Greenlee 35346, Instruction Manual

Page 1: ...s Inc IM 1081 REV 5 3 19 35346 Capstan Retrofit Kit for Super Tugger Models 6000 6001 and 6006 With Serial Code Prefix VB or VT Read and understand all of the instructions and safety information in this manual before operating or servicing this tool ...

Page 2: ...p 28 9 kN 6500 lb of pulling force The Capstan Retrofit Kit is intended to improve early Super Tugger cable pullers with VB or VT serial code The main components of the kit are a capstan unit which consists of a tapered capstan and rope ramp and capstan arm These features are intended to enhance the safety of the Super Tugger See a Greenlee catalog for sheaves pulling rope and other cable pulling ...

Page 3: ...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 o...

Page 4: ...wivel 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 w...

Page 5: ... 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 ...

Page 6: ...lled and grounded in accordance with all national and local codes and ordinances Do not use an adapter 220 Volt Model 15 Amp 125 Volt Plug and Receptacle 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 ele...

Page 7: ... 397 7070 Identification 8 Tapered Capstan 9 Rope Ramp 10 Pivoting Capstan Arm 11 Positioning Peg 1 Entrapment Peg 2 Capstan Chain Guard 3 Handle 4 Motor 5 Motor Chain Guard 6 Force Gauge with ON OFF Switch 7 Handle Cleat Super Tugger Identification shown with Retrofit Kit installed 1 2 3 4 9 10 11 8 7 6 5 ...

Page 8: ... 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 m min 16 5 ft min 8900 newtons 2000 lb 3 4 m min 11 ft min 17 8 kN 4000 lb 2 3 m min 7 5 ft min Duty Cycle 0 22 2 kN 0 5000 lb Continuous Operation 22 2 24 5 kN 5000 5500 lb 15 minutes on 15 minutes off 24 5 28 9 kN 5500 6500 lb 5 minutes o...

Page 9: ...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 for...

Page 10: ... 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...

Page 11: ... where the cable contacts the sheaves conduit and tray Friction resists any movement forward or backward and tends to hold the cables in place To accomplish a cable pull the cable pulling system must develop more force than the combination of gravity and friction Generating Pulling Force To generate pulling force the capstan works as a force multiplier The operator exerts a small amount of force o...

Page 12: ...re based on the concepts presented in the previous section Pulling Theory Cable Pulling Principles cont d 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 ins...

Page 13: ... 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 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 following tab...

Page 14: ...he 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 ...

Page 15: ... 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 Circumference Range Required Grip Diameter inches mm inches mm 1 57 1 95 39 9 49 5 0 50 0 61 12 7 15 5 ...

Page 16: ... 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 999 2998 8 Resultant Force Table for the Super Tugger 28 9 kN or 6500 Lb Maximum Pulling Force Resultant Force 22 3 kN 5005 lb...

Page 17: ...umber of wraps allows the operator to control the progress of the pull with a comfortable amount of effort Using too few 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 too many wraps causes the rope to grab the capstan more tightly This accelerates rope wear w...

Page 18: ...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 ro...

Page 19: ... 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 An Adapter Sheave To Pull Through Exposed Conduit Using an Extension Bushing Flexible Pipe Adapter Adapter Sheave and T Boom to Pull Through Concealed Conduit Extension Bushing Thread onto Conduit ...

Page 20: ...ord IL 61109 2988 USA 815 397 7070 Typical Setups cont d Using A Flexible Pipe Adapter Adapter Sheave and T Boom For Overhead Pulls 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 ...

Page 21: ...l Setups cont d Using a Manhole Sheave Using Feeding Sheaves in Manholes UNOCCUPIED MANHOLE UNOCCUPIED MANHOLE UNOCCUPIED MANHOLE ABOVE GROUND Using a Floor Mount 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 Generator ...

Page 22: ...ain pockets or recesses e Turn the handle to slightly tighten the chain f Repeat Steps A E for the other chain 4 Rotate the vise chain handles by hand clockwise to fully tighten the chain Do not use tools exten sions or cheaters Vise Chain Installation Rope Approaching the Capstan When setting up the flexible pipe adapter or puller do not use the vise chains on a structural support that is less th...

Page 23: ...mps Use the shortest cord possible Longer cords reduce puller speed 7 Position the force gauge so that it can be monitored by the puller operator 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 Note The capstan arm is intended to pivot Do not attem...

