attachment 1 piping detail m100

ATTACHMENT 1
PIPING DETAIL M100
MULE ROPE INSTALLATION
M100
ATTACHMENT 2
MMSD SELECTED RECORD DRAWINGS
ATTACHMENT 3
GREENLEE TUGGER O&M INFORMATION
INSTRUCTION MANUAL
Effective with Serial Code YF 2000 for 115 Volt Pullers
and Serial Code ACN for 220 Volt Pullers
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99971194
© 2006 Greenlee Textron Inc.
IM 970 REV 38 3/06
6000-Series Super Tugger® Cable Pullers
Table of Contents
Description
The Greenlee Super Tugger® cable puller is intended to
be used to pull cable through conduit and in tray. The
Super Tugger will develop 28.9 kN (6500 lb) of pulling
force. See a Greenlee catalog for sheaves, pulling rope,
and other cable pulling accessories rated for use with the
Super Tugger to create an entire cable pulling system.
No single manual can provide instructions for every
cable pulling application. This manual contains general
information for pulling cable. Illustrations of some typical
setups are also provided.
Description ..................................................................... 2
Purpose of this Manual .................................................. 2
Important Safety Instructions ...................................... 3-5
Grounding Instructions ................................................... 6
Identification ................................................................... 7
Specifications ................................................................. 8
Cable Pulling Glossary ................................................... 9
Cable Pulling Principles .......................................... 10-18
Cable Pulling Systems ........................................... 10
Pulling Theory ........................................................ 11
Cable Pulling Forces ........................................ 12-16
Tailing the Rope .................................................... 17
Summary of Cable Pulling Principles .................... 18
Planning the Pull .......................................................... 18
Typical Setups ......................................................... 19-21
Setup and Operation ............................................... 22-23
Removing Cable........................................................... 24
Dual Pulling .................................................................. 25
Maintenance ............................................................ 26-28
Troubleshooting ........................................................... 29
Exploded Views and Parts Lists .............................. 30-41
Wiring Diagrams...................................................... 42-43
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any decals on the tool provide information for avoiding
hazards and unsafe practices related to the use of this
too. Observe all of the safety information provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
Greenlee 6000-series Super Tugger® cable pullers.
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Super Tugger is a registered trademark of Greenlee Textron
Mobilgrease is a registered trademark of Mobil Oil Corporation.
Greenlee / A Textron Company
2
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
SAFETY
ALERT
SYMBOL
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.
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury
or property damage. The signal word, defined
below, indicates the severity of the hazard. The
message after the signal word provides information
for preventing or avoiding the hazard.
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.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Electric shock hazard:
Disconnect the cable puller from
the power supply before servicing.
Failure to observe this warning could
result in severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Inspect all components of the cablepulling system. 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 cablepulling forces may break and strike
nearby personnel with great force.
Failure to observe this warning could
result in 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 could 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 could
result in severe injury or death.
An under-rated rope may break and whip violently.
Use a double-braided composite rope with the
following characteristics:
Maximum Rated Capacity:
at least 28.9 kN (6500 lb)
Average Breaking Strength:
at least 115.6 kN (26,000 lb)
Failure to observe this warning could result in severe
injury or death.
Do not stand directly under a vertical
pull. Cable could fall suddenly from the
conduit, injuring nearby personnel.
Failure to observe this warning could
result in severe injury or death.
Do not operate puller if the anti-reverse mechanism
is not working. If you do not hear the clicking of
the anti-reversing pawl when the capstan is rotating,
shut the puller off and have it repaired by an
authorized Greenlee service center.
Failure to observe this warning could result in severe
injury or death.
Greenlee / A Textron Company
Check the condition of the entire rope before use.
A worn or damaged rope can break under tension
and whip violently.
Do not maintain a stationary rope on a rotating
capstan. The wear generated may cause the rope
to break under tension and whip violently.
Failure to observe these warnings could result in
severe injury or death.
4
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Do not operate without chain guards
in place.
