999 5029.4 #1 - cableorganizer.com...the greenlee ultra tugger 5 cable puller is intended to be used...

INSTRUCTION MANUAL

99950294 REV 4 © 2006 Greenlee Textron Inc. 3/06

Read and understand all of the instructions andsafety information in this manual before operatingor servicing this tool.

Ultra Tugger® 5Cable Puller and Pulling Packages

6501, 6503 and 6505For Serial Numbers beginning with AHL 00001

Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

Ultra Tugger® 5 Cable Puller and Pulling Packages

KEEP THIS MANUAL

Description ..................................................................... 3

Purpose .......................................................................... 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 ................ 15

At the Capstan ..................................................... 16

At the Pulling Rope .............................................. 17

At the Connectors ................................................ 18

At 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 .............................................................. 22

T-Stand .................................................................... 23

Wheeled Carriage .................................................... 24

Table of Contents

Setup:

Pipe Adapter ....................................................... 25-27

T-Stand .................................................................... 28


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

Removing Cable........................................................... 37

Maintenance............................................................ 38-39

Exploded Views / Parts Lists:

Ultra Tugger 5 (with wiring diagram) ................... 40-41

Gearmotor (50006460) ....................................... 42-43

Motor (50006649) .................................................... 44

Force Gauge (50011198) ........................................ 45

Accessories:

Couplers .................................................................. 46

Boom Tubes ............................................................ 46

T-Stand .................................................................... 47


Boom Mount ............................................................ 48

Nose Unit ................................................................. 49

Elbow Unit ................................................................ 50

Floor Mount .............................................................. 51

Chain Mount ............................................................ 52



DescriptionThe Greenlee Ultra Tugger 5 Cable Puller is intendedto be used to pull cable through conduit and in tray.The Ultra Tugger 5 will develop 22.2 kilo-Newtons(5000 lb) of pulling force. See a Greenlee catalog forsheaves, pulling rope, and other cable pulling acces-sories to create an entire cable pulling system.

No single manual can provide instructions for everypossible cable pulling application; this manual containsgeneral information necessary to accomplish cable pullsof many different setups.

SafetySafety is essential in the use and maintenance ofGreenlee tools and equipment. 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 provided.

PurposeThis manual is intended to familiarize all personnel withthe safe operation and maintenance procedures for thefollowing Greenlee tool:

Ultra Tugger® 5 cable pullers (6500-series)

Keep this manual available to all personnel.

Replacement manuals are available upon request atno charge.

All specifications are nominal and may change as design improve-ments occur. Greenlee Textron Inc. shall not be liable for damagesresulting from misapplication or misuse of its products.

Ultra Tugger is a registered trademark of Greenlee Textron Inc.

Versi-Boom is a trademark of Greenlee Textron Inc.

Loctite and 242 are registered trademarks of Loctite Corporation.

Texaco is a registered trademark of Texaco Inc.



This symbol is used to call your attention to hazardsor unsafe practices which could result in an injuryor property damage. The signal word, definedbelow, indicates the severity of the hazard. Themessage after the signal word provides informationfor preventing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,MAY result in injury or property damage.

Hazards which, if not avoided, COULD result insevere injury or death.

Immediate hazards which, if not avoided, WILLresult in severe injury or death.

SAFETYALERTSYMBOL

IMPORTANT SAFETY INFORMATION

Read and understand all of theinstructions and safety informationin this manual before operating orservicing this tool.

Failure to observe this warning willresult in severe injury or death.

Electric shock hazard:

Disconnect the cable puller from thepower supply before servicing.

Failure to observe this warning couldresult in severe injury or death.

Do not operate the cable puller ina hazardous environment. Hazardsinclude flammable liquids andgases.

Failure to observe this warning willresult in severe injury or death.




Flying Components Hazard:

• Inspect and verify the maximumload-bearing capacity or maximumstrength of all structural supports,pulling system components andanchoring systems before settingup the puller. Any component thatcannot withstand the maximumcable-pulling forces may breakand strike nearby personnel withsufficient force to cause severeinjury or death.

• Do not allow anything other thanthe pulling rope to contact thecapstan. A grip, swivel, or othercomponent could break and strikenearby personnel with great force.


Do not stand directly under a verticalpull. Cable could fall suddenly fromthe conduit.


Locate the puller so that it is close to the conduit.Rope, cable, or connectors can break undertension, causing the rope to whip violently.

Failure to observe this warning could result insevere injury or death.

An under-rated or worn rope may break and whipviolently. Use a double-braided composite ropewith the following characteristics:

• Maximum Rated Capacity:at least 22.2 kN (5000 lb)

• Average Breaking Strength:at least 89 kN (20,000 lb)






• Check the condition of the entire rope before use.A 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 violently.

Failure to observe these warnings could result insevere injury or death.

Attach the pulling rope to the cable with appropriatetypes of connectors as described in this manual.Select connectors with a maximum rated capacityof 22.2 kN (5000 lb). An under-rated connector canbreak under tension.


Crushing Hazard:

Keep hands away from the capstan.Rope at the capstan can crush ahand.


Shear Point:

Do not put fingers through holes inelbow unit. Rotating parts may cutoff fingers.


Entanglement Hazard:

Do not wrap rope around hands,arms, waist or other body parts.Do not stand in spent coils or tailedrope. Hold rope so that it may bereleased quickly.



Rope, 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 rope.


Rope Overlap Hazard:

Do not allow the rope to become overlapped onthe capstan. If an overlap begins to develop, relaxthe tailing force immediately and shut off the cablepuller.


Do not operate without chain guardsin place.




Use this tool for manufacturer’s intended purposeonly. Do not use the cable puller as a hoist or winch.

• The cable puller cannot lower a load.

• The load could fall.

Failure to observe this warning could result in severeinjury or death.


Wear eye protection when using thistool. Failure to wear eye protectioncould result in severe eye injury fromflying debris.

Inspect 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 death.

Entanglement Hazard:

• Do not operate the cable puller while wearingloose-fitting clothing.

• Retain long hair.


Tipping Hazard:

When using the wheeled carriage to transport theUltra Tugger:

• Keep personnel out of the path of transport.

• Evaluate the terrain of over which the carriage isto move. If in doubt, obtain additional help andmove 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' tubes.




Grounding Instructions

Electric shock hazard:

• Do not modify the plug providedwith the tool.

• Connect this tool to a groundedreceptacle on a 20-amp GFCI-protected circuit.

Failure to observe these warningscould result in severe injury or death.

This 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. This path ofleast resistance is intended to reduce the risk of electricshock to the operator.

This tool’s electric cord has a grounding conductor anda grounding plug as shown. Do not modify the plug.Connect the plug to receptacle that is properly installedand grounded in accordance with all national and localcodes and ordinances. Do not use an adapter.

