Greenlee G6 Turbo Tugger Cable Puller Manuel utilisateur

OPERATION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Register this product at www.greenlee.com

3

/17

G6 Turbo

Cable Puller

and Pulling

Packages

G6 Turbo

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

2

Description

The Greenlee G6 Turbo Cable Puller is intended to be

used to pull cable through conduit and in tray. The

G6Turbo will develop 6000 lb (26.7 kN) of pulling force.

Refer to a Greenlee catalog for sheaves, pulling rope,

and other cable pulling accessories to create an entire

cable pulling system.

No single manual can provide instructions for every

possible cable pulling application; this manual contains

general information necessary to accomplish cable pulls

of many different setups.

Note: This equipment has been tested and found to

comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC rules. These limits are

designed to provide reasonable protection against

harmful interference when the equipment is operated in

a commercial environment. This equipment generates,

uses and can radiate radio frequency energy and, if not

installed and used in accordance with the instruction

manual, may cause harmful interference to radio com-

munications. Operation of this equipment in a residen-

tial area is likely to cause harmful interference in which

case the user will be required to correct the interference

at his own expense.

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 all personnel with

the safe operation and maintenance procedures for the

Greenlee G6 Turbo Cable Pulling System.

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge at www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Textron Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

® Registered: The color green for cable pulling equipment is a

registered trademark of Textron Innovations Inc.

KEEP THIS MANUAL

Table of Contents

SAFETY

CABLE PULLING OVERVIEW

FUNCTIONAL DESCRIPTION

Identication ............................................................. 21

Specications ........................................................... 25

Assembly/Disassembly ............................................ 26

OPERATION

Transportation .......................................................... 27

Handle Orientation ......................................................... 27

Wheeling ........................................................................ 27

Lifting ............................................................................. 27

Nose Operation .............................................................. 28

Pivot ............................................................................... 28

Swivel ............................................................................. 28

Clamping ........................................................................ 28

Nose Handles ................................................................ 28

Boom Operation ............................................................. 29

Disengaging/Engaging the Boom Quick Pin ................. 29

Extending/Retracting the boom ..................................... 29

Setting up the pull .................................................... 30

Puller Operation ........................................................ 33

Wire Pulling up to 6000lb (26.7 kN)

with Main Capstan ......................................................... 34

Wire Pulling up to 1750lb (_kN)

with Secondary Capstan ............................................... 37

EXPLODED VIEWS AND PARTS LISTS

Puller ........................................................................ 43

Control Box .............................................................. 45

Nose ......................................................................... 47

Boom ........................................................................ 49

Decals ....................................................................... 51

G6 Turbo

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

3

GENERAL SAFETY RULES

WARNING! Read and understand all instructions.

Failure to follow all instructions listed below may result

in electric shock, re, and/or serious personal injury.

SAVE THESE INSTRUCTIONS

WORK AREA SAFETY

Keep your work area clean and well lit. Cluttered

benches and dark areas invite accidents.

Do not operate power tools in explosive atmo-

spheres, such as in the presence of ﬂammable

liquids, gases, or dust. Power tools create sparks

which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while

operating a power tool. Distractions can cause you to

lose control.

ELECTRICAL SAFETY

Grounded tools must be plugged into an outlet prop-

erly installed and grounded in accordance with all

codes and ordinances. Never remove the grounding

prong or modify the plug in any way. Do not use any

adapter plugs. Check with a qualiﬁed electrician if

you are in doubt as to whether the outlet is properly

grounded. If the tools should electrically malfunction or

break down, grounding provides a low resistance path

to carry electricity away from the user.

Avoid body contact with grounded surfaces such

as pipes, radiators, ranges, and refrigerators. There

is an increased risk of electric shock if your body is

grounded.

Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of

electric shock.

Do not abuse the cord. Never use the cord to carry

the tools or pull the plug from an outlet. Keep cord

away from heat, oil, sharp edges or moving parts.

Replace damaged cords immediately. Damaged

cords increase the risk of electric shock.

When operating a power tool outside, use an

outdoor extension cord marked “W-A” or “W.” These

cords are rated for outdoor use and reduce the risk of

electric shock.

PERSONAL SAFETY

Stay alert, watch what you are doing and use

common sense when operating a power tool. Do not

use tool while tired or under the inﬂuence of drugs,

alcohol, or medication. A moment of inattention while

operating power tools may result in serious personal

injury.

Dress properly. Do not wear loose clothing or

jewelry. Contain long hair. Keep your hair, clothing,

and gloves away from moving parts. Loose clothes,

jewelry, or long hair can be caught in moving parts.

Avoid accidental starting. Be sure switch is off

before plugging in. Carrying tools with your nger on

the switch or plugging in tools that have the switch on

invites accidents.

Remove adjusting keys or switches before turning

the tool on. A wrench or a key that is left attached to a

rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance

at all times. Proper footing and balance enables better

control of the tool in unexpected situations.

Use safety equipment. Always wear eye protection.

Dust mask, non-skid safety shoes, hard hat, or hearing

protection must be used for appropriate conditions.