Failure to observe this warning could
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 at least 28.9 kN (6500 lb). An under-rated connector can break under tension.
Failure to observe this warning could result in severe
injury or death.
Use this tool for manufacturer s 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 could 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 could
result in severe injury or death.
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 great force.
Failure to observe this warning could result in
severe injury or death.
Do not wrap rope around hands,
arms, waist or other body parts.
Do not stand in spent coils or tailed
rope. Hold rope so that it may be
released quickly.
Failure to observe this warning could
result in severe injury or death.
Entanglement hazard:
Do not operate the cable puller while wearing
loose-fitting clothing.
Retain long hair.
Failure to observe these warnings could 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 could result in
serious injury or death.
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in severe eye injury from
flying debris.
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 could result in severe
injury or death.
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Grounding Instructions
220-Volt Model
120-Volt Model
Electric shock hazard.
Do not modify the plug provided
with the tool.
Connect this tool to a grounded
receptacle on a 10-amp GFCIprotected circuit.
Failure to observe these warnings
could result in severe injury or death.
Electric shock hazard.
Do not modify the plug provided
with the tool.
Connect this tool to a grounded
receptacle on a 20-amp GFCIprotected circuit.
Failure to observe these warnings
could 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.
This tool s electric cord has a grounding conductor
and a grounding plug as shown. Do not modify the
plug. Connect the plug to a corresponding receptacle
that is properly installed and grounded in accordance
with all national and local codes and ordinances.
Do not use an adapter.
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.
This tool s electric cord has a grounding conductor
and a grounding plug as shown. Do not modify the
plug. Connect the plug to a corresponding receptacle
that is properly installed and grounded in accordance
with all national and local codes and ordinances.
Do not use an adapter.
20 Amp/125 Volt
10 Amp/250 Volt
Plug and Receptacle
Plug and Receptacle
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Identification
Super Tugger Identification
1.
2.
3.
4.
5.
6.
Greenlee / A Textron Company
Entrapment Peg
Capstan Chain Guard
Handle
Guarded ON/OFF Switch
and Circuit Breaker
Motor
Motor Chain Guard
7.
8.
9.
10.
11.
12.
13.
7
Force Gauge with ON/OFF Switch
Handle/Cleat
Right-Angle Idler Sheave
Tapered Capstan
Rope Ramp
Pivoting Capstan Arm
Positioning Peg
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Specifications
Weight: ............................................................................................. 41.7 kg (92 lb)
Dimensions:
Length .................................................................................. 52.7 cm (20-3/4")
Width .................................................................................... 57.2 cm (22-1/2")
Height ........................................................................................ 30.5 cm (12")
Power (120-Volt Model)
:
Voltage ................................................................................... 120 VAC, 60 Hz
Current ................................................................................................ 17 Amps
Source ............................................................ 20 Amp GFCI-Protected Circuit
Power (220-Volt Model):
Voltage ................................................................................... 220 VAC, 50 Hz
Current ............................................................................................... 7.5 Amps
Source ............................................................ 15 Amp GFCI-Protected Circuit
Maximum Pulling Force: .............................................................. 28.9 kN (6500 lb)
Speed:
No load ...................................................... 5 meters/minute (16.5 feet/minute)
8900 Newtons (2000 lb) ............................ 3.4 meters/minute (11 feet/minute)
17.8 kN (4000 lb) ...................................... 2.3 meters/minute (7.5 feet/minute)
Duty Cycle:
0 - 22.2 kN (0 - 5000 lb) ................................................. Continuous Operation
22.2 - 24.5 kN (5000 - 5500 lb)
(alarm will sound) .............................................15 minutes on / 15 minutes off
24.5 - 28.9 kN (5500 - 6500 lb)
(alarm will sound) ............................................... 5 minutes on / 15 minutes off
Pulling Rope:
Average Breaking Strength .............................. 115.6 kN (26,000 lb) minimum
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Glossary
anchoring system
pulling force
any item or group of items that keeps a cable pulling
component in place during the cable pull
the amount of pulling tension developed by the cable
puller, rated in Newtons (metric) or pounds; a cable
puller is usually described by the maximum pulling force
that it can develop
capstan
the hollow cylinder of the cable puller that acts on the
pulling rope to generate pulling force
resultant force
coefficient of friction
any force that is produced when two or more forces act
on an object; applies to the sheaves of a cable pulling
system
the ratio that compares two amounts of force:
(1) the force needed to move an object over a surface and
(2) the force holding the object against the surface
rope ramp
a device that works with a tapered capstan; guides the
rope onto the capstan to help prevent rope overlap
This ratio is used to describe how the capstan and the
rope work together.