20-Amp / 115-Volt Plug and Grounded Receptacle

ReceptaclePlug



Identification

Ultra Tugger 5 Cable Puller

1. Motor 7. Right Angle Sheave

2. Circuit Breaker/Switch 8. Rope Ramp

3. Mounting Plates 9. Hitch Clip

4. Rope Tie-Off 10. Gearbox

5. Adjustable Sheave Bracket 11. Mounting Pin

6. Tapered Steel Capstan 12. Force Gauge withRemote ON/OFF Switch

1

2

3

4

6

7

8

109

11

5

12



Identification (cont’d)

Versi-Boom™ Components

1. Elbow Unit 9. Wheeled Carriage

2. Sight Hole 10. Slip-in Coupler

3. 4' Boom Tube 11. Nose Unit

4. Sight Hole 12. Mounting Pins

5. Boom Mount 13. Hitch Pin Clips

6. T-Stand 14. 3' Boom Tube

7. Puller 15. Long Pin

8. Force Gauge

7

1

14

1113

12

10

2

3

5

9

6

4

15

8



Specifications

Weight ...................................................................................................... 38 kg (84 lb)

Dimensions:

Length ................................................................................................. 29 cm (11.5")

Width ....................................................................................................... 66 cm (26")

Height .................................................................................................. 17 cm (6.75")

Motor:

Voltage ................................................................ 120 VAC, 50/60 Hz, Single Phase

Current Draw at Full Load ........................................................................... 15 Amps

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)

17.8 kN (4000 lb) ................................................................... 3.35 m/min (11 ft/min)

22.2 kN (5000 lb) .................................................................... 3.0 m/min (9.5 ft/min)

Pulling Force:

0 - 17.8 kN (0 -�4000 lb)......................................................... Continuous Operation

28.9 kN - 35.6 kN (6500 - 8000 lb) ........................... 15 minutes on / 15 minutes off

Pulling Rope:

Required Rope ......................... 3/4" diameter, double-braided, polyester composite

Average Breaking Strength ............................................ 89 kN (20,000 lb) minimum



anchoring system

any item or group of items that keeps a cable pullingcomponent in place during the cable pull

capstan

the hollow cylinder of the cable puller that acts on thepulling rope to generate pulling force

coefficient of friction

the ratio that compares two amounts of force:(1) the force needed to move an object over a surfaceand (2) the force holding the object against the surface

This ratio is used to describe how the capstan and therope work together.

connector

any item, such as a wire grip, clevis, swivel, or pullinggrip, that connects the rope to the cable

direct line of pull

the areas next to the pulling rope and along its path;this includes the areas in front of, in back of, and under-neath the rope

maximum rated capacity

the amount of pulling tension that any componentcan safely withstand, rated in kilo-Newtons (metric)or pounds; the maximum rated capacity of everycomponent must meet or exceed the maximum pullingforce of the cable puller

Newton

a metric unit of force, equivalent to .225 pounds of force

pipe adapter sheave

attaches to conduit for pulling or feeding cable

pulling grip

connects the rope to the cable; consists of a wire meshbasket that slides over the cable and grips the insulation

pulling force

the amount of pulling tension developed by the cablepuller, rated in Newtons (metric) or pounds; a cablepuller is usually described by the maximum pulling forcethat it can develop

Cable Pulling Glossary

resultant force

any force that is produced when two or more forces acton an object; applies to the sheaves of a cable pullingsystem

rope ramp

a device that works with a tapered capstan; guides therope onto the capstan to prevent rope overlap

sheave

a pulley that changes the direction of the rope and cable

stored energy

the energy that accumulates in the pulling rope as itstretches, described in Newton-meters (metric) orfoot-pounds

support structure

any stationary object that a cable pulling systemcomponent is anchored to, such as a concrete floor(for the floor mount) or an I-beam (for a sheave)

tactile feedback

the way the rope feels as it feeds off of the capstan; thefeel of the rope provides information about the progressof the pull to the operator

tail

the portion of the rope that the operator applies force to;this is the rope coming off of the capstan, and is notunder the tension of the pull

tailing the rope

the operator’s main function; this is the process ofapplying force to the tail of the pulling rope—see thecomplete explanation under Principles of Cable Pulling

wire grip

connects the rope to the cable; some use a set screw toclamp onto the conductors of the cable



Cable Pulling Principles

Pulling cable is a complex process. This section of themanual describes and explains four main topics ofpulling cable:

• each cable pulling system component

• how these components work together

• forces that are generated

• procedures for the cable puller operator to follow

While reading through this section of the manual, lookfor components that are shaded in the illustrations. Theshading indicates components that are associated withthe text.

Greenlee strongly recommends that each member ofthe cable pulling crew review this section of the manualbefore each cable pull.

Cable Pulling Systems

Pulling cable requires a system of components. At aminimum, a cable pulling system will include a cablepuller, a cable pulling rope, and connectors to join therope to the cable. Most systems will also include, but arenot limited to, a cable puller anchoring system, pullingsheaves and sheave anchoring systems.

The cable puller has a maximum amount of pulling force,which is the amount of pulling tension that it develops.Every other component of the pulling system has amaximum rated capacity, which is the amount of pullingtension that it can withstand. The maximum ratedcapacity of every component must meet or exceed thecable puller’s maximum pulling force.

Typical Cable Pulling System



Cable Pulling Principles (cont’d)

Cable Pulling Theory Illustrated

Pulling Theory

This section introduces the main ideas involved withpulling cable.

Pulling Resistance

The cable puller must overcome two types of resistance:gravity and friction.

Gravity constantly exerts its force on the verticalportions of the run. When the pulling force is relaxed,gravity attempts to pull the cable downward. Frictiondevelops where the cable contacts the sheaves, conduitand tray. Friction resists any movement, forward orbackward, and tends to hold the cables in place.

To accomplish a cable pull, the cable pulling systemmust develop more force than the combination of gravityand friction.

Generating Pulling Force

To generate pulling force, the capstan works as aforce multiplier. The operator exerts a small amountof force on the rope. The cable puller multiplies thisand generates the pulling force.

This pulling force is applied to the rope, connectors,and cable in order to accomplish the pull. The directionof force is changed, where necessary, with pullingsheaves.

Gravity

Weight of Cable

Conduit

Friction

TailingForce

Pulling Force22.2 kN

(5000 lb)




Pulling Force at the Cable Puller’s Anchoring System

Cable Pulling Forces

This section provides detailed explanations and illustra-tions of the forces that are generated during the cablepull. These explanations are based on the conceptspresented in the last section, Pulling Theory.

At the Cable Puller Anchoring System

The cable puller will exert its maximum pulling force oncable puller’s anchoring system. It is extremely importantthe anchoring system can withstand this amount offorce. See the instruction manual provided with youranchoring system for proper setup or installation.

22.2 kN(5000 lb)Maximum22.2 kN

(5000 lb)Maximum

Pulling Force22.2 kN

(5000 lb)

Maximum Pulling Force at Anchoring System




Cable Pulling Forces (cont’d)

At the Capstan

The capstan acts as a force multiplier. The operatorexerts a small amount of tension, or tailing force, on therope; the capstan multiplies this force to pull the cable.The resultant force depends upon the number of timesthe rope is wrapped around the capstan, as shown in theformula below.

Pulling Force = Tailing Force x e0.0175µø

Where: e = the natural logarithm, or 2.7183

µ = the coefficient of friction between therope and the capstan *

ø = the number of degrees of wrap of ropearound the capstan

* The average value for the coefficient of friction whendouble-braided composite rope is pulled over a cleandry capstan is 0.125.

