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ULTRA TUGGER
Cable Puller and Pulling Packages
6800-22, 6802-22, 6805-22
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
999 2216.9
Purpose
This manual is intended to familiarize all personnel with Greenlee 6800-22 series Ultra Tugger cable pullers. Keep this manual available to all personnel. Replacement manuals are available upon request at no charge. and Greenlee Textron. are registered trademarks of
Ultra Tugger and Versi-Boom are trademarks of Greenlee Textron. Loctite and 242 are registered trademarks of Loctite Corporation. Texaco is a registered trademark of Texaco Inc.
Safety
Safety is essential in the use and maintenance of Greenlee tools and equipment. This instruction manual and any markings on the tools provide information for avoiding hazards and unsafe practices related to use of this tool. Observe all of the safety information provided.
Purchase Record
When tool is received, complete the following record: SERIAL NUMBER: _____________________ DATE OF PURCHASE: __________________ WHERE PURCHASED: ________________________
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 supply before servicing. Immediate hazards which, if not avoided, WILL result in severe injury or death. Failure to observe this warning can 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.
Inspect and verify the maximum load-bearing capacity or maximum strength of all structural supports, pulling system components and anchoring systems before setting up the puller. Any component that cannot withstand the maximum cable-pulling forces may break and strike nearby personnel with sufficient force to cause severe injury or death.
Locate the puller so that it is close to the conduit. Rope, cable, or connectors can break under tension, causing the rope to whip violently. Failure to observe this warning can result in severe injury or death.
Do not allow anything other than the pulling rope to contact the capstan. A grip, swivel, or other component could break and strike nearby personnel with great force. Failure to observe this warning can 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 can result in severe injury or death.
An under-rated or worn rope may break and whip violently. Use a double-braided composite rope with the following characteristics: Maximum Rated Capacity: at least 35.6 kN (8000 lbs) Average Breaking Strength: at least 143 kN (32,000 lbs) Failure to observe this warning can result in severe injury or death.
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. Failure to observe these warnings can result in severe injury or death.
Attach the pulling rope to the cable with appropriate types of connectors as described in this manual. Select connectors with a maximum rated capacity of 35.6 kN (8000 lbs). An under-rated connector can break under tension. Failure to observe this warning can result in severe injury or death.
Do not allow the rope to become overlapped on the capstan. If an overlap begins to develop, relax the tailing force immediately and shut off the cable puller. Failure to observe this warning can result in severe injury or death.
Shear Point: Do not put fingers through holes in elbow unit. Rotating parts may cut off fingers. Failure to observe this warning can result in severe injury or death.
Use this tool for manufacturers intended purpose only. Do not use the cable puller as a hoist or winch. The cable puller cannot lower a load. The load may fall. Failure to observe this warning can 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 can 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.
Inspect puller and accessories before use. Replace any worn or damaged components with Greenlee replacement parts. A damaged or improperly assembled item can break and strike nearby personnel with sufficient force to cause severe injury or death.
When using the wheeled carriage to transport the Ultra Tugger: Keep personnel out of the path of transport. Evaluate 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.
Entanglement hazard: Do not operate the cable puller while wearing loose-fitting clothing. Retain long hair. Failure to observe this warning can result in severe injury or death.
Wear eye protection when using this tool. Failure to wear eye protection can result in severe eye injury from flying debris.
Electric shock hazard: Do not modify the plug provided with the tool. Connect this tool to a grounded receptacle on a 15-amp GFCIprotected circuit. Failure to observe these warnings can result in severe injury or death.
This tool must be grounded. In the event of a malfunction 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 shock to the operator. This tools electric cord has a grounding conductor and a grounding plug as shown. Do not modify the plug. Connect the plug to receptacle that is properly installed and grounded in accordance with all national and local codes and ordinances. Do not use an adapter.
Plug
Receptacle
1 11 9 8 10 2
4 5 6
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. Rope Ramp 9. Hitch Clip 10. Gearbox 11. Mounting Pin 12. Force Gauge with Remote ON/OFF Switch
1 15
2 14
3 6
13
11 5
12
10
9 8
Versi-Boom Components 1. Elbow Unit 2. Sight Hole 3. 4' Boom Tube 4. Sight Hole 5. Boom Mount 6. T-Stand 7. Puller 8. Force Gauge
Greenlee Textron / Subsidiary of Textron Inc.