sheave
connector
a pulley that changes the direction of the rope and cable
any item, such as a wire grip, clevis, swivel, or pulling
grip, that connects the rope to the cable
stored energy
direct line of pull
the energy that accumulates in the pulling rope as it
stretches, described in Newtons-meters (metric) or
foot-pounds
the areas next to the pulling rope and along its path;
this includes the areas in front of, in back of, and underneath the rope
support structure
any stationary object that a cable pulling system
component is anchored to, such as a concrete floor
(for the floor mount) or an I-beam (for a sheave)
maximum rated capacity
the amount of pulling tension that any component
can safely withstand, rated in kilo-Newtons (metric)
or pounds; the maximum rated capacity of every
component must meet or exceed the maximum pulling
force of the cable puller
tail
the portion of the rope that the operator applies force to;
this is the rope coming off of the capstan, and is not
under the tension of the pull
Newton
tailing the rope
a metric unit of force, equivalent to .225 pounds of force
attaches to conduit for pulling or feeding cable
the operator s main function; this is the process of
applying force to the tail of the pulling rope see the
complete explanation under Principles of Cable Pulling
pulling grip
wire grip
connects the rope to the cable; consists of a wire mesh
basket that slides over the cable and grips the insulation
connects the rope to the cable; some use a set screw to
clamp onto the conductors of the cable
pipe adapter sheave
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles
Cable Pulling Systems
Pulling cable is a complex process. This section of
the manual describes and explains four main topics
of pulling 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, look
for components that are shaded in the illustrations. The
shading indicates components that are associated with
the text.
Greenlee strongly recommends that each member of the
cable pulling crew review this section of the manual
before each cable pull.
Pulling cable requires a system of components. At a
minimum, a cable pulling system will include a cable
puller, a cable pulling rope, and connectors to join the
rope to the cable. Most systems will also include, but are
not limited to, a cable puller anchoring system, pulling
sheaves and sheave anchoring systems.
The cable puller has a maximum amount of
,
which is the amount of pulling tension that it develops.
Every other component of the pulling system has a
maximum rated capacity, which is the amount of pulling
tension that it can withstand. The
of every component must meet or exceed the
cable puller s maximum pulling force.
Typical Cable Pulling System
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Pulling Theory
To accomplish a cable pull, the cable pulling system
must develop more force than the combination of gravity
and friction.
This section introduces the main ideas involved with
pulling cable.
Generating Pulling Force
To generate pulling force, the capstan works as a
The operator exerts a small amount
of force on the rope. The cable puller multiplies this
and generates the pulling force.
This pulling force is applied to the rope, connectors,
and cable in order to accomplish the pull. The direction
of force is changed, where necessary, with pulling
sheaves.
Pulling Resistance
The cable puller must overcome two types of resistance:
gravity and friction.
Gravity constantly exerts its force on the vertical
portions of the run. When the pulling force is relaxed,
gravity attempts to pull the cable downward. Friction
develops where the cable contacts the sheaves, conduit
and tray. Friction resists any movement, forward or
backward, and tends to hold the cables in place.
Cable Pulling Theory Illustrated
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Cable Pulling Forces
At the Cable Puller Anchoring System
The cable puller will exert its maximum pulling force on
cable puller s anchoring system. It is extremely important
the anchoring system can withstand this amount of
force. See the instruction manual provided with your
anchoring system for proper setup or installation.