This table shows how the capstan acts as a forcemultiplier. Because the coefficient of friction dependsupon the condition of the rope and capstan, this formulacannot determine an exact amount of pulling force.

The following table is based on the formula above.The input, or tailing force, is constant at 44.5 Newtons(10 lb). Increasing the number of wraps increasesthe pulling force.

The Capstan as a Force Multiplier

Pulling Force: 22.2 kN (5000 lb)

TailingForce

NumberOperator’s of Wraps Approximate

Tailing Force of Rope Pulling Force

1 93.4 N (21 lb)2 213.5 N (48 lb)3 474.9 N (106 lb)

44.5 N (10 lb) 4 1043.8 N (233 lb)5 2293.7 N (512 lb)6 5048.9 N (1127 lb)7 11.1 kN (2478 lb)




Stored Energy


At the Pulling Rope

The product of a force (f) moving through a distance (d)is energy (f x d), and may be measured in Newton-meters or foot-pounds. Energy is stored in a rope whenthe rope is stretched. This is similar to the way energy isstored in a rubber band when it is stretched. Failure ofthe rope or any other component of the pulling systemcan cause a sudden uncontrolled release of the energystored in the rope.

For example, a 100-meter nylon rope with a 50,000Newton average breaking strength could stretch 40meters and store 1,000,000 joules of energy. This is

enough energy to throw a 900-kilogram object, such asa small automobile, 113 meters into the air.

A similar double-braided composite rope could storeapproximately 300,000 joules of energy. This couldthrow the same object only 34 meters into the air.The double-braided composite rope stores much lessenergy and has much less potential for injury if it wereto break.

Double-braided composite rope is the only type of roperecommended for use with the Ultra Tugger 5 cablepuller. Select a double-braided composite rope with anaverage rated breaking strength of at least 143 kN(20,000 lb).

Stored Energy



Cable Pulling Principles (cont’d)Cable Pulling Forces (cont’d)

At the Connectors

The connectors will be subjected to the cable puller’smaximum pulling force.

Several types of rope connectors—clevises, swivels,and rope-to-swivel connectors—are available. Followthe instructions provided with each to provide a goodconnection.

Two types of wire connectors—wire grips and pullinggrips—are available. The wire grip uses a set screwto clamp onto the conductors of the cable. The pullinggrip consists of a wire mesh basket that slides overthe cable and grips the insulation.

When selecting a pulling grip, it is extremely important toselect a grip of the correct (1) type, (2) size, and (3)maximum rated capacity.

1. Select the correct type based on the descriptionsof each type in the Greenlee catalog.

2. Measure the circumference of the wire bundle.(To do this accurately, fasten a tie strap around thebundle. Cut off and discard the tail. Then cut the tiestrap and measure its length.). Use the table providedto find the correct size.

3. See the maximum rated capacities in the Greenleecatalog.

Circumference Range Required Grip Diameter

inches mm inches mm

1.57 - 1.95 39.9 - 49.5 0.50 - 0.61 12.7 - 15.5

1.95 - 2.36 49.5 - 59.9 0.62 - 0.74 15.8 - 18.8

2.36 - 3.14 59.9 - 79.8 0.75 - 0.99 19.1 - 25.1

3.14 - 3.93 79.8 - 99.8 1.00 - 1.24 25.4 - 31.5

3.93 - 4.71 99.8 - 119.6 1.25 - 1.49 31.8 - 37.8

4.71 - 5.50 119.6 - 139.7 1.50 - 1.74 38.1 - 44.2

5.50 - 6.28 139.7 - 159.5 1.75 - 1.99 44.5 - 50.5

6.28 - 7.85 159.5 - 199.4 2.00 - 2.49 50.8 - 63.2

7.85 - 9.42 199.4 - 239.3 2.50 - 2.99 63.5 - 75.9

9.42 - 11.00 239.3 - 279.4 3.00 - 3.49 76.2 - 88.6

11.00 - 12.57 279.4 - 319.3 3.50 - 3.99 88.9 - 101.3

12.57 - 14.14 319.3 - 359.2 4.00 - 4.49 101.6 - 114.0

14.14 - 15.71 359.2 - 399.0 4.50 - 4.99 114.3 - 126.7

Pulling Grip Size TableA Typical Grip Setup—Clevis and Wire Grip

A Typical Grip Setup—Swivel and Pulling Grip

Maximum Pulling Force

22.2 kN(5000 lb)

Maximum Pulling Force

22.2 kN(5000 lb)




Typical Resultant Force at Sheave


At the Sheaves

Sheaves are used to change the direction of the pull.A change in direction creates a new resultant force thatmay be greater than the cable puller’s maximum pullingforce. This new resultant force exerts itself on thesheaves, sheave anchoring system, and support struc-tures illustrated.

The resultant amount of force depends on the angle ofthe change in direction. A brief table is provided here;For details on calculating the resultant force for anyangle, see IM 1363 (999 2998.8).

Resultant Force Table for the Ultra Tugger 5(22.2 kN or 5,000 lb Maximum Pulling Force)

Resultant Force =27.4 kN (6160 lb)

135°

Angle of Change Resultant Forcein Direction in kN (lb)

180° 0 (0)

150° 18.5 (4160)

135° 27.4 (6160)

120° 35.6 (8000)

90° 50.2 (11,300)

60° 61.6 (13,800)

45° 65.8 (14,800)

30° 68.7 (15,400)

0° 71.2 (16,000)

Illustration




Tailing the Rope

The rope must be pulled off of the capstan as the pullprogresses. The rope that has left the capstan is the“tail.” The process of pulling the rope off of the capstanis called tailing the rope.

The resistance of the cable varies throughout theduration of the cable pull. Changes in resistance are dueto characteristics of the rope, changes in conduit direc-tion, and changes in the amount of friction. The “feel” ofthe rope provides this information about the pull. This iscalled tactile feedback. Adjust the tailing force as neces-sary to compensate for these changes.

Control of the Pull

Decreasing the tailing force will decrease the pullingforce, until the rope slips on the capstan and the pullstops. This provides a high level of control over theprogress of the cable pull.

Do not allow the rope to slip on the capstan for morethan a few moments. If it becomes necessary to com-pletely stop a pull, shut off the puller and maintainenough tailing force to hold cable in place. Tie the ropeoff to hold it in place.

Amount of Tailing Force

While the rope and cable are under tension, it is impor-tant to maintain the proper amount of tailing force.

Too little tailing force will allow the rope to slip on thecapstan. This will build up excessive heat and acceleraterope wear, increasing the possibility of breaking therope.

The proper amount of tailing force will stop the rope fromslipping on the capstan and produce a sufficient amountof pulling force to pull in the rope and cable.

Too much tailing force is any amount more than isnecessary to stop the rope from slipping on the capstan.Excessive tailing force will not increase the pulling forceor pulling speed.

Number of Wraps of Rope Around the Capstan

An experienced operator should choose the numbertimes the rope is wrapped around the capstan.

