IM 1300 REV 5 - greenlee-cdn.ebizcdn.com

1 ULTRA TUGGER Cable Puller and Pulling Packages6800-22, 6802-22, 6805-22 INSTRUCTION MANUALRead and understand all of the instructions andsafety information in this manual before operatingor servicing this 2001 greenlee TextronIM 1300 REV 5 7/01 greenlee Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesDescription .. 3 Purpose .. 3 Purpose Record .. 3 Important Safety Information .. 4-7 Grounding instructions .. 8 Identification .. 9-10 Specifications .. 11 Cable Pulling Glossary .. 12 Cable Pulling Principles:Cable Pulling Systems .. 13 Pulling Theory .. 14 Cable Pulling Forces:At the Cable Puller Anchoring System .. 15At the Capstan .. 16At the Pulling Rope.

2 17At the Connectors .. 18At the Sheaves .. 19 Tailing the Rope: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:Pipe Adapter .. 22 Chain Mount .. 22 Floor Mount .. 22T-Stand .. 23 Wheeled Carriage .. 24 Table of ContentsSetup:Pipe Adapter .. 25-27T-Stand .. 28 Wheeled Carriage .. 29 Mounting Components:Boom with Nose Unit .. 30 Booms with Elbow Unit and Nose Unit .. 31 Slip-in Coupler .. 32 Straddling the Conduit with Slip-in Coupler .. 32 Chain Mount .. 33-34 Floor Mount .. 35 Installation .. 35 Operation .. 36 Maintenance .. 38-39 Exploded Views / Parts Lists:Ultra Tugger (with wiring diagram).

3 40-41 Gearmotor (500 ) .. 42-43 Motor (500 ) .. 44 Force Gauge .. 45 Accessories .. 46-53 greenlee Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesKEEP THIS MANUALD escriptionThe greenlee Ultra Tugger cable puller is intendedto be used to pull cable through conduit and in Ultra Tugger will develop kilo-Newtons(8000 lbs) of pulling force. See a greenlee catalog forsheaves, pulling rope, and other cable pulling acces-sories to create an entire cable pulling single manual can provide instructions for everypossible cable pulling application; this manual containsgeneral information necessary to accomplish cable pullsof many different is essential in the use and maintenance ofGreenlee tools and equipment.

4 This instruction manualand any markings on the tools provide information foravoiding hazards and unsafe practices related to use ofthis tool. Observe all of the safety information manual is intended to familiarize all personnel withGreenlee 6800-22 series Ultra Tugger cable this manual available to all manuals are available upon requestat no charge. and are registered trademarks ofGreenlee Tugger and Versi-Boom are trademarks ofGreenlee and 242 are registered trademarks of is a registered trademark of Texaco RecordWhen tool is received, complete the following record:SERIAL NUMBER: _____DATE OF PURCHASE: _____WHERE PURCHASED: _____Greenlee Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesIMPORTANT SAFETY INFORMATIONE lectric shock hazard:Disconnect the cable puller from thepower supply before to observe this warning canresult in severe injury or symbol is used to call your attention to hazardsor unsafe practices which could result in an injuryor property damage.

5 The signal word, defined below,indicates the severity of the hazard. The messageafter the signal word provides information for prevent-ing or avoiding the or unsafe practices which, if not avoided,MAY result in injury or property which, if not avoided, COULD result insevere injury or hazards which, if not avoided, WILL resultin severe injury or and understand all of theinstructions and safety informationin this manual before operating orservicing this to observe this warning willresult in severe injury or not operate the cable puller in ahazardous environment. Hazardsinclude flammable liquids to observe this warning willresult in severe injury or Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesIMPORTANT SAFETY INFORMATIONDo not allow anything other than thepulling rope to contact the grip, swivel, or other componentcould break and strike nearbypersonnel with great to observe this warning canresult in severe injury or and verify the maximumload-bearing capacity or maximumstrength of all structural supports,pulling system components andanchoring systems before settingup the puller.

6 Any component thatcannot withstand the maximumcable-pulling forces may break andstrike nearby personnel with suffi-cient force to cause severe injuryor not stand directly under a verticalpull. Cable could fall suddenly fromthe to observe this warning canresult in severe injury or the puller so that it is close to the , cable, or connectors can break undertension, causing the rope to whip to observe this warning can result insevere injury or under-rated or worn rope may break and whipviolently. Use a double-braided composite ropewith the following characteristics: Maximum Rated Capacity:at least kN (8000 lbs) Average Breaking Strength:at least 143 kN (32,000 lbs)Failure to observe this warning can result in severeinjury or Textron / Subsidiary of Textron Boeing Dr.

7 , Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesIMPORTANT SAFETY INFORMATION Check the condition of the entire rope before worn or damaged rope can break under tensionand whip violently. Do not maintain a stationary rope on a rotatingcapstan. The wear generated may cause the ropeto break under tension and whip to observe these warnings can result insevere injury or the pulling rope to the cable with appropriatetypes of connectors as described in this connectors with a maximum rated capacityof kN (8000 lbs). An under-rated connectorcan break under to observe this warning can result in severeinjury or hands away from the at the capstan can crush to observe this warning canresult in severe injury or Point:Do not put fingers through holes inelbow unit.

8 Rotating parts may cutoff to observe this warning canresult in severe injury or not wrap rope around hands,arms, waist or other body not stand in spent coils or tailedrope. Hold rope so that it may bereleased , cable, or a connecting device can breakunder tension, causing the rope to whip violently. Do not allow any unnecessary personnel toremain in the area during the pull. Do not allow any personnel to stand in line withthe pulling to observe these warnings can result insevere injury or not allow the rope to become overlapped onthe capstan. If an overlap begins to develop, relaxthe tailing force immediately and shut off the to observe this warning can result in severeinjury or this tool for manufacturer s intended purposeonly.

9 Do not use the cable puller as a hoist or winch. The cable puller cannot lower a load. The load may to observe this warning can result in severeinjury or Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesIMPORTANT SAFETY INFORMATIONWear eye protection when using thistool. Failure to wear eye protectioncan result in severe eye injury fromflying puller and accessories before use. Replaceany worn or damaged components with Greenleereplacement parts. A damaged or improperlyassembled item can break and strike nearbypersonnel with sufficient force to cause severeinjury or hazard: Do not operate the cable puller while wearingloose-fitting clothing. Retain long to observe this warning can result in severeinjury or using the wheeled carriage to transport theUltra Tugger: Keep personnel out of the path of transport.

10 Evaluate the terrain of over which the carriageis to move. If in doubt, obtain additional helpand move the carriage slowly. Do not transport over inclines of more than 15 . Do not transport the carriage with boom tubeslonger than the supplied 3' and 4' Textron / Subsidiary of Textron Boeing Dr., Rockford, IL 61109-2988 815/397-7070 Ultra Tugger Cable Puller and Pulling PackagesGrounding InstructionsElectric shock hazard: Do not modify the plug providedwith the tool. Connect this tool to a groundedreceptacle on a 15-amp GFCI-protected to observe these warningscan result in severe injury or tool must be grounded. In the event of a malfunc-tion or breakdown, an electrical ground provides a pathof least resistance for the electric current.