TOOL USE AND CARE

Use clamps or other practical way to secure and

support the workpiece to a stable platform. Holding

the work by hand or against your body is unstable and

may lead to loss of control.

Do not force tool. Use the correct tool for your appli-

cation. The correct tool will do the job better and safer

at the rate for which it was designed.

Do not use tool if switch does not turn it on and off.

Any tool that cannot be controlled with the switch is

dangerous and must be repaired.

Disconnect the plug from the power source before

making any adjustments, changing accessories,

or storing the tool. Such preventive safety measures

reduce the risk of starting the tool accidentally.

Store idle tools out of reach of children and other

untrained persons. Tools are dangerous in the hands of

untrained users.

Maintain tools with care. Keep cutting tools sharp

and clean. Properly maintained tools, with sharp cutting

edges, are less likely to bind and are easier to control.

Check for misalignment or binding of moving parts,

breakage of parts, and any other condition that may

affect the tool’s operation. If damaged, have the tool

serviced before using. Many accidents are caused by

poorly maintained tools.

Use only accessories that are recommended by the

manufacturer for your model. Accessories that may

be suitable for one tool may become hazardous when

used on another tool.

SERVICE

Tool service must be performed only by qualiﬁed

repair personnel. Service or maintenance performed by

unqualied personnel could result in a risk of injury.

When servicing a tool, use only identical replace-

ment parts. Follow instructions in the “Maintenance”

section of this manual. Use of unauthorized parts or

failure to follow maintenance instructions may create a

risk of electric shock or injury.

G6 Turbo

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

4

SPECIFIC SAFETY RULES AND SYMBOLS

SAFETY

ALERT

SYMBOL

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, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

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.

Do not operate the cable puller in

a hazardous environment. Hazards

include ammable liquids and gases.

Failure to observe this warning will

result in severe injury or death.

Electric shock hazard:

Disconnect the cable puller from

the power source before servicing.

Failure to observe this warning could

result in severe injury or death.

Attach only to steel or schedule 40 PVC conduit.

Do not attach to PVC conduit unless it is supported

within 2" (51 mm) of the end.

Failure to observe this warning could result in severe

injury or death.

G6 Turbo

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

5

SPECIFIC SAFETY RULES AND SYMBOLS

Inspect and 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 could break

and strike nearby personnel with

sufcient force to cause 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.

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.

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.

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.

An under-rated rope may break and whip violently.

Use a double-braided composite rope with the

following characteristics:

• Maximum Rated Capacity:

at least 6000 lb (26.7 kN)

• Average Breaking Strength:

at least 26,000 lb (115.6 kN)

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.

G6 Turbo

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

6

SPECIFIC SAFETY RULES AND SYMBOLS

Attach the pulling rope to the cable with appropri-

ate types of connectors. Select connectors with a

maximum rated capacity of 6000 lb (26.7 kN). An

under-rated connector can break under tension.

Failure to observe this warning could result in severe

injury or death.

Do not put ngers through holes in

elbow unit. Rotating parts may cut off

ngers.

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.

• Support extended boom before retracting or disen-

gaging locking barrel.

• Do not overextend boom. It can come out of the

tube and fall.

• Do not extend boom past paint line (1).

(1)

Failure to observe these warnings could result in

severe 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.

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 allow the rope to overlap on the capstan.

If the rope approaches the top of the angled part

of the capstan, relax the tailing force. If an overlap

does occur, shut off the puller immediately.

• Do not wrap rope around both capstans.

Failure to observe these warnings could result in

severe injury or death.

Do not wrap both capstans. No force

or speed benet to wrapping both

capstans.

Failure to observe this warning could

result in severe injury or death.

Tipping hazard:

Lower boom tubes to completely collapsed state

before transporting the cable puller.

Failure to observe this warning could result in severe

injury or death.

G6 Turbo

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

7

SPECIFIC SAFETY RULES AND SYMBOLS

Do not use handle as support during pull.

Failure to observe this warning could result in severe

injury or death.

When using the wheeled dolly to transport the

G6Turbo:

• Keep personnel out of the path of transport.

• Evaluate the terrain over which the dolly is to

move. If in doubt, obtain additional help and move

the dolly slowly.

• Do not transport over inclines of more than 15°.

• Do not transport the dolly with boom tubes longer

than supplied.

15°

• ON HIGH SPEED: Switch to low speed when lower

4 lights ash.

• ON LOW SPEED: Switch to main capstan or stron-

ger puller when red light ashes.

Failure to observe these warnings could result in

severe injury or death.

Do not operate the puller without the

guards in place.

Failure to observe this warning could

result in severe injury or death.

Make full contact with clamp shoul-

der onto conduit.

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.

Inspect puller and accessories before use. Replace

any worn or damaged components with Greenlee

replacement parts. A damaged or improperly assem-

bled item can break and strike nearby personnel with

great force.

Failure to observe this warning could result in severe

injury or death.

G6 Turbo

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

8

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 malfunc-

tion 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 GFCI-protected

receptacle that is properly installed and grounded in

accordance with all national and local codes and

ordinances.

Do not use an adapter.