The proper number of wraps allows the operator tocontrol the progress of the pull with a comfortableamount of effort.

Using too few wraps requires a large tailing force toaccomplish the pull. Using too few wraps also makes therope more likely to slip on the capstan. This builds upheat and accelerates rope wear.

Using too many wraps causes the rope to grab thecapstan tighter. This accelerates rope wear, wastespower, and increases the possibility of a rope overlap.Using too many wraps also reduces tactile feedback, soyou receive less information about the pull. You cannotquickly relax the tailing force when there are too manywraps.

If the rope becomes difficult to tail, add another wrap ofrope. Turn off the puller and release all of the tension inthe rope. Add a wrap and resume pulling. Be aware,however, that some pulls will require tension to holdthe cables in place. In these cases, do not attempt torelease all of the tension and add a wrap of rope. Youwill need to anticipate the number of wraps beforestarting the pull.

Preventing Rope Overlap

Do not allow the rope to become overlapped on thecapstan during a pull.

A rope overlap will make it will impossible to continue orback out of the pull.

If the rope becomes overlapped, you will lose control ofthe pull—the rope will advance with no tailing force andwill not feed off of the capstan. The capstan will not allowyou to reverse the direction of the rope, so you cannotback out of an overlap.

Set up the puller properly. The rope ramp and taperedcapstan are intended to prevent rope overlap. See theinstructions in the Operation section of this manual.

Every wrap of the rope must remain in direct contact withthe capstan. During the pull, take great care to preventthe incoming rope from riding up and overlapping thenext wrap. If an overlap begins to develop, immediatelyrelax the tailing force on the rope so that the rope canfeed back toward the conduit or tray.When the rope resumes its normal path, apply tailingforce and continue the pull.

There is no suggested remedy for a rope overlap.Do not allow the rope to overlap!




Summary of Cable Pulling Principles

• A cable pulling system consists of many componentsthat work together to accomplish a pull.

• The cable puller is rated by its maximum pullingforce; every other component is rated by its maximumrated capacity. The maximum rated capacity of everycomponent must meet or exceed the maximum pullingforce of the cable puller.

• The cable puller must overcome two types of resis-tance: gravity and friction. The puller’s capstan, thepulling rope, and the operator tailing the rope worktogether to produce pulling force.

• The cable puller exerts force on every component ofthe cable pulling system, including the anchoringsystems and the support structures.

• Energy is stored in a rope when the load causesthe rope to stretch. Failure of the rope or any othercomponent can cause a sudden release of energy.Replace any rope that is worn or damaged.

• Carefully select the number or wraps of rope aroundthe capstan before starting the pull.

• Control the pull by tailing the rope. Be familiar with theinteraction of the rope and capstan.

• Do not allow a rope overlap to develop.

• Pull in a direction that will require the lowest amountof pulling force.

• Plan several shorter pulls rather than fewer longerpulls.

• Locate the puller as close to the end of the conduit aspossible to minimize the amount of exposed ropeunder tension.

• Place each component so that the pulling forces areused effectively.

• Select an anchoring system: adapter sheaves, whichare preferred, or the floor mount.

• Verify that each component has the proper load rating.

• Inspect the structural supports. Verify that they haveenough strength to withstand the maximum forces thatmay be generated.

Planning the Pull



Typical Setups

Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view ofthe meter and quick access to its ON/OFF switch.

02846 Chain MountSecured to Steel Conduit or Pipe

Floor MountSecured to a Concrete Floor



Typical Setups (cont’d)

T-StandPulling Horizontally Using One Boom Tube,

Nose Unit and Slip-in Coupler

T-StandPulling Up Using One Boom Tube, Nose Unit and Slip-in Coupler

T-StandPulling Horizontally Using Two Boom Tubes, Nose Unit,

Elbow Unit and Slip-in Coupler




Wheeled CarriagePulling Up Using One Boom, Nose Unit and Slip-in Coupler

Wheeled CarriagePulling Up Using Two Booms, Nose Unit,


Wheeled CarriagePulling Horizontally in Manhole Using Two Booms, Nose Unit,


Wheeled CarriagePulling Horizontally in Manhole Using Two Booms,

Nose Unit, Elbow Unit and Slip-in Coupler


Typical Setups (cont’d)



Requires: Exposed metallic pull conduit of least63.5 mm (2-1/2") diameter

When setting up the pipe adapter,do not use the vise chains on astructural support that is less than51 mm (2") or more than 254 mm(10") wide. An oversized or under-sized structural support can allowthe puller to slide or break loose andstrike nearby personnel.


Do not mount the pipe adapter to thefollowing:

• steel conduit less than 65 mm(2-1/2”) in diameter

• PVC conduit of any size

These conduits will not support theloads imposed by the puller.


1. Remove the sheave from the frame.

2. Position the frame against the conduit.

Setup—Pipe Adapter

Sheave

Sheave Shaft

Hitch Pin Clip

Frame

NO

NO

As of 2006, the pipe adapter has been discontinued and replaced by the 11147 boom adapter.This information is reference for existing units.

Mount pipe adapter only to conduitto be pulled from.




Setup—Pipe Adapter (cont’d)

4. Rotate the vise chain handles, by hand, clockwiseto tighten the chain. Do not use tools, extensions or“cheaters.”

5. Put the sheave back onto the frame. Install the pinand hitch pin clip.Note: If the 18" sheave interferes with existingstructures, install a 12" sheave (Greenlee 00843).

3. On each vise chain unit:

a. Rotate the vise chain handle counterclockwise toexpose most of the threads. Leave only three orfour threads engaged in the handle.

b. Insert the chain into the slot in the frame. Wrapthe chain around the conduit, pipe sheaveadapter, or structural element.

c. Set the positioner against the positioning blocksthat protrude from the frame.

d. Pull the vise chain tight and insert the chain pinsinto the chain pockets, or recesses.

e. Turn the handle clockwise to slightly tighten thechain.

Install the vise chains properly.

• Follow the vise chain tightening instructionscarefully. Improperly tightened chains can allowthe puller to slide or break loose and strike nearbypersonnel.

• Do not allow the vise chains to bind at the cornerswhen mounting the puller to a square or rectangu-lar support. The vise chain must be uniformly tightat all points.


Positioner

PositioningBlock

(not shown)

ChainPockets

(not shown)

Sheave Shaft

Hitch Pin Clip

Frame

Sheave



Setup—Pipe Adapter (cont’d)

6. Align the puller so that the gearbox will fit into thecradle of the pipe adapter AND the puller mountingplates straddle the pipe adapter mounting plates.

7. Install two pins from the motor side. Secure the pinswith two hitch pin clips.

Adapter Mounting

Plates

PullerMounting

Plates

GearboxCradle

Install Hitch Pins from Motor Side

Install Hitch Pin Clips on Capstan Side



Setup (cont’d)

T-Stand

Requires: Adequate clearance. See Typical SetupsIllustrated.

1. Set the puller on the floor with the mounting holesupward.

2. Position the boom mount so that the puller gearboxwill fit into the cradle of the boom mount and thepuller mounting plates straddle the boom mountplates.