9. Wheeled Carriage 10. Slip-in Coupler 11. Nose Unit 12. Mounting Pins 13. Hitch Pin Clips 14. 3' Boom Tube 15. Long Pin
10
11
12
13
Gravity
Weight of Cable
Tailing Force
14
15
Operators Tailing Force 44.5 N (10 lbs) 44.5 N (10 lbs) 44.5 N (10 lbs) 44.5 N (10 lbs) 44.5 N (10 lbs) 44.5 N (10 lbs) 44.5 N (10 lbs)
Approximate Pulling Force 93.4 N (21 lbs) 213.5 N (48 lbs) 474.9 N (106 lbs) 1043.8 N (233 lbs) 2293.7 N (512 lbs) 5048.9 N (1127 lbs) 11.1 kN (2478 lbs)
This table shows how the capstan acts as a force multiplier. Because the coefficient of friction depends upon the condition of the rope and capstan, this formula cannot determine an exact amount of pulling force.
Tailing Force
16
Stored Energy
Stored Energy
17
A Typical Grip SetupClevis and Wire Grip Maximum Pulling Force 35.6 kN (8000 lbs)
mm
39.9 - 49.5 49.5 - 59.9 59.9 - 79.8 79.8 - 99.8 99.8 - 119.6 119.6 - 139.7 139.7 - 159.5 159.5 - 199.4 199.4 - 239.3 239.3 - 279.4 279.4 - 319.3 319.3 - 359.2 359.2 - 399.0
mm
12.7 - 15.5 15.8 - 18.8 19.1 - 25.1 25.4 - 31.5 31.8 - 37.8 38.1 - 44.2 44.5 - 50.5 50.8 - 63.2 63.5 - 75.9 76.2 - 88.6 88.9 - 101.3 101.6 - 114.0 114.3 - 126.7
7.85 - 9.42 9.42 - 11.00 11.00 - 12.57 12.57 - 14.14 14.14 - 15.71
18
0 (0)
90
T T
50.2 (11,300)
60 45 30
71.2 (16,000)
19
Too little tailing force will allow the rope to slip on the capstan. This will build up excessive heat and accelerate rope wear, increasing the possibility of breaking the rope.
The proper amount of tailing force will stop the rope from slipping on the capstan and produce a sufficient amount of pulling force to pull in the rope and cable.
Too much tailing force is any amount more than is necessary to stop the rope from slipping on the capstan. Excessive tailing force will not increase the pulling force or pulling speed.
20
21
22
T-Stand Pulling Horizontally 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
T-Stand Pulling Up Using One Boom Tube, Nose Unit and Slip-in Coupler
23
Wheeled Carriage Pulling Up Using One Boom, Nose 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 Up Using 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
24
Do not mount the pipe adapter to the following: steel conduit less than 63.5 mm (2-1/2") in diameter PVC conduit of any size. These conduits will not support the loads imposed by the puller. Failure to observe this warning can result in severe injury or death.
Frame Sheave Shaft
NO
NO
When setting up the pipe adapter, do not use the vise chains on a structural support that is less than 63.5 mm (2-1/2") 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 can result in severe injury or death. 2. Position the frame against the conduit.
25
Install the vise chains properly. Follow the vise chain tightening instructions carefully. Improperly tightened chains can allow the puller to slide or break loose and strike nearby personnel. Do not allow the vise chains to bind at the corners when mounting the puller to a square or rectangular support. The vise chain must be uniformly tight at all points. Failure to observe this warning can result in severe injury or death. 3. On each vise chain unit: a. Rotate the vise chain handle counterclockwise to expose most of the threads. Leave only three or four threads engaged in the handle. b. Insert the chain into the 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 tight and insert the chain pins into the chain pockets, or recesses. e. Turn the handle clockwise to slightly tighten the chain.
Sheave
Frame
Positioner
26
Gearbox Cradle
7. Install two pins from the motor side. Secure the pins with two hitch pin clips.
Install Hitch Pins from Motor Side Install Hitch Pin Clips on Capstan Side
27
5. Align the two sets of holes in the T-stand with the two sets of holes in the boom mount. 6. Install two pins. Secure the pins with hitch pin clips.
Cradle
Boom Mount
3. Mount the boom mount to the puller. 4. Install two pins from the motor side. Secure the pins with two hitch pin clips.
