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Greenlee Super Tugger 6000 Series User Manual

Greenlee Super Tugger 6000 Series
98 pages
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6000-Series
Super Tugger
®
Cable Pullers
Effective with Serial Code YF 2000 for 115 Volt Pullers
and Serial Code ACN 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.
99971194 © 2019 Greenlee Tools, Inc. IM 970 REV 40 2/19
Español ............... 29
Français .............. 57

Table of Contents

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Greenlee Super Tugger 6000 Series Specifications

General IconGeneral
BrandGreenlee
ModelSuper Tugger 6000 Series
CategoryWinches
LanguageEnglish

Summary

Description

Safety

Purpose of this Manual

IMPORTANT SAFETY INFORMATION

SAFETY ALERT SYMBOL

Explanation of symbols used to denote hazards and their severity levels.

Signal Word Definitions

Definitions of DANGER, WARNING, and CAUTION signal words and their associated hazard levels.

Specific Hazard Warnings

Detailed warnings regarding component inspection, rope usage, operating procedures, and entanglement hazards.

Grounding Instructions

Identification

Specifications

Cable Pulling Glossary

Cable Pulling Principles

Cable Pulling Systems

Components required for a cable pulling system and the relationship between component capacity and puller force.

Pulling Theory

Explanation of pulling resistance (gravity, friction) and how the capstan generates pulling force.

Cable Pulling Forces

Detailed explanations and illustrations of forces generated during cable pulls, covering various components and concepts.

Tailing the Rope

Process of pulling rope off the capstan and adjusting tailing force for control.

Summary of Cable Pulling Principles

Key takeaways summarizing the principles of cable pulling systems and their components.

Planning the Pull

Steps and considerations for effective planning of a cable pulling operation.

Typical Setups

using 11147 Adapter Package

Illustrations of horizontal pulling setups using specific adapter package components.

Typical Setups (cont'd)

using 11147 Adapter Package (cont'd)

Illustrations of vertical pulling setups using specific adapter package components.

Typical Setups (cont'd)

Using a Manhole Sheave

Illustration of a setup using a manhole sheave with a generator.

Using Feeding Sheaves in Manholes

Illustrations of setups for feeding sheaves in manholes.

Using a Floor Mount

Illustration of a setup using a floor mount for the cable puller.

Setup and Operation

Vise Chain Installation

Step-by-step instructions for properly installing and tightening the vise chains for mounting.

Setup and Operation (cont'd)

Rope Path, Top View

Illustration showing the correct rope path and component alignment for preventing overlap.

Rope Path, Side View

Illustration showing the correct rope path and component alignment for preventing overlap.

Duty Cycle Table

Table detailing duty cycle limits based on pulling force and meter color bands.

Removing Cable

Puller Placement

Guidance on positioning the puller and operator for safe removal of old cable.

Dual Pulling

Maintenance

Lubricating the Drive Chains

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

Greasing the Drivetrain Shafts

Instructions for greasing drivetrain shafts using multipurpose NLGI Grade 2 grease.

Maintenance (cont'd)

Inspecting the Chains and Ratchet Pawl

Procedure for inspecting chains for wear and play, and checking the ratchet pawl function.

Inspecting the Commutator Brushes

Procedure for inspecting and measuring commutator brushes for wear.

Maintenance (cont'd)

Replacing the Frame

Detailed steps for disassembling and replacing the puller frame, including part replacement.

Troubleshooting the Electrical Circuit

Procedure for checking electrical continuity using a continuity checker and wiring diagram.

Troubleshooting

Exploded View

Exploded View (cont'd)

Parts List

Parts List (cont'd)

Parts List (cont'd)

Exploded View (Motor and Gearbox)

Parts List (Motor and Gearbox)

Exploded View (Force Gauge Unit)

Parts List (Force Gauge Unit)

Exploded View (Force Gauge Unit)

Parts List (Force Gauge Unit)

Wiring Diagram

Wiring Diagrams