This section provides detailed explanations and illustrations of the forces that are generated during the cable
pull. These explanations are based on the concepts
presented in the previous section, Pulling Theory.
Pulling Force at the Cable Puller s Anchoring System
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Cable Pulling Forces (cont d)
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 increases
the pulling force.
At the Capstan
The capstan acts as a
The operator
exerts a small amount of tension, or tailing force, on the
rope; the capstan multiplies this force to pull the cable.
The resultant force depends upon the number of times
the rope is wrapped around the capstan, as shown in the
formula below.
Operator s
Tailing Force
Pulling Force = Tailing Force x e0.0175µø
Where:
e = the natural logarithm, or 2.7183
µ = the coefficient of friction between the
rope and the capstan *
44.5 N (10 lb)
ø = the number of degrees of wrap of rope
around the capstan
* The average value for the coefficient of friction when
double-braided composite rope is pulled over a clean
dry capstan is 0.125.
Number
of Wraps
of Rope
Approximate
Pulling Force
1
2
3
4
5
6
7
93.4 N (21 lb)
213.5 N (48 lb)
474.9 N (106 lb)
1043.8 N (233 lb)
2293.7 N (512 lb)
5048.9 N (1127 lb)
11.1 kN (2478 lb)
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.
The Capstan as a Force Multiplier
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Cable Pulling Forces (cont d)
Double-braided composite rope is the only type of rope
recommended for use with the Super Tugger cable
puller. Select a double-braided composite rope with an
average rated breaking strength of at least 115.6 kN
(26,000 lb).
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 Newtonmeters or foot-pounds. Energy is stored in a rope when
the rope is stretched. This is similar to the way energy is
stored in a rubber band when it is stretched. Failure of
the rope or any other component of the pulling system
can cause a sudden uncontrolled release of the energy
stored in the rope.
For example, a 100-meter nylon rope with a
50,000 Newton average breaking strength could
stretch 40 meters and store 1,000,000 joules
of energy. This is enough energy to throw a
900-kilogram object, such as a small automobile,
113 meters into the air.
A similar double-braided composite rope could store
approximately 300,000 joules of energy. This could
throw the same object only 34 meters into the air.
The double-braided composite rope stores much less
energy and has much less potential for injury if it were to
break.
Stored Energy
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
When selecting a pulling grip, it is extremely important
to select a grip of the correct (1) type, (2) size, and (3)
maximum rated capacity.
1. Select the correct type based on the descriptions
of each type in the Greenlee catalog.
2. Measure the circumference of the wire bundle.
(To do this accurately, fasten a tie strap around the
bundle. Cut off and discard the tail. Then cut the tie
strap and measure its length.) Use the table provided to find the correct size.
3. See the maximum rated capacities in the Greenlee
catalog.
Cable Pulling Forces (cont d)
At the Connectors
The connectors will be subjected to the cable puller s
maximum pulling force.
Several types of rope connectors clevises, swivels,
and rope-to-swivel connectors are available. Follow
the instructions provided with each to provide a good
connection.
Two types of wire connectors wire grips and pulling
grips are available. The wire grip uses a set screw
to clamp onto the conductors of the cable. The pulling
grip consists of a wire mesh basket that slides over
the cable and grips the insulation.
A Typical Grip Setup Clevis and Wire Grip
Pulling Grip Size Table
A Typical Grip Setup Swivel and Pulling Grip
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Resultant Force Table for the Super Tugger
(28.9 kN or 6500 lb Maximum Pulling Force)
Cable Pulling Forces (cont d)
At the Sheaves
Sheaves are used to change the direction of the pull.
A change in direction creates a new
that
is
the cable puller s maximum pulling force.
This new resultant force exerts itself on the sheaves,
sheave anchoring system, and support structures
illustrated.
