Crank 8 Conduit Adapter Couplings 9 Adapter Storage Hanger 10 Storage Tray 11 Brake 12 Swivel Caster 13 Transport Handle 14 Boom Mount 15 Ring Pull Detent Pin 16 Location for Additional Adapter Storage Racks 8 10 15 6 2 9 7 5 4 14 13 12 11 15 16 3 1 15 ...

Page 9: ...nd 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 N 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 kN to 28 9 kN 0 lb to 6500 lb Continuous operation 28 9 kN to 35 6 kN 6500 lb to 8000 lb 15 minutes on 15 minutes off Pulling Rope ...

Page 10: ...pe 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 resultant force any force that is produced when two or more forces act on an object applies to the sheaves o...

Page 11: ...ecommends 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 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 pullin...

Page 12: ...s 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 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 pul...

Page 13: ...ring 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 force on cable puller s anchoring system It is extremely impor tant the anchoring system can withstand this amount of force Refer to the instruction manual provided with your anchoring system for proper se...

Page 14: ...he number 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 based on the formula above The input or tailing force is constant at 44 5 N 10 lb Increasing the number of wraps increases the pulling force Operator s Tailing Force Number of Wraps of Rope Ap...

Page 15: ...se 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 A similar double braided composite rope could store approximately 300 000 joules of energy This could throw the same ...

Page 16: ...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 the table pro vided to find the correct size 3 Refer to the maximum rated capacities in the Greenlee catalog Pulling Grip Size Table Circumference Range Required Grip Diameter inches mm inches mm 1 57...

Page 17: ...s 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 table is provided here For details on calculating the resultant force for any angle refer to IM 1363 99929988 Resultant Force Table for the Ultra Tugger 35 6 kN or 8 000 lb Maximum Pulling Force Illustra...

Page 18: ...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 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...

Page 19: ... 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 a...

Page 20: ...he unit that attaches to the conduit via couplers Elbow refers to the unit that connects the two boom tubes The elbow nose units pivot and lock at various degrees of rotation They are locked in place by a detent pin set located between the sheave and the end of the boom tube receptable To pivot squeeze the grips on the detent pins fully inward Squeeze Grips Make sure the detent pins on both sides ...

Page 21: ...place in the receptacles the conduit must be clamped in place opposite the detent pins using 1 2 13 screws not supplied Because the weight will be too great to use the crank to raise and lower the boom manual assist is required Conduit Adapter Couplings Couplings to attach the puller system to the conduit are available in 2 2 1 2 3 3 1 2 4 and 5 sizes There are two types slip in and screw on Slip ...

Page 22: ...n Grab Point 4 Pull out on the detent ring that locks the boom tube and twist the nose slightly so the hole in the boom tube and detent pin are misaligned Ring Pull Detent Pin 5 Release the detent ring and pull the nose and forward boom from the elbow 6 Repeat this process to remove the back boom and elbow Raise or lower the boom s as desired beforehand to gain a comfortable position 7 Turn the cr...

Page 23: ...duit Position Nose Higher than Conduit To use slip in couplings a Insert the appropriate slip in conduit adapter coupling into the nose b Pivot the nose until the coupling is aligned with the conduit and lock in position c Raise the boom until the bottom of the coupling clears the conduit d Release the brakes if not already released e Roll the carriage forward until the coupling is over the condui...

Page 24: ...etup 6 Raise or lower the boom until the nose is just below the conduit to be pulled from To use slip in couplings a Insert the appropriate slip in conduit adapter coupling into the nose b Pivot the nose until the coupling is aligned with the conduit and lock in position c Lower the boom until the coupling clears the conduit d Release the brakes e Roll the carriage forward until the coupling is un...

Page 25: ...ifference is in the horizontal alignment of the coupling with the conduit and using the carriage to walk the coupling into the conduit or the nose into the cou pling for the screw on adapters Horizontal Pull in Underground Vault Single Boom Pull All of the previous boom setup instructions assume that two booms are used While using two booms can be useful for working around obstructions keeping ang...

Page 26: ...serve this warning could result in severe injury or death Shear point Never put fingers through holes in boom components Pivoting of mating arts may cut off fingers Always keep elbow unit locked with pivot pin except while adjusting Failure to observe this warning could result in severe injury or death Use these boom tubes only Boom tubes supplied with the UT10 3 rigid steel conduit 3 m or 10 maxi...