3. Mount the boom mount to the puller.


5. Align the two sets of holes in the T-stand with thetwo sets of holes in the boom mount.

6. Install two pins. Secure the pins with hitch pin clips.

7. Continue with Setup: Mounting Components later inthis manual.

Boom MountPlates

Boom Mount

Cradle

Gearbox

PullerMounting

Plates

Install Hitch Pin Clips on Capstan Side

Install Hitch Pins from Motor Side

T-Stand

Insert Pins Here



Setup (cont’d)

Wheeled Carriage

Requires: Adequate clearance. See Typical SetupsIllustrated.

1. Mount the boom mount to the wheeled carriage.Align the boom mount holes with the top holes in thewheeled carriage, as illustrated. Install a pin throughthe boom mount and wheeled carriage. Secure thepin with a hitch pin clip.

2. Position the puller’s gearbox above the boom mountcradle. Align the puller so that the puller mountingplates straddle the boom mount plates. Lower thepuller onto the boom mount. Install two pins from themotor side. Secure the pins with two hitch pin clips.

3. Check the right angle sheave support tube to besure it is fastened with the pin.

4. Rotate the puller and boom mount as shown. Whenthe second hole in the boom mount is aligned withthe second hole in the wheeled carriage, install apin. Secure the pin with a hitch pin clip.

Removable Pin



Setup (cont’d)

Mounting Components

Boom with Nose Unit

Use these boom tubes only:

• boom tubes supplied with the Ultra Tugger 5

• 3" rigid steel conduit (3 meters or 10 feet maximum)

• 3" Schedule 40 pipe (3 meters or 10 feet maximum)

1. Slide the boom tube into the boom mount until thetube bottoms out. Sight the tube through the sighthole to be sure the tube is fully inserted. Tighten theset screw.

2. Slide the nose unit onto the tube until the tubebottoms out. Sight the tube through the sight hole tobe sure the tube is fully inserted. Tighten the setscrew.

• Use only straight 3" diameter rigid steel conduit orSchedule 40 steel pipe for the boom tubes.

• Do not use boom tubes longer than 3 meters (10').Longer booms may bend or break.


Set up the elbow unit as shown.Improper setup will cause the elbowunit to collapse.


STRAIGHT EDGE

Sight Hole

Sight Hole



Setup (cont’d)

Mounting Components (cont’d)

Booms with Elbow Unit and Nose Unit

Use these boom tubes only:

• boom tubes supplied with the Ultra Tugger 5

• 3" rigid steel conduit (3 meters or 10 feet maximum)

• 3" Schedule 40 pipe (3 meters or 10 feet maximum)

1. Slide the boom tube into the boom mount until thetube bottoms out. Sight the tube through the sighthole to be sure the tube is fully inserted. Tighten theset screw.

2. Slide the elbow unit onto the tube until the tubebottoms out. Sight the tube through the sight hole tobe sure the tube is fully inserted. Tighten the setscrew.

3. Adjust the elbow to an appropriate angle and lock itin place with a pin. Secure the pin with a hitch pinclip.

4. Slide the boom tube into the elbow unit until the tubebottoms out. Sight the tube through the sight hole tobe sure the tube is fully inserted. Tighten the setscrew.

5. Slide the nose unit onto the tube until the tubebottoms out. Sight the tube through the sight hole tobe sure the tube is fully inserted. Tighten the setscrew.

• Use only straight 3" diameter rigid steel conduit orSchedule 40 steel pipe for the boom tubes.

• Do not use boom tubes longer than 3 meters (10').Longer booms may bend or break.


Set up the elbow unit as shown.Improper setup will cause the elbowunit to collapse.


STRAIGHT EDGE

Sight Hole

Sight Hole

Sight Hole



Setup (cont’d)

Mounting Components (cont’d)

Slip-in Coupler

Requires: One pin to connect to Nose Unit

1. Select the coupler that best fits the conduit.

2. Slide the coupler into the conduit until the couplerseats on the end of the conduit.Note: If the coupler doesn’t seat on the conduit,see Straddling the Conduit with a Slip-In Coupler.

Straddling the Conduit with Slip-in Coupler

Requires: Two pins to connect to Nose Unit

1. Select a coupler at least 25 mm (1") larger than theconduit.

2. Place the coupler over the conduit.Note: Do not use this method if the coupler doesnot seat on a support structure that can support22.2 kN (5000 lb) of force.

3. Slide the nose unit over the coupler. Align any set ofholes and insert one pin. Secure the pin with a hitchpin clip.Note: If possible, add a second pin and hitch pin clip.

3. Slide the nose unit over the coupler. Align any twosets of holes and insert two pins. Secure the pinswith hitch pin clips.

PullConduit

Coupler

Coupler must seat on the Conduit here

PullConduit

Coupler

Conduit must not protrudepast here

SupportStructure

Nose Unit

Coupler

Pin secured with Hitch Pin Clip

Pull Conduit

Coupler

Conduit must not protrude past here

SupportStructure



Setup (cont’d)Chain Mount

Requires: Exposed metallic conduit with the followingcharacteristics:

• 63.5 – 254 mm (2-1/2" – 10") in diameter

• capable of withstanding at least 22.5 kN (5,000 lb)of force

Install the vise chains properly.

• Follow the vise chain tightening instructionscarefully. Improperly tightened chains can allowthe puller to slide or break loose and strike nearbypersonnel.

• Do not allow the vise chains to bind at the cornerswhen mounting the puller to a square or rectangu-lar support. The vise chain must be uniformly tightat all points.


When setting up the pipe adapter,do not use the vise chains on astructural support that is less than51 mm (2") or more than 254 mm(10") wide. An oversized or under-sized structural support can allowthe puller to slide or break looseand strike nearby personnel.


Do not mount the pipe adapter to thefollowing:

• steel conduit less than 63.5 mm(2-1/2") in diameter

• PVC conduit of any size

These conduits will not support theloads imposed by the puller.


Do not pull between the 10 o’clock and 2 o’clockdirections. Pulling between 10 o’clock and 2 o’clockcan damage the mounting conduit.

12O’CLOCK

1

2

3

11

10

9

6O’CLOCK

PULLINGROPE

PULLLOAD

TAILINGROPE

VISE CHAINS

SUPPORT

NO

NOFailure to observe this warning could result insevere injury or death.



Setup (cont’d)

Chain Mount (cont’d)

1. On each vise chain unit:

a. Rotate the vise chain handle counterclockwise toexpose most of the threads. Leave only three orfour threads engaged in the handle.

b. Wrap the chain around the conduit.

c. Pull the vise chain tight and insert the chain pinsinto the chain pockets, or recesses.

d. Turn the handle clockwise to slightly tighten thechain.

2. Set the puller into the cradle of the chain mount.




Setup (cont’d)Floor Mount

Requires: A concrete floor with the followingcharacteristics:

• fully cured structural-type concrete

• minimum compressive strength of 211 kg/cm2

(3000 psi)

• free of cracks, crumbling, or patchwork

Installation

Greenlee recommends using Greenlee 35607 WedgeAnchors. If another type of anchor is used, they musthave an ICBO (International Conference of BuildingOfficials) allowable tension and shear rating of 10.7 kN(2400 lb) in 211 kg/cm2 (3000 psi) concrete.