The resultant amount of force depends on the angle of
the change in direction. A brief table is provided here;
for more details, see IM 1363 (99929988).
180°
0 (0)
150°
15 (3380)
135°
22.3 (5005)
120°
28.9 (6500)
90°
40.8 (9165)
60°
50.0 (11,245)
45°
53.5 (12,025)
30°
55.8 (12,545)
0°
57.8 (13,000)
Typical Resultant Force at Sheave
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Cable Pulling Principles (cont d)
Tailing the Rope
Number of Wraps of Rope Around the Capstan
An experienced operator should choose the number of
times the rope is wrapped around the capstan.
The proper number of wraps allows the operator to
control the progress of the pull with a comfortable
amount of effort.
Using
wraps requires a large tailing force to
accomplish the pull. Using too few wraps also makes the
rope more likely to slip on the capstan. This builds up
heat and accelerates rope wear.
Using
wraps causes the rope to grab the
capstan more tightly. This accelerates rope wear, wastes
power, and increases the possibility of a rope overlap.
Using too many wraps also reduces tactile feedback, so
you receive less information about the pull. You cannot
quickly relax the tailing force when there are too many
wraps.
If the rope becomes difficult to tail, add another wrap of
rope. Turn off the puller and release all of the tension in
the rope. Add a wrap and resume pulling. Be aware,
however, that some pulls will require tension to hold the
cables in place. In these cases, do not attempt to
release all of the tension and add a wrap of rope. You
will need to anticipate the number of wraps before
starting the pull.
The rope must be pulled off of the capstan as the pull
progresses. The rope that has left the capstan is the
tail . The process of pulling the rope off of the capstan
is called
The resistance of the cable varies throughout the
duration of the cable pull. Changes in resistance are due
to characteristics of the rope, changes in conduit direction, and changes in the amount of friction. The feel of
the rope provides this information about the pull. This is
called
. Adjust the tailing force as necessary to compensate for these changes.
Control of the Pull
Decreasing the tailing force will decrease the pulling
force, until the rope slips on the capstan and the pull
stops. This provides a high level of control over the
progress of the cable pull.
Do not allow the rope to slip on the capstan for more
than a few moments. If it becomes necessary to completely stop a pull, shut off the puller and maintain
enough tailing force to hold cable in place. Tie the rope
off to hold it in place.
Amount of Tailing Force
While the rope and cable are under tension, it is important to maintain the proper amount of tailing force.
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.
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.
Greenlee / A Textron Company
Preventing Rope Overlap
Do not allow the rope to become overlapped on the
capstan during a pull.
A rope overlap will make it impossible to continue or
back out of the pull.
If the rope becomes overlapped, you will lose control of
the pull the rope will advance with no tailing force and
will not feed off of the capstan. The capstan will not allow
you to reverse the direction of the rope, so you cannot
back out of an overlap.
Set up the puller properly. The positioning peg, entrapment peg, rope ramp and tapered capstan are intended
to prevent rope overlap. See the instructions in the
Operation section of this manual.
Every wrap of the rope must remain in direct contact with
the capstan. During the pull, take great care to prevent
the incoming rope from riding up and overlapping the
next wrap. If an overlap begins to develop, immediately
relax the tailing force on the rope so that the rope can
feed back toward the conduit or tray. When the rope
resumes its normal path, apply tailing force and continue
the pull.
There is no suggested remedy for a rope overlap.
Do not allow the rope to overlap!
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Planning The Pull
Cable Pulling Principles (cont d)
Summary of Cable Pulling Principles
Pull in a direction that will require the lowest amount of
pulling force.
Plan several shorter pulls rather than fewer longer pulls.
Locate the puller as close to the end of the conduit as
possible to minimize the amount of exposed rope
under tension.
Place each component so that the pulling forces are
used effectively.
Select an anchoring system: adapter sheaves, which
are preferred, or the floor mount.
Verify that each component has the proper load rating.
Inspect the structural supports. Verify that they have
enough strength to withstand the maximum forces that
may be generated.
