Ultra Tugger
®
10 Cable Puller and Pulling Packages
Greenlee Tools, Inc.
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
31
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.
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.
Control Box Removal and Disassembly
1. Remove the four hex head cap screws and nuts that
secure the clamp to the control box.
2. Loosen the motor and power cord strain reliefs.
Remove the six screws securing the cover to the
base plate.
3. Disconnect the white and black motor leads from
the circuit board.
4. Unscrew the green ground wire from the base plate.
5. Disconnect the ribbon cable.
6. Disconnect the power cord at the circuit board and
breaker.
7. Disconnect the foot switch plug.
8. Pull the control unit free.
Switchbox Assembly Notes
1. The ribbon cable has an arrow at the No. 1 pin
connection, which goes next to the foot switch
receptacle.
2. The foot switch plugs into the receptacle closest to
the ribbon cable.
3. The white motor lead connects to the tab closest to
the foot switch plug.
The first reduction hub will be damaged if the leads
are reversed.
Motor Removal
1. Remove the control box.
2. Remove the black com mutator brush caps and pull
out the commutator brushes.
3. Use a 7/16" socket to remove nuts and washers at
rear of motor.
4. Pull the tail housing off the motor.
5. Pull off the magnet housing.
6. Pull out the armature.
Motor Assembly Notes
1. If the armature does not turn freely after installation,
the wrong gear teeth were engaged.
2. Hold armature in place when installing the magnet
housing.
3. Insert magnet housing roll pin into the recess on the
tail housing.
Capstan Removal
1. Use a 1-1/8" socket to remove capstan retaining
bolt and washers.
2. Pull the capstan 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.
3. Remove key.
4. Remove rope ramp.
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.