1. Assemble the nut and washer to the anchor so thetop of the nut is flush with the top of the anchor, asshown.

2. Insert the four anchors through the floor mount andinto the holes in the floor.

3. Hammer the anchors in until the washer is in firmcontact with the floor mount.

4. Expand the anchors by torquing the nuts to 122 to128 Newton-meters (90 to 95 ft-lb).

5. Have the installation checked by a qualifiedinspector.

1. Determine the best position for locating the floormount. 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 theamount of exposed rope under tension

• so that the pull rope will approach the puller’scapstan at a 90° (± 5°) angle.

2. Set the floor mount in the desired location. Use thefloor mount as a template to drill four 5/8" holes atleast 152 mm (6") deep.Note: Use a 5/8" carbide-tipped masonry bitmanufactured in accordance with ANSI standardB94.12-77.

3. Vacuum the debris from the holes.

If any of the four anchors spin before the minimumtorque is achieved, abandon the location and startelsewhere. An improperly installed anchor canallow the puller to break loose.


Follow all floor mounting instructions carefully.

• An improperly attached floor mount can comeloose and strike nearby personnel.

• Do not attach the floor mount to masonry, brick,or cinder block. These materials will not hold theanchors securely.


at least 152 mm (6")



90°

Top ofAnchor

Nut

Washer



Operation

1. Fish the rope through the conduit.

2. Set up the cable puller. See Typical Setups illustra-tions and instructions in this manual.

Duty Cycle Table

ColorBand Pounds of Alarm Duty Cycle

on Meter Pulling Force (in minutes)

Green 0-4000 off continuousYellow 4000 - 5000 on 15 on / 15 off

Red over 5000 on puller will stop

3. Set the rope ramp as follows:

a. Wind the rope several times around the capstan.

b. Pull the ramp away from the mounting plate androtate it until Surface A contacts the rope.

c. Push the ramp toward the mounting plate androtate it counterclockwise until it locks into place.

4. Check the ON/OFF switch on the puller to be sure itis OFF. Plug the puller into the receptacle of thestandard force gauge.

5. Connect the force gauge to an appropriate powersupply (see Grounding Instructions in this manual).Note: If using an extension cord, it must be ratedfor 20 amps. Use the shortest cord possible. Longercords reduce puller speed.

6. Position the force gauge so that it can be monitoredby the puller operator.

7. Turn the circuit breaker in the force gauge ON.

8. Grasp the tailing end of the rope. Apply a slightamount of tailing force.

9. Turn the puller ON.

10. Tail the rope, allowing the spent rope to accumulateon 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.

90° (±5°)

Surface A

Pull Side

Set up the cable puller so that the rope willapproach the capstan at an angle of 90° (±5°).Angles outside of this range may cause the ropeto overlap.




Removing Cable

Removing old cable involves the same principles asinstalling new cable. However, there are some importantdifferences.

Pulling Force

It is difficult to predict the amount of pulling force neces-sary to remove an old cable. The cable may be damaged,and it may break with an unexpectedly low pulling force.

The required pulling forces may be very high:

• The cable has probably “taken a set.” Unlike the newcable on a reel, cable in conduit has probably beenin the conduit for years, or perhaps decades. Thecable will resist bending and straightening as it ispulled through the conduit.

• The pulling lubricant has probably hardened,increasing pulling resistance.

• The insulation may be damaged and the cable maybe corroded.

• Dirt or other foreign matter may have entered theconduit and may have cemented the cable in place.

Using a Force Gauge

When pulling old cable out of a conduit, the pulling forcewill be highest when starting the pull. Select a cablepuller and pulling components to meet or exceed theestimated amount of pulling force necessary to removethe old cable. Because breaking the cable free willrequire the largest amount of pulling force, it is necessaryto use a force gauge to prevent overloading the systemcomponents. Select either the 01069 Standard ForceGauge or the 00967 Deluxe Force Gauge.

Carefully monitor the pulling force at the force gauge;if the puller is not able to begin the pull, shut off thepuller and disassemble the setup. Start over with apuller and components of a higher force rating.

Puller Placement

Pulling out old cable is generally accomplished with thepuller located some distance away from the end of theconduit. This allows the pulling crew to pull out a longsection of cable before turning off the puller, cutting offthe cable, and reattaching the grip(s). Mounting thecable puller a distance away from the end of the conduitincreases the amount of exposed rope, which greatlyincreases the amount of violent whipping action whichwould occur if the rope were to break.

To isolate the operator from the rope path:

• Locate the puller so that you will stand behind anobstruction, such as a wall. Set up the puller so thatyou will be able to maintain control of the pull. Youneed a clear view of the rope as it feeds onto thecapstan, including several feet of the rope in front ofthe capstan. You must be able to turn off the pullerbefore the pulling grip, connector, or swivel contactsthe capstan.

• Use an additional pulling sheave to change thedirection of the tailing rope. Anchor the sheave sothat you are close enough to maintain control of thepull. You need a clear view of the rope as it feedsonto the capstan, including several feet of the ropein front of the capstan. You must be able to turn offthe puller before the pulling grip, connector, or swivelcontacts the capstan.

Note: Use the additional pulling sheave to change thedirection of the tailing rope (after the rope leaves thecapstan). Do not change the direction of the pulling rope.

• Use a longer tailing rope than usual and stand awayfrom the puller. Stand as far from the puller aspossible, while maintaining control of the pull. Youneed a clear view of the rope as it feeds onto thecapstan, including several feet of the rope in front ofthe capstan. You must be able to turn off the pullerbefore the pulling grip, connector, or swivel contactsthe capstan.



Motor Removal

See Exploded View – 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 atrear of motor.

4. Pull the motor off of the tail housing (3).

5. Pull off commutator brush assembly (1, 2 and 4).

6. Pull off magnet housing (5).

7. Pull out armature (6).

8. Remove screw holding the air vent protectivescreen. Remove protective screen.

Motor Assembly Notes

1. Apply gasket sealant between gearbox housing andthe outside of the front armature housing.

2. If the armature does not turn freely after installation,the wrong gear teeth were engaged.

3. Hold armature in place when installing the magnethousing. Position magnet housing with the roll pinoutward and pointed towards 8 o’clock. The squarehole of the mounting plate should be positioned at10 o’clock.

4. Install commutator brush assembly. Wires should beat the 9 o’clock position.

5. Insert magnet housing roll pin into the recess on thetail housing.

Capstan Removal

1. Use a 1-inch 18 point socket to remove capstanretaining bolt (11) and washer (19).

2. Pull the capstan (2) off of the shaft.

If the capstan is stuck: Pull out the rope ramp.Use two pry bars on opposite sides of the capstanbetween the gear housing and the capstan.

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 Texaco® Regal AFBor equivalent.

Specific Service Notes

• Average brush life for commutator brushes is about100 hours. Replace brushes if they are shorterthan 9.5 mm (3/8").

• Replace rope ramp if it is grooved more than6.5 mm (1/4").

• Replace the capstan if it is grooved more than0.15 mm (1/16").