28
Removable Pin
4. Rotate the puller and boom mount as shown. When the second hole in the boom mount is aligned with the second hole in the wheeled carriage, install a pin. Secure the pin with a hitch pin clip.
2. Position the pullers gearbox above the boom mount cradle. Align the puller so that the puller mounting plates straddle the boom mount plates. Lower the puller onto the boom mount. Install two pins from the motor side. Secure the pins with two hitch pin clips.
29
STRAIGHT EDGE
Set up the elbow unit as shown. Improper setup will cause the elbow unit to collapse. Failure to observe this warning can result in severe injury or death.
Sight Hole
Sight Hole
30
Set up the elbow unit as shown. Improper setup will cause the elbow unit to collapse. Failure to observe this warning can result in severe injury or death.
4. Slide the boom tube into the elbow unit until the tube bottoms out. Sight the tube through the sight hole to be sure the tube is fully inserted. Tighten the set screw. 5. Slide the nose unit onto the tube until the tube bottoms out. Sight the tube through the sight hole to be sure the tube is fully inserted. Tighten the set screw.
Sight Hole
Sight Hole
Sight Hole
31
3. Slide the nose unit over the coupler. Align any set of holes and insert one pin. Secure the pin with a hitch pin clip. Note: If possible, add a second pin and hitch pin clip.
Pull Conduit
3. Slide the nose unit over the coupler. Align any two sets of holes and insert two pins. Secure the pins with hitch pin clips.
Nose Unit
Coupler
Coupler
Pull Conduit
32
12 11
OCLOCK
1
TAILING ROPE
Do not mount the pipe adapter to the following: steel conduit less than 63.5 mm (2-1/2") in diameter PVC conduit of any size. These conduits will not support the loads imposed by the puller. Failure to observe this warning can result in severe injury or death.
10
PULL LOAD
PULLING ROPE
SUPPORT
VISE CHAINS
NO
NO
When setting up the pipe adapter, do not use the vise chains on a structural support that is less than 63.5 mm (2-1/2") 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 can result in severe injury or death.
6
OCLOCK
Install the vise chains properly. Follow the vise chain tightening instructions carefully. Improperly tightened chains can allow the puller to slide or break loose and strike nearby personnel. Do not allow the vise chains to bind at the corners when mounting the puller to a square or rectangular support. The vise chain must be uniformly tight at all points. Failure to observe this warning can result in severe injury or death.
33
c. Pull the vise chain tight and insert the chain pins into the chain pockets, or recesses. d. Turn the handle clockwise to slightly tighten the chain. 2. Set the puller into the cradle of the chain mount. 3. Install two pins from the motor side. Secure the pins with two hitch pin clips.
34
Follow all floor mounting instructions carefully. An improperly attached floor mount can come loose and strike nearby personnel. Do not attach the floor mount to masonry, brick, or cinder block. These materials will not hold the anchors securely. Failure to observe this warning can result in severe injury or death. 1. Determine the best position for locating the floor mount. Locate the floor mount: on a flat section at least 152 mm (6") from edge of concrete as close to the conduit as possible to reduce the amount of exposed rope under tension so that the pull rope will approach the pullers capstan at a 90 ( 5) angle.
Nut
Washer
2. Insert the four anchors through the floor mount and into the holes in the floor. 3. Hammer the anchors in until the washer is in firm contact with the floor mount.
4. Expand the anchors by torquing the nuts to 122 to 128 Newton-meters (90 to 95 foot-pounds).
90
at least 152 mm (6") at least 152 mm (6")
If any of the four anchors spin before the minimum torque is achieved, abandon the location and start elsewhere. An improperly installed anchor can allow the puller to break loose. 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.
Greenlee Textron / Subsidiary of Textron Inc.
Failure to observe this warning can result in severe injury or death. 5. Have the installation checked by a qualified inspector.
35
Set up the cable puller so that the rope will approach the capstan at an angle of 90 ( 5). Angles outside of this range may cause the rope to overlap.
90 (5)
7. Turn the circuit breaker in the force gauge ON. 3. Set the rope ramp as follows: 8. Grasp the tailing end of the rope. Apply a slight amount of tailing force. 9. Turn the puller ON. 10. Tail the rope, allowing the spent rope to accumulate on the floor between the operator and the puller. 11. When the pull is complete, turn the puller OFF. Tie off the rope and anchor the cable.