Page 24: ...ce rating Puller Placement Pulling out old cable is generally accomplished with the puller located some distance away from the end of the conduit This allows the pulling crew to pull out a long section of cable before turning off the puller cutting off the cable and reattaching the grip s Mounting the cable puller a distance away from the end of the conduit increases the amount of exposed rope whi...

Page 25: ...70 Dual Pulling When the estimated amount of pulling resistance exceeds the ability of the puller two pullers may be used to accomplish the pull Connect the two pullers to the cables in parallel use two sets of ropes grips and other accessories to avoid overloading any component of the pulling system Dual Pulling ...

Page 26: ...urs Inspect the commutator brushes every 40 hours Lubricating the Drive Chains every 20 hours 1 Remove the right outer guard 71 and left outer guard 4 2 Lubricate the inside of the chains with 80W 90W gear oil 3 Replace the guards and screws Greasing the Drivetrain Shafts every 20 hours Apply a multipurpose NLGI Grade 2 grease such as Mobilgrease HP or Amoco Permalub at the grease fittings 5 and 5...

Page 27: ...Replace both brushes if either brush is less than 3 8 long 6 Lubricate the chains with 80W 90W gear oil 7 Remove the ratchet pawl 56 and compression spring 57 Apply multipurpose NLGI Grade 2 grease such as Mobilgrease HP or Amoco Permalub to all working surfaces Replace the spring and pawl 8 Assemble the 40 chain 65 Note Install the clip of the connecting link so that the closed end of the clip fa...

Page 28: ...any components that show signs of wear or damage When replacing the items of the sprocket 47 as sembly install new needle bearings 74 and 75 Install the clip of each connecting link so that the closed end of the clip faces the direction of chain travel as shown in the Exploded View Electric shock hazard Disconnect the cable puller from the power supply before servicing Failure to observe this warn...

Page 29: ...gram G F H C D E J K P Q R I Black Brown Black Brown Black Brown White Blue White Blue White Blue Black Brown Second Pole 220 Volt Model only White Blue Note Wire colors for the 220 volt model appear in parentheses Green Green with Yellow Stripe Green Green with Yellow Stripe L N M O Motor A B Meter Super Tugger and Force Gauges ...

Page 30: ...ford IL 61109 2988 USA 815 397 7070 Wiring Layout 503 1470 0 Control Box Unit 220 Volt Green White Connector Power Cord Black Black Meter Switch Black Green with Yellow Stripe Power Cord Blue Blue Brown Brown Brown Brown Brown Switch Force Meter 503 1465 1 Control Box Unit 120 Volt ...

Page 31: ... a voltmeter See the Specifications section of this manual Faulty switch or wiring Check the switch and wiring for continuity Motor faulty Check the motor and wiring for continuity Checkconditionofbrushes Replace any worn or damaged items Replace motor Capstan does not rotate while 60 chain broken Replace 60 chain motor is running 40 chain broken Replace 40 chain Broken sprocket in gearbox or stri...

Page 32: ...109 2988 USA 815 397 7070 Exploded View 23 16 17 18 19 22 25 24 20 21 5 6 7 8 9 10 12 13 14 15 11 11 3 1 1 4 3 3 2 4 1 36 35 34 33 32 30 31 29 28 27 26 Torque Specifications 1 4 52 Newton meters 40 in lb 2 10 8 Newton meters 8 ft lb 3 13 6 Newton meters 10 ft lb 4 20 3 Newton meters 15 ft lb ...

Page 33: ...e Tools Inc 33 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 Exploded View cont d 38 39 40 59 53 62 60 63 68 67 66 65 68 75 74 73 3 70 69 3 24 19 58 43 44 47 48 49 50 51 52 46 45 41 82 79 80 81 37 2 55 54 3 61 3 78 2 4 42 4 64 97 53 56 57 ...

Page 34: ...2517 Connecting link for 60 chain 1 22 50353616 Sprocket 60 40 teeth 1 23 50296833 Washer flat 1 39 X 2 00 X 125 fiber 4 24 90514602 Screw self tap 10 32 X 375 Phillips head 120 volt model 8 220 volt model 7 25 50296752 Guard left inner 1 26 90502582 Screw cap 10 32 X 375 socket head 1 27 90532821 Washer flat 234 X 875 X 062 1 28 50299581 Washer flat 631 X 2 25 X 093 2 29 50299565 Housing weldment...