Page 27: ...ext to last position and lock the elbow b Raise the boom all the way up until it hits the stop c Release the ring pull detent that locks the back boom to the elbow and rotate the elbow 180 into its Teepee position 2 Lift the push pull handle up until it contacts the boom mount to push the carriage Use the same handle to pull the unit Handle raised for pushing Handle Position for Pushing Handle rai...

Page 28: ... Rockford IL 61109 2988 USA 815 397 7070 28 Other 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 ...

Page 29: ... will 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 support that is less than 51 mm 2 or more than 254 mm 10 wide An oversized or under sized structural support can allow the puller to slide or break loose and strike nearby personnel Failure to obse...

Page 30: ...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 Positioner Positioning Block not shown Chain Pockets not shown 4 Rotate the vise chain handles by hand clockwise to tighten the chain Do not use tools ex...

Page 31: ...1 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 n...

Page 32: ...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 tighten the chain Tighten as much as possible by hand Do not use a cheater 2 Set the puller into the cradle of the chain mount as shown so that the inside of the capstan is directly over the mounting 3 Install two pins from the motor side Secure the pins with t...

Page 33: ...2 mm 6 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 ANSI standard B94 12 77 3 Vacuum the debris from the holes Installation Greenlee recommends using Greenlee 35607 Wedge Anchors If another type of anchor is used they must have an ICBO Internat...

Page 34: ...k 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 refer to 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 monitor...

Page 35: ...ting 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 gr...

Page 36: ...not contact the commutator 4 Position the switchbox and clamp so that the vent holes are towards the rear of the motor Motor Removal Refer to Illustration 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 ...

Page 37: ...r 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 fit into the counterbores of the mounting plates Disassembly of Planet Gear Carriers...

Page 38: ...xtron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 38 Illustration and Wiring Diagram Ultra Tugger 8 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 WIRING DIAGRAM 23 25 26 27 BLACK BLACK BLACK BLACK RED RED WHITE MOTOR 10 ...

Page 39: ... 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 flat 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 Screw machine 8 32 x 328 hex head g...

Page 40: ...A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 40 Illustration 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 24 31 7 33 35 31 30 21 30 9 13 8 12 32 18 39 2 20 38 19 34 14 ...

Page 41: ...otor 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 90548...

Page 42: ...rts List Motor 50006649 1 2 3 6 7 8 5 4 9 9 Key Part No Description Qty 50006649 Motor 1 91867053 Commutator brushes 2 2 91867061 Commutator brush retention spring 2 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 91869145 Threaded rod 2 ...

Page 43: ... rubber 4 10 90506332 Nut hex 8 32 4 11 90531949 Screw self tapping 10 16 x 250 Phillips head 6 11 8 7 6 3 12 2 14 16 15 5 17 FORCE INDICATOR CONNECTOR A SWITCH POWER CORD BLACK BLACK BLACK GREEN WHITE 4 10 19 18 1 13 14 9 Key Part No Description Qty Key Part No Description Qty 12 90522036 Screw machine 6 32 x 25 slotted pan head 2 13 Screw machine 8 32 x 375 round head 2 14 91866847 Receptacle 20...

Page 44: ...455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 44 Illustration Mobile Carriage and Boom 23 16A 12C 12A 12B 11D 11C 11A 11B 11F 11E 17B 17A 17C 1 18B 18A 15C 22A 16B 9 22B 15B 14C 14A 14B 15A 21A 2 13B 15D 13A 13D 21B 13C 5 7 19C 6 4 8 3 10A 19D 19A 19E 19B 20A 20B 20C 10B ...

Page 45: ...ng 1 15C Screw 5 16 18 x 3 25 hex head 4 15D Nut 5 16 18 flange 4 16 52061277 Guard kit includes 16A 16B 1 16A Guard gear 1 16B Guard worm 2 17 52061278 Swivel caster kit includes 17A 17C 2 17A Caster 1 17B Screw 3 8 16 x 1 00 hex head 4 17C Nut 3 8 16 hex lock 4 18 52061279 Wheel kit includes 18A 18B 1 18A Wheel 2 18B Ring retaining 2 19 52061280 Elbow detent pin kit includes 19A 19E 2 19A Sleeve...

Page 46: ...08650 3 1 2 Key Part No Description Qty 1 Frame 1 2 50356070 Anchor wedge 625 x 6 00 4 3 Decal warning 1 Chain Mount 50028464 1 3 4 6 5 2 Key Part No Description Qty 1 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 50356615 Screw unit vise chain 2 6 50007734 Block pivot 2 Decal warning not shown 1 ...

Page 47: ...Ultra Tugger 8 Cable Puller and Pulling Packages Greenlee A Textron Company 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 47 ...

Page 48: ...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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