Pull Side
Surface A
a. Wind the rope several times around the capstan. b. Pull the ramp away from the mounting plate and rotate it until Surface A contacts the rope. c. Push the ramp toward the mounting plate and rotate it counterclockwise until it locks into place.
36
37
Note: The 1st reduction hub will be damaged if the puller is run with the polarity reversed. 3. Secure motor leads to motor using tie-wraps. Make sure the wires will not contact the commutator.
4. Position the switchbox and clamp so that the vent holes are towards the rear of the motor.
38
39
BLACK
WIRING DIAGRAM
8 21
20 27 26 5 12 28
16, 17 9 14 1
3 2
13
20 24 6 15 11 19 7 18 4 22
40
41
37
20
7 30 21 30 31 9 13 8 33 12 32
28 25
26 27 3
35
18
24 31 11 23 29 17
39 2
20 29 4 33 36 24 5 10 29 22 15 29 6 33 35 24 14 24 31 16 24 31 19 34
38
42
7 8
6 10 10
2 1
KEY 1 2 3 4 5 6 7 8 9 10
PART NO. 500 2692.5 918 6705.3 918 6706.1 918 6558.1 918 6560.3 918 6561.1 918 6840.8 905 4348.3 918 6071.7 918 6921.8 918 6914.5
DESCRIPTION Motor
QTY.
Commutator Brushes ................................................. 2 Commutator Brush Retention Spring ......................... 1 Tail Housing ............................................................... 1 Brush Assembly Plate ................................................ 1 Magnet Housing ......................................................... 1 Armature 230V ........................................................... 1 Belleville Washers ...................................................... 2 Bearing ....................................................................... 1 Screen ........................................................................ 1 Threaded Rod ............................................................ 2 44
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
16
Receptacle
Meter
4 14 14
BLUE BROWN
17 21 13 19 1 5 9 10 11 20 6 18
Plug GREEN with YELLOW stripe Switch
7 12 12
KEY 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
PART NO. 500 3054.0 503 1471.8 502 9708.2 500 2691.7 503 5922.3 503 0392.9 503 3055.8 503 1473.4 503 1480.7 503 5631.3 503 1478.5 905 3934.6 905 0633.2 905 2240.0 905 0632.4 905 2203.6 918 6143.8 918 6009.1 918 6413.5 503 5632.1 905 5036.6
DESCRIPTION QTY. Force Gauge, 230-volt Box Control ................................................................. 1 Guard, Switch ............................................................. 1 Meter ........................................................................... 1 Cover ........................................................................... 1 Decal, Damp Warning ................................................. 1 Decal, Identification ..................................................... 1 Cord, Power ................................................................ 1 2" Wire Unit (brown) .................................................... 1 4" Wire Unit (brown) .................................................... 1 Wire Unit, Ground (green/yellow) ............................... 1 Brumper, Rubber Screw ............................................. 4 Nut, #832 Hex ........................................................... 4 Screw, #620 x 3/8 ..................................................... 2 Nut, #632 Hex ........................................................... 2 Screw, #632 x 1/4 ..................................................... 2 Connector, 15 Amp Female ........................................ 1 Bushing, Strain Relief ................................................. 1 Switch .......................................................................... 1 4" Wire Unit (blue) ....................................................... 1 Screw, #632 x 1/4 Truss Head ................................. 2 45
4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
KEY 1 1 1 1 1
PART NO. 500 0804.8 500 0811.0 500 0815.3 500 0820.0 500 0827.7
QTY.
Slip-In Coupler for 2-1/2" EMT, IMC or Rigid ............. 1 Slip-In Coupler for 3" EMT, IMC or Rigid .................... 1 Slip-In Coupler for 3-1/2" EMT, IMC or Rigid ............. 1 Slip-In Coupler for 4" EMT, IMC or Rigid .................... 1 Slip-In Coupler for 5" EMT, IMC or Rigid .................... 1
2 3
KEY 2 3
QTY.
46
9 5 6
KEY
QTY.
