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Greenlee Tugger 640 User Manual

Greenlee Tugger 640
42 pages
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640-Series
Tugger
®
Cable Pullers
Effective with Serial Code YJ for 115 Volt Pullers
and Serial Code ACR for 220 Volt Pullers
INSTRUCTION MANUAL
99997657 © 2006 Greenlee Textron Inc. IM 1076 REV 14 2/06
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Questions and Answers:

Greenlee Tugger 640 Specifications

General IconGeneral
BrandGreenlee
ModelTugger 640
CategoryPower Tool
LanguageEnglish

Summary

Description of the Tugger

Purpose of this Manual

General Safety Overview

Important Safety Information

Safety Symbol and Signal Word Definitions

Explains safety alert symbol and signal words (DANGER, WARNING, CAUTION).

Critical Operational Dangers

Addresses DANGER warnings for reading instructions and operating in hazardous environments.

Electrical and Mechanical Hazards

Covers WARNINGs related to electric shock, anti-reverse mechanisms, and component integrity.

System and Rope Safety Warnings

Details WARNINGs for component inspection, rope whip, capstan, and rope condition.

Usage, Component, and Personal Safety

Focuses on WARNINGs for proper use, worn parts, entanglement, and eye protection.

Grounding Instructions

120-Volt Model Grounding

Specifies grounding requirements for the 120-volt model, including GFCI circuit and plug connection.

220-Volt Model Grounding

Specifies grounding requirements for the 220-volt model, including GFCI circuit and plug connection.

Identification

Tugger Component Identification

Illustrates and labels the various components of the Tugger for identification purposes.

Specifications

Cable Pulling Glossary

Cable Pulling Principles

Cable Pulling Systems Overview

Describes the essential components of a cable pulling system and their requirements.

Pulling Theory and Forces

Explains gravity, friction, and how the capstan generates pulling force.

Capstan Force Multiplication

Details how the capstan multiplies force based on rope wraps and friction, with a table.

Stored Energy in the Pulling Rope

Discusses stored energy in the rope and recommends specific rope types for safety.

Connectors and Sheave Forces

Covers connector selection, size tables, and how sheaves create resultant forces.

Tailing the Rope and Control

Details tailing force, rope wraps, and preventing rope overlap for safe operation.

Planning the Pull

Provides guidelines for planning cable pulls to ensure efficiency and safety.

Typical Setups

Using 11147 Adapter Package

Illustrates horizontal and vertical pulling setups with the 11147 adapter package.

Manhole Sheave, Feeding Sheaves, and Floor Mount

Shows setups for manhole sheave, feeding sheaves in manholes, and floor mount configurations.

Setup and Operation

Rope Approach and Vise Chain Installation

Details correct rope approach angle and vise chain installation with warnings.

Rope Path and Tailing

Illustrates rope paths and instructs on tailing the rope for controlled pulling.

Duty Cycle Table

Presents a table detailing duty cycles based on pulling force and alarm indicators.

Removing Cable

Pulling Force, Gauge Use, and Placement

Covers force estimation, using a force gauge, and safe puller placement for old cable removal.

Dual Pulling

Maintenance

Service Schedule and Lubrication

Outlines maintenance schedule, chain lubrication, and drivetrain shaft greasing.

Inspection Procedures

Details inspection of chains, ratchet pawl, and commutator brushes for wear.

Frame Replacement and Electrical Troubleshooting

Guides on frame replacement and troubleshooting electrical circuits using continuity checks.

Troubleshooting

Problem, Cause, and Remedy Table

Lists common puller problems, their probable causes, and recommended remedies.

Parts List

Torque Specifications and Main Components

Lists torque specs and illustrates major parts of the cable puller.

Detailed Parts Listing

Provides a comprehensive list of part numbers, descriptions, and quantities.

Decals

Lists specific decals available for the Tugger unit.

Gear-Motor Unit Exploded View

Motor and Gearbox Parts List

Lists parts for the motor and gearbox assembly, including part numbers and quantities.

Force Gauge Unit (120V) Exploded View

Force Gauge Unit (120V) Parts List

Details parts for the 120-volt force gauge unit, including part numbers and quantities.

Force Gauge Unit (220V) Exploded View

Force Gauge Unit (220V) Parts List

Lists parts for the 220-volt force gauge unit, including part numbers and quantities.

Tugger Wiring Diagram

Force Gauge Wiring Diagram

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