Greenlee 640 Tugger User Manual

Essential information for safe operation, requiring manual understanding and employer instruction.

Details the built-in safety mechanisms of the Tugger, such as anti-reversing capstan and guarded controls.

Instructions for planning a pull, emphasizing safety and proper setup.

Explains the 'force multiplier' effect of the capstan and its relation to tailing force and rope wraps.

Guidance on preplanning a pulling system, considering factors like segment length, direction, and crew communication.

Detailed steps for securely mounting the Tugger cable puller to a fixed support.

Instructions on operating the Tugger, including rope feeding, tension adjustment, and safety checks.

Information on managing the tailing rope, including hazards and proper handling to prevent injury.

Procedure for lubricating drive chains every 20 hours using 80W-90W gear oil.

Instructions for inspecting chain drive condition, checking for free play and wear every 40 hours.

Applying multipurpose grease to drive train shafts every 20 hours.

Lubricating the ratchet pawl (anti-reversing mechanism) every 40 hours.

Checking commutator brush length every 40 hours and replacing if less than 3/8 inch.

Troubleshooting steps for when the motor fails to operate, checking connections and components.

Diagnosing issues when the motor runs but the capstan does not rotate, checking chain and gears.

Detailed steps for replacing the motor, including chain and sprocket removal and reinstallation.

Procedure for replacing a non-functional switch without removing the motor unit.

Steps for replacing damaged #35 or #40 chains, or frame components.