1 2 3 4 5 6 7 8 9
500 0770.0 905 4839.6 500 0768.8 503 2026.2 500 0743.2 905 0700.2 905 0302.3 905 1528.5 500 1063.8
Frame ......................................................................... 1 Wheel, 4.10/3.506 x 3/4 Shaft ................................. 4 Axle ............................................................................ 2 Spacer, .824 x 1.05 x .75 ........................................... 4 Pin, Puller ................................................................... 2 Pin, Roll .187 x 1.50 ................................................... 2 Clip, Hitch Pin #8 ....................................................... 2 Ring, Retaining .750 Truarc #5160-75-S-PP ............. 4 Decal, Warning .......................................................... 1
47
4 3
KEY 1 2 3 4 5 6 7 8 9
PART NO. 500 0871.4 500 0761.0 500 0755.6 905 0700.2 905 0302.3 905 0530.1 500 0743.2 500 0920.6 501 6798.7 500 1031.0
QTY.
Frame .......................................................................... 1 Shaft ............................................................................ 1 Pin, Roll .187 x 1.50 .................................................... 3 Clip, Hitch Pin #8 ........................................................ 3 Screw, 3/816 x 1.00 Hex Head Cap ......................... 1 Pin, Puller .................................................................... 2 Wheel Unit, Idler ......................................................... 1 Bushing ....................................................................... 2 Decal, Warning ........................................................... 1
48
5 3 9 4
KEY 1 2 3 4 5 6 7 8 9
PART NO. 500 0864.1 500 0832.3 500 0843.9 500 0790.4 500 0743.2 905 0700.2 905 0302.3 905 0530.1 905 4838.8 500 1042.5
QTY.
Elbow Weldment, Adjustable ...................................... 1 Sheave Unit, 12" ......................................................... 1 Shaft, Elbow ................................................................ 1 Pin, Puller .................................................................... 1 Pin, Roll .187 x 1.50 .................................................... 3 Clip, Hitch Pin #8 ........................................................ 1 Screw, 3/816 x 1.00 Hex Head Cap ......................... 1 Bushing ....................................................................... 2 Decal, Warning ........................................................... 1
49
8 6 2
4 7
10
5 11 8
KEY 1 2 3 4 5 6 7 8 9 10 11 PART NO. 500 0863.3 500 0832.3 500 0828.5 500 0843.9 500 0836.6 500 0837.4 905 0700.2 905 0302.3 905 0530.1 905 4838.8 500 1397.1 500 1032.8 DESCRIPTION Elbow Unit Elbow Weldment, Adjustable ...................................... 1 Elbow Weldment, Pivot ............................................... 1 Sheave Unit, 12" ......................................................... 1 Shaft, Pivot .................................................................. 1 Pin, Elbow ................................................................... 1 Pin, Roll .187 x 1.50 .................................................... 3 Clip, Hitch Pin #8 ........................................................ 1 Screw, 3/816 x 1.00 Hex Head Cap ......................... 2 Bushing ....................................................................... 2 Lanyard ....................................................................... 1 Decal, Warning ........................................................... 1 QTY.
50
9 10 8
11 2 6
12
KEY 1 2 3 4 5 6 7 8 9 10 11 12
PART NO. 500 0862.5 500 0668.1 500 0844.7 500 0690.8 905 0700.2 905 0302.3 502 9664.7 905 0579.4 502 7831.2 502 9630.2 502 9638.8 905 4838.8 500 1046.8
QTY.
Frame .......................................................................... 1 Sheave Unit, 18" ......................................................... 1 Shaft ............................................................................ 1 Pin, Roll .187 x 1.50 .................................................... 1 Clip, Hitch Pin #8 ........................................................ 1 Foot ............................................................................. 4 Screw, 1/4 x .500 Socket Head Cap ........................... 8 Screw Unit, 24" Vise Chain ......................................... 2 Handle Unit, Vise Chain .............................................. 2 Positioner Casting, Chain ........................................... 2 Bushing ....................................................................... 2 Decal, Warning ........................................................... 1
51
KEY 1 2 3
PART NO. 500 0865.0 500 0789.0 503 5607.0 500 1047.6
QTY.
Frame .......................................................................... 1 Anchor, Wedge .625 x 6.00 ........................................ 4 Decal, Warning ........................................................... 1
52
2 1
4 5 3
KEY 1 2 3 4 5
PART NO. 500 0778.5 502 9664.7 905 0579.4 502 9630.2 502 5661.5
QTY.
Frame Weldment ........................................................ 1 Foot ............................................................................. 4 Screw, 1/4 x 1/2 Socket Head Cap ............................. 8 Handle Unit, Vise Chain .............................................. 2 Screw Unit, Vise Chain ............................................... 2
53