A cable pulling system consists of many components
that work together to accomplish a pull.
The cable puller is rated by its maximum pulling force;
every other component is rated by its maximum rated
capacity. The maximum rated capacity of every
component must meet or exceed the maximum pulling
force of the cable puller.
The cable puller must overcome two types of resistance: gravity and friction. The puller s capstan, the
pulling rope, and the operator tailing the rope work
together to produce pulling force.
The cable puller exerts force on every component of
the cable pulling system, including the anchoring
systems and the support structures.
Energy is stored in a rope when the load causes the
rope to stretch. Failure of the rope or any other component can cause a sudden release of energy. Replace
any rope that is worn or damaged.
Carefully select the number or wraps of rope around
the capstan before starting the pull.
Control the pull by tailing the rope. Be familiar with the
interaction of the rope and capstan.
Do not allow a rope overlap to develop.
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Typical Setups using 11147 Adapter Package
Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view of
the meter and quick access to its ON/OFF switch.
Pulling Horizontally in Manhole
Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler
Pulling Horizontally in Manhole
Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler
Greenlee / A Textron Company
19
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Typical Setups using 11147 Adapter Package (cont d)
Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view of
the meter and quick access to its ON/OFF switch.
Pulling Up Using One Boom,
Nose Unit and Slip-in Coupler
Pulling Up Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler
Greenlee / A Textron Company
20
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Typical Setups (cont d)
Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view
of the meter and quick access to its ON/OFF switch.
Using a Manhole Sheave
Using Feeding Sheaves in Manholes
Using a Floor Mount
Greenlee / A Textron Company
21
4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Setup and Operation
While reading through this section of the manual, look
for components that are shaded in the illustrations. The
shading indicates components that are associated with
the accompanying text.
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 could result in severe
injury or death.
1. Fish the rope through the conduit.
2. Set up the cable puller mounting. Set it up so that the
rope will approach the capstan at an angle of 90° (±5°)
as illustrated in Rope Approaching the Capstan.
Rope Approaching the Capstan
3. Install the vise chains as shown.
Vise Chain Installation
a. Rotate the vise chain handle to expose most of
the threads. Leave only three or four threads
engaged in the handle.
b. Thread the chain though the hole in the frame.
Set the positioner against the positioning blocks.
c. Wrap the chain around the conduit, pipe sheave
adapter, or structural element.
d. Pull the vise chain tight and insert the chain pins
into the chain pockets, or recesses.
e. Turn the handle to slightly tighten the chain.
f. Repeat Steps A - E for the other chain.
When setting up the flexible pipe
adapter or puller, do not use the vise
chains on a structural support that
is less than 51 mm (2") or more than
254 mm (10") wide. An oversized
or undersized structural support
can allow the puller to slide or break
loose and strike nearby personnel
with sufficient force to cause severe
injury or death.
Greenlee / A Textron Company
4. Rotate the vise chain handles, by hand, clockwise to
fully tighten the chain. Do not use tools, extensions
or cheaters .
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070
6000-Series Super Tugger® Cable Pullers
Setup and Operation (cont d)
5. Align the rope ramp and route the rope as illustrated
in Rope Path, Top View and Rope Path, Side View.
6. Check the ON/OFF switch on the puller to be sure
it is OFF. Plug the puller into the receptacle of the
standard force gauge. Plug the force gauge into an
appropriate power supply (see Grounding Instructions in this manual).
Rope Path, Top View
7. Position the force gauge so that it can be monitored
by the puller operator.
Duty Cycle Table
Color
Band
on Meter
Pounds of
Pulling Force
Alarm
Duty Cycle
(in minutes)
Green
Yellow
Yellow
Red
0-5000
5000 - 5500
5500 - 6500
over 6500
off
on
on
on
continuous
15 on / 15 off
5 on / 15 off
puller will stop
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 to the T-shaped cleat and anchor
the cable.
Rope Path, Side View
Greenlee / A Textron Company
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4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070