Greenlee Tugger 640 Bedienungsanleitung

640-Series

Tugger®

Cable Pullers

Effective with Serial CodeYJ for 115 Volt Pullers

and Serial Code ACR for 220 Volt Pullers

INSTRUCTION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

Description ..................................................................... 2

Purpose of this Manual .................................................. 2

Important Safety Information ....................................... 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 ..............................30-39

Wiring Diagrams......................................................40-41

Table of Contents

KEEP THIS MANUAL

All specifications are nominal and may change as design improve-

ments occur. Greenlee Textron Inc. shall not be liable for damages

resulting from misapplication or misuse of its products.

Mobilgrease is a registered trademark of Mobil Oil Corporation.

Description

The Greenlee Tugger®cable puller is intended to be

used to pull cable through conduit and in tray. The

Tugger will develop 17.8 kilo-Newtons (4000 lb) of

pulling force. See a Greenlee catalog for sheaves,

pulling rope, and other cable pulling accessories rated

for use with the 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.

Safety

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This instruction manual

and any markings on the tool provide information for

avoiding hazards and unsafe practices related to the use

of this tool. Observe all of the safety information provided.

Purpose of this Manual

This manual is intended to familiarize operators and

maintenance personnel with the following Greenlee

640-series cable pullers:

120-Volt Models: 640

642

676

686

220-Volt Models: 640-22

642-22

686-22

This manual should be kept available to operating and

maintenance personnel.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

IMPORTANT SAFETY INFORMATION

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.

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.

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.

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.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Hazards which, if not avoided, COULD result in

severe injury or death.

Immediate hazards which, if not avoided, WILL

result in severe injury or death.

SAFETY

ALERT

SYMBOL

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

IMPORTANT SAFETY INFORMATION

Inspect all components of the cable-

pulling 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 cable-

pulling forces may break and strike

nearby personnel with great force.

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.

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 17.8 kN (4000 lb)

• Average Breaking Strength:

at least 71.2 kN (16,000 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.

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.

• 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.

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

IMPORTANT SAFETY INFORMATION

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.

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.

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.

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.

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.

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.

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 17.8 kN (4000 lb). An under-rated con-

nector can break under tension.

Failure to observe this warning could result in

severe injury or death.

Wear eye protection when using this

tool.

Failure to wear eye protection could

result in severe eye injury from

flying debris.

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.

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

Grounding Instructions

Electric shock hazard.

• Do not modify the plug provided

with the tool.

• Connect this tool to a grounded

receptacle on a 20-amp GFCI-

protected 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.

220-Volt Model

20 Amp/125 Volt

Plug and Receptacle

ReceptaclePlug

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.

10 Amp/250 Volt

Plug and Receptacle

ReceptaclePlug

Electric shock hazard.

• Do not modify the plug provided

with the tool.

• Connect this tool to a grounded

receptacle on a 10-amp GFCI-

protected circuit.

Failure to observe these warnings

could result in severe injury or death.

120-Volt Model

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

Identification

7. Handle/Cleat

8. Right-Angle Idler Sheave

9. Tapered Capstan

10. Rope Ramp

11. Pivoting Capstan Arm

12. Positioning Peg

1. Entrapment Peg

2. Capstan Chain Guard

3. Guarded ON/OFF Switch

and Circuit Breaker

4. Motor

5. Motor Chain Guard

6. Force Gauge with ON/OFF Switch

(optional)

Tugger Identification

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

Mass/Weight ....................................................................................30.8 kg (68 lb)

Dimensions:

Length........................................................................................ 533 mm (21")

Width .......................................................................................... 533 mm (21")

Height ......................................................................................... 305 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............................................................... 17.8 kN (4000 lb)

Speed:

No load .................................................... 10.7 meters/minute (35 feet/minute)

8900 Newtons (2000 lb) .......................... 4.88 meters/minute (16 feet/minute)

17.8 kN (4000 lb) ....................................... 1.83 meters/minute (6 feet/minute)

Duty Cycle:

0 - 11.1 kN (0 - 2500 lb)................................................. Continuous Operation

11.1 - 15.6 kN (2500 - 3500 lb)

(alarm will sound) .............................................15 minutes on / 15 minutes off

15.6 - 17.8 kN (3500 - 4000 lb)

(alarm will sound) ...............................................5 minutes on / 15 minutes off

Pulling Rope:

Average breaking strength .................................71.2 kN (16,000 lb) minimum

Specifications

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

anchoring system

any item or group of items that keeps a cable pulling

component in place during the cable pull

capstan

the hollow cylinder of the cable puller that acts on the

pulling 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 surface and

(2) the force holding the object against the surface

This ratio is used to describe how the capstan and the

rope work together.

connector

any item, such as a wire grip, clevis, swivel, or pulling

grip, 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

underneath the rope

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

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 mesh

basket that slides over the cable and grips the insulation

pulling force

the amount of pulling tension developed by the cable

puller, rated in Newtons (metric) or pounds; a cable

puller is usually described by the maximum pulling force

that it can develop

resultant force

any force that is produced when two or more forces act

on an object; applies to the sheaves of a cable pulling

system

rope ramp

a device that works with a tapered capstan; guides the

rope onto the capstan to help 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 it

stretches, described in Newtons-meters (metric) or

foot-pounds

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)

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

tailing the rope

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

wire grip

connects the rope to the cable; some use a set screw to

clamp onto the conductors of the cable

Cable Pulling Glossary

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger®Cable Pullers

Cable Pulling Principles

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.

Cable Pulling Systems

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

pulling force

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 maximum rated

capacity of every component must meet or exceed the

cable puller’s maximum pulling force.

Typical Cable Pulling System

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