Page 35: ...quare 1 68 90532104 Screw set 3 8 24 X 375 cup point socket 2 69 90532317 Retaining ring 1 125 Truarc 5100 112 1 70 90532325 Washer shim 1 125 X 2 00 X 031 steel 2 71 50301071 Guard right outer 1 72 50301241 Sprocket 40 47 teeth 1 73 50296868 Washer flat 1 14 X 2 00 X 125 fiber 3 74 90531981 Needle bearing Torrington BH 2216 1 75 90532007 Needle bearing Torrington BH 2220 1 76 50049178 Guard right...

Page 36: ...e Pullers Greenlee Tools Inc 36 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 Exploded View Motor and Gearbox 101 100 107 103 110 102 103 116 117 118 119 120 115 109 103 108 112 111 123 124 105 104 125 114 113 121 122 106 ...

Page 37: ...1862744 Gear shaft drive assembly includes bearings 1 110 91862752 Gear shaft driven assembly includes bearings 1 111 50301284 Screen motor 1 112 90518411 Screw thread cutting 5 40 x 250 pan head 4 113 90516869 Nut hex 10 32 full 2 114 90507509 Washer lock 200 x 373 x 023 internal tooth 2 115 91860652 Field 120 volt model 1 91861455 Field 220 volt model 1 116 91860679 Brush 2 117 91860660 Power co...

Page 38: ...ord IL 61109 2988 USA 815 397 7070 Exploded View 503 1465 1 Control Box Unit 120 Volt 117 114 118 120 119 113 116 115 111 125 126 121 122 123 124 106 110 120 130 105 107 108 109 108 110 112 129 127 Attach this end of the spring to the ninth link of the chain 100 101 102 103 104 128 ...

Page 39: ...ck 225 x 377 x 056 4 112 50359231 Cover control box 1 113 90522400 Screw self tapping 6 20 x 375 Phillips pan head 2 114 50316460 Meter includes next three items 1 115 Nut hex 6 32 3 116 Washer 6 3 117 Screw mach 6 32 x 750 round head 3 118 50316508 Spacer 312 x 625 x 560 4 119 50316478 Guard 1 120 90533593 Screw machine 12 24 x 1 000 round head 5 121 91861527 Switch circuit breaker 120 V 16 Amp 1...

Page 40: ... Rockford IL 61109 2988 USA 815 397 7070 Exploded View 114 113 112 116 115 122 123 118 119 120 121 107 126 127 129 106 108 109 110 109 117 111 128 124 Attach this end of the spring to the ninth link of the chain 101 102 103 104 105 100 125 503 1470 0 Control Box Unit 220 Volt ...

Page 41: ...box 1 112 90522400 Screw self tapping 6 20 x 375 Phillips pan head 2 113 50314699 Meter includes next three items 1 114 Screw mach 6 32 x 750 round head 3 115 Nut hex 6 32 3 116 Washer 6 3 117 50297082 Guard switch 1 118 91861403 Switch circuit breaker 220 V 8 Amp 1 119 90533615 Screw self tapping 8 32 x 750 slotted round 1 120 90533623 Washer flat 188 x 438 x 049 1 121 91859972 Rectifier bridge 6...

Page 42: ...the anti rotation support unit 4 as shown and slide rearward so the bottom of the support unit is trapped behind the idler sprocket mounting plate 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 3 Slide the capstan unit off of the capstan shaft Remove four fiber washers 1 Remove the chai...

Page 43: ...nit 5 so that the anti rotation support unit engages the hole in the anti rotation plate Install the capstan bolt 6 Feed the chain onto the bottom side of the sprocket while turning the sprocket clockwise Install the new connecting link 5 So that the open end of the connecting link faces away from the direction of the chain travel Installation Instructions cont d 7 Slide the idler arm up until the...

Page 44: ... unit ramp 1 7 90539222 Screw cap 3 8 16 x 2 75 socket head 4 8 90501349 Pin dowel 375 x 2 00 4 9 50352911 Ramp 1 10 50353225 Bearing ramp 1 11 50353187 Plate unit anti rotation 1 12 50353101 Washer flat 4 80 x 8 00 x 060 thrust 1 13 50353209 Washer flat 4 80 x 8 00 x 060 backing 1 14 50353616 Sprocket 60 40 teeth 1 50357069 Decal mounting 1 50356666 Decal rope path 1 5 1 2 3 6 4 35346 Capstan Ret...