• The puller should not require any lubrication duringits normal service life.

Switchbox Removal

1. Remove the four hex head cap screws (12)and nuts (13) that secure the clamp (6) to theswitchbox (5).

2. Remove the clamp and pull switchbox from themotor.

3. Disconnect the white and black motor leads fromthe rectifier.

4. Unscrew the green ground wire from the motor.

5. Remove switchbox.

Switchbox Assembly Notes

1. If replacing the rectifier, use a heat conductive pastebetween the rectifier and the switchbox.

2. Connect the white motor lead to the positive (+)terminal on the rectifier. Connect the black motorlead to the negative (–) terminal.

Maintenance should be performed by authorizedpersonnel only.

The first reduction hub will be damaged if the leadsare reversed.

Do not pry against the grease seal. Doing so willdamage the seal.

Maintenance

3. Secure motor leads to motor using tie-wraps. Makesure the wires will not contact the commutator.

4. Position the switchbox and clamp so that the ventholes are towards the rear of the motor.

3. Remove key (24).

4. Remove rope ramp (3).

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 theshaft.



Disassembly of Planet Gear Carriers

1. Remove the flat head screws.

2. Tap or pry off the hub plate from the hub and dowelpins.

3. Remove the thrust washers, gears, thrust washersand shaft.

4. Remove sun gear ONLY if replacement is required.

Planet Gear Carrier Assembly

1. Place the shafts in the hub. The end with the flatshould face outward.

2. The 1st planet reduction gears must be positionedwith the gear end towards the capstan.

3. When replacing the 1st reduction gear bearing/clutch, the locked arrow direction must be counter-clockwise (when viewed from the gear end).

4. When replacing the ball bearing on the outputshaft, the thick side of the outer race must facethe capstan.

5. Use a removable thread locking compound, suchas Loctite 242 Threadlocker or equivalent, on the#10 – 32 flat head screws (items 35 and 36 on thegearmotor). Follow the manufacturer’s instructionsfor curing.

Maintenance (cont’d)

Right Angle Sheave Bracket Removal

1. Remove detent pin (22).

2. Slide arm towards motor. Use a small punch toremove the roll pin (20).

3. Remove bracket (4).

Gearbox Disassembly

1. Remove motor, capstan and right angle sheavebracket.

2. Remove the screws (38) on the motor side of thegearbox. Remove the mounting plate (20).

3. Remove the motor mounting housing (2).

4. Pull out the 1st reduction planet gear assembly andthrust washer.

5. Pull out the center shaft (12).

6. Pull out the 2nd reduction planet gear assembly andthrust washer.

7. Push out the output shaft/3rd reduction gear assem-bly and thrust washer.

8. Remove the screws holding the ring gear (37).

9. Tap the bearing housing off the ring gear and dowelpins. Do not mar the mating surface to the ringgear.

Gearbox Assembly Note

1. Clean all ring mating surfaces. Apply a flangesealant (Loctite 515 or equivalent) to all ring matingsurfaces.

2. Install center shaft with the small diameter towardsthe motor.

3. Install the mounting plates. When viewed from themotor end, the motor mounting studs should bepositioned at 1 and 7 o’clock. The square hole inthe mounting plate should be between 10 and 11o’clock.

4. Position mounting plates so the screw heads onthe capstan side fit into the counterbores of themounting plates.



Exploded View and Wiring Diagram – Ultra Tugger 5

23 2526

27

BLACK

BLACK

BLACK BLACK

RED RED

WHITE

WIRING DIAGRAM

MOTOR

10

1

2

3

4

5

6

7

8

9

11

12

13

15

16, 17

18

19

20

20

21

2224

26

27

28, 29

14



Parts List—Ultra Tugger 5 (50150006)

Key Part No. Description Qty

1 50111990 Gearmotor ......................................................................................... 1

2 50007440 Capstan ............................................................................................. 1

3 50007513 Ramp, rope........................................................................................ 1

4 50007416 Bar, tie ............................................................................................... 1

5 50007491 Switchbox .......................................................................................... 1

6 50007505 Clamp ................................................................................................ 1

7 50353110 Sheave, right angle ........................................................................... 1

8* 50007432 Puller pin ........................................................................................... 2

9 50008757 Cord unit, power ................................................................................ 1

10 50006690 Capacitor unit .................................................................................... 1

11 90548485 Screw, cap, 3/4 – 16 x 1.500" hex head, Grade 5 ............................. 1

12 90502787 Screw, cap, #6 – 32 x .500" socket head .......................................... 4

13 90548493 Nut, hex, #6 – 32 ............................................................................... 4

14 90522036 Screw, machine, #6 – 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 90533305 Screw, machine, #8 – 32 x .328" hex head, green ............................ 1

24 90548515 Key, square, .375" x 1.88" ................................................................. 1

25 50008765 Wire unit ............................................................................................ 1

26 91871328 Switch / circuit breaker ...................................................................... 1

27 91868130 Rectifier, 50 Amp, bridge ................................................................... 1

28 90541243 Bushing, strain relief .......................................................................... 1

29 91862639 Nut, conduit, 1/2" lock ....................................................................... 1

Repair Kit

* 50061887 Kit, puller pin (includes one each ofthe items marked with an asterisk) .................................................... 2

Decals

50010298 Decal, warning ................................................................................... 1

50010590 Decal, read IM ................................................................................... 1

99935767 Decal, technical assistance ............................................................... 1



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

315

10

29

22

15

29

6

33 24

35

24

31

7

33

35

3130

21

30

9

13

8

12

32

18

39

2

20

38

19

14

34



Parts List—Gearmotor (50006460)Key Part No. Description Qty

1 50006657 Bearing housing ................................................................................ 1

2 50006630 Motor mount ...................................................................................... 1

3 50006576 Output hub......................................................................................... 1

4 50006584 Output hub plate ................................................................................ 1

5 50006622 2nd reduction hub ............................................................................. 1

6 50006592 2nd reduction hub plate ..................................................................... 1

7 50111949 1st reduction hub ............................................................................... 1

8 50111957 1st reduction hub plate ...................................................................... 1

9 50006487 1st reduction shaft ............................................................................. 3

10 50006495 2nd reduction shaft ............................................................................ 3

11 50006509 3rd reduction shaft ............................................................................. 4

12 50111973 Center shaft ....................................................................................... 1

13 50111795 1st reduction planet gear ................................................................... 3

14 50006533 2nd reduction sun gear ..................................................................... 1

15 50006541 2nd reduction planet gear ................................................................. 3

16 50006550 3rd reduction sun gear ...................................................................... 1

17 50006568 3rd reduction planet gear .................................................................. 4

18 50006614 Ring gear ........................................................................................... 1

19 50111965 Motor ................................................................................................. 1

20 50006665 Motor 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 90548310 Thrust washer, .510 x 1.00 x .020" .................................................... 4

31 90548337 Thrust washer, .260 x .50 x .030" ...................................................... 8

32 90534719 Dowel pin, .250 x 1.250" ................................................................... 6

33 90541036 Dowel pin, .312 x .625" ..................................................................... 9

