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INSTRUCTION MANUAL

Ultra Tugger

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

IM 1259 REV 22 11/07

with Serial Code ABJ

Содержание Ultra Tugger

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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