34 50111787 Gear, 1st reduction ............................................................................ 1

35 90548345 Screw, cap, #10–32 x .500", socket flat head ................................... 5

36 90548353 Screw, cap, #10–32 x .750", socket flat head ................................... 4

37 90548361 Screw, cap, 1/4 – 28 x 2.00", socket head ........................................ 6

38 90501535 Screw, cap, 1/4 – 28 x 1.500", socket head ...................................... 6

39 90521080 Nut, hex, 1/4 – 20 .............................................................................. 2

Repair Kits

50022920 Gearmotor repair group #1(includes 3, 4, 11, 17, 23, 24[2], 29[2], 33, 36)

50022954 Gearmotor repair group #2(includes 5, 6, 10, 15, 16, 22, 24, 29[2], 34, 35)

50051075 Gearmotor repair group #3(includes 7-9, 13, 14, 21, 24, 30[2], 31, 34, 35)



Exploded View and Parts List—Motor (50006649)


1 91867053 Commutator brushes ......................................................................... 2

2 91867061 Commutator brush retention spring ................................................... 1

3 91865590 Tail housing ....................................................................................... 1

4 91865603 Brush assembly plate ........................................................................ 1

5 50051083 Magnet housing ................................................................................. 1

6 50051091 Armature............................................................................................ 1

7 90543483 Belleville washers .............................................................................. 2

8 91860717 Bearing .............................................................................................. 1

9 91869218 Screen ............................................................................................... 1

10 91869145 Threaded rod ..................................................................................... 2

1

2

3

6

7

8

5

4

1010

9



Exploded View and Parts List—Force Gauge (50011198)


1 50371088 Box lower ........................................................................................... 12 50371070 Box, upper ......................................................................................... 13 50297082 Guard, switch .................................................................................... 14 50112015 Meter ................................................................................................. 15 50371703 Cord, power ....................................................................................... 16 50371622 Wire unit, 12 AWG x 3.00", black ...................................................... 17 50371630 Wire unit, 12 AWG x 7.00", black ...................................................... 18 50371649 Wire unit, 12 AWG x 4.00", green ..................................................... 19 90539346 Bumper, #8 – 32 machine screw, rubber .......................................... 4

10 90506332 Nut, hex, #8 – 32 ............................................................................... 411 90531949 Screw, self-tapping, #10 – 16 x .250 Phillips head............................ 612 90522036 Screw, machine, #6 – 32 x .25", slotted pan head ............................ 213 90514408 Screw, machine, #8 – 32 x .375", round head .................................. 214 91866847 Receptacle, 20 amp female............................................................... 115 90541243 Bushing, strain relief .......................................................................... 116 91863830 Switch ................................................................................................ 117 91862639 Nut, conduit, 1/2" lock ....................................................................... 118 90537254 Screw, cap, #6 – 32 x .750", socket button head .............................. 319 90506324 Nut, hex, #6 – 32 ............................................................................... 3

Decals503 0392.9 Decal, damp warning......................................................................... 1500 5100.8 Decal, identification ........................................................................... 1

11

876

3

12

2

14

16

15

5

17

FORCE INDICATOR

CONNECTOR

A

SWITCH

POWER CORD

BLAC

KBL

ACK

BLAC

K

GREE

N

WHI

TE

4

10

19

18

1

1314

9



AccessoriesSlip-in Couplers


— 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 or Rigid only ........................................ 1

2 50007815 Screw-on coupler for 2-1/2" IMC or Rigid only .................................. 1


2 50007831 Screw-on coupler for 3-1/2" IMC or Rigid only .................................. 1


3 50007998 Adapter for screw-on IMC or Rigid only ............................................ 1

4 50008773 Screw assembly (includes items 5, 6 and 7) ..................................... 2

5 50007955 Screw............................................................................................ 1

6 50007963 Handle .......................................................................................... 1

7 90527178 Roll pin .......................................................................................... 1


1 50008048 Slip-in coupler for 2-1/2" conduit (EMT, IMC or Rigid) ...................... 1

1 50008110 Slip-in coupler for 3" conduit (EMT, IMC or Rigid) ............................ 1

1 50008153 Slip-in coupler for 3-1/2" conduit (EMT, IMC or Rigid) ...................... 1



3

5

4

7

6

8

9

1

2

Screw-on Couplers

Boom Tubes


8 50008358 3' Boom tube ..................................................................................... 1

9 50007912 4' Boom tube ..................................................................................... 1



Accessories (cont’d)

T-Stand (50008676)

Wheeled Carriage (50008706)


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 Clip, hitch pin #8 ................................................................................ 2

8 90515285 Retaining ring, .750", Truarc #5160-75-S-PP.................................... 4

9 50010638 Decal, warning................................................................................... 1

Repair Kit

* 50061887 Kit, puller pin (includes one eachof the items marked with an asterisk) ............................................ 2

8

4

4

3

1

28

4

4

9

65

7




Boom Mount (50008714)


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, idler ................................................................................. 1

8 50167987 Bushing ............................................................................................. 2

9 50010310 Decal, warning ................................................................................... 1

Repair Kits

* 50061887 Kit, puller pin (includes one each of theitems marked with an asterisk ) ..................................................... 2

+ 50061917 Kit, shaft (includes one each of theitems marked with a plus sign) ...................................................... 1

19

6

3

3

8

7

2

4

3

4

5




Nose Unit (50008641)


1 50008323 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


8 90548388 Bushing ............................................................................................. 2

9 50010425 Decal, warning ................................................................................... 1

Repair Kit

* 50061887 Kit, puller pin (includes one each ofthe items marked with an asterisk) ................................................ 2

50061925 Kit, elbow shaft (includes one of item 3 and two of item 5) ............... 2

8

2

1

9

4

5

6

3

7




Elbow Unit (50008633)


1 50008323 Elbow, adjustable .............................................................................. 1

2 50008285 Elbow, pivot ....................................................................................... 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


9 90548388 Bushing ............................................................................................. 2

10 50013971 Lanyard ............................................................................................. 1

11 50010328 Decal, warning................................................................................... 1

Repair Kits

* 50061941 Kit, elbow pins (includes one each ofthe items marked with an asterisk) ................................................ 1

50061950 Kit, pivot pins (includes one of item 4 and two of item 6) .................. 1

3

1

2

8

115

7

4

6

8

9

6

10




Floor Mount (50008650)


1 50007890 Frame ................................................................................................ 1

2 50356070 Anchor, wedge, .625 x 6.00" ............................................................. 4

3 50010476 Decal, warning ................................................................................... 1

3

1

2



USA 800-435-0786 Fax: 800-451-2632 815-397-7070 Fax: 815-397-1865Canada 800-435-0786 Fax: 800-524-2853International +1-815-397-7070 Fax: +1-815-397-9247

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.

www.greenlee.com Printed in USA


Chain Mount (50008668)


1 50111639 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 50256615 Screw unit, vise chain ........................................................................ 2

50010514 Decal, warning (not shown) ............................................................... 1

12

3

4

5

999 5029.4 #1 - cableorganizer.com...the greenlee ultra tugger 5 cable puller is intended to be used...

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