20 Amp / 115 Volt

Plug and Grounded Receptacle

ReceptaclePlug

SPECIFIC SAFETY RULES AND SYMBOLS

Entanglement hazard:

• Do not operate the cable puller while wearing

loose-tting clothing.

• Retain long hair.

Failure to observe these warnings could result in

severe injury or death.

Chock the wheels.

If wheels are not secured, boom

may lose grip of conduit and fall

when pull tension is released.

Wear eye protection when using this

tool.

Failure to wear eye protection could

result in severe eye injury from ying

debris.

G6 Turbo

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

9

CABLE PULLING OVERVIEW

Cable Pulling Glossary

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 kilonewtons (metric)

or pounds; the maximum rated capacity of every

component must meet or exceed the maximum pulling

force of the cable puller

Newton (N)

a metric unit of force, equivalent to 0.225 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 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 newton-meters (metric) or

foot-pounds

support structure

any stationary object that a cable pulling system

component is anchored to, such as a concrete oor

(for the oor mount) or an I-beam (for a sheave)

tactile feedback

the way the rope feels as it feeds off of the capstan; the

feel of the rope provides information about the progress

of the pull to the operator

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—refer to the

complete explanation under “Cable Pulling Principles”

wire grip

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

clamp onto the conductors of the cable

G6 Turbo

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

10

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

G6 Turbo

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

11

Cable Pulling Principles (cont’d)

Gravity

Weight

of Cable

Conduit

Friction

Tailing

Force

Pulling Force

6000 lb

(26.7 kN)

Cable Pulling Theory Illustrated

Pulling Theory

This section introduces the main ideas involved with

pulling cable.

Pulling Resistance

The cable puller must overcome two types of resistance:

gravity and friction.

Gravity constantly exerts its force on the vertical

portions of the run. When the pulling force is relaxed,

gravity attempts to pull the cable downward. Friction

develops 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 on the rope. The cable puller multiplies this

and generates the pulling force.

This pulling force is applied to the rope, connectors,

and cable in order to accomplish the pull. The direc-

tion of force is changed, where necessary, with pulling

sheaves.

G6 Turbo

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

12

Cable Pulling Principles (cont’d)

Cable Pulling Forces

This section provides detailed explanations and illustra-

tions of the forces that are generated during the cable

pull. These explanations are based on the concepts

presented in the last section, “Pulling Theory.”

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. The anchoring system is commonly a

oor mount, but can also be a boom mounted conduit

clamp as is the case with the G6. It is extremely

important that the clamp shoulders are fully engaged.

Refer to the instruction manual provided with your

anchoring system for proper setup or installation.

G6 Turbo

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

13

Pulling Force

6000 lb

(26.7 KN)

Reaction Force

on Conduit

6000 lb

(26.7 KN)

Maximum

Pulling Force at the Cable Puller’s Anchoring System

a) Boom Mounted Pull

6000 lb

(26.7 kN)

Maximum

6000 lb

(26.7 kN)

Maximum

Pulling Force

6000 lb

(26.7 kN)

Reaction Force

on Anchors

Reaction Force

on Anchors

Cable Pulling Principles (cont’d)

b) Floor Mounted Pull

G6 Turbo

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

14

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d)

At the Capstan

The capstan acts as a force multiplier. The operator

exerts a small amount of tension, or tailing force, on the

rope; the capstan multiplies this force to pull the cable.

The resultant force depends upon the number of times

the rope is wrapped around the capstan, as shown in

the formula below.

Pulling Force = Tailing Force x e

0.0175µø

Where:

e = the natural logarithm, or 2.7183

µ = the coefcient of friction between the

rope and the capstan*

ø = the number of degrees of wrap of rope

around the capstan

* The average value for the coefcient of friction when

double-braided composite rope is pulled over a

clean dry capstan is 0.125.

The following table is based on the formula above.

The input, or tailing force, is constant at 44.5 N (10 lb).

Increasing the number of wraps increases the pulling

force.

Operator’s

Tailing Force

Number of

Wraps of Rope

Approximate

Pulling Force

44.5 N (10 lb)

1 21 lb (93.4 N)

2 48 lb (213.5 N)

3 106 lb (474.9 N)

4 233 lb (1043.8 N)

5 512 lb (2293.7 N)

6 1127 lb (5048.9 N)

7 2478 lb (11.1 kN)

This table shows how the capstan acts as a force

multiplier. Because the coefcient of friction depends

upon the condition of the rope and capstan, this formula

cannot determine an exact amount of pulling force.

Pulling Force

6000 lb (26.7 kN)

The Capstan as a Force Multiplier

G6 Turbo

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

15

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d)

At the Pulling Rope

The product of a force (f) moving through a distance

(d) is energy (f x d), and may be measured in newton-

meters or ft-lb. Energy is stored in a rope when the rope

is stretched. This is similar to the way energy is stored in

a rubber band when it is stretched. Failure of the rope or

any other component of the pulling system can cause a

sudden uncontrolled release of the 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 only 34 meters into the air.

The double-braided composite rope stores much less

energy and has much less potential for injury if it were

to break.

Double-braided composite rope is the only type of

rope recommended for use with the G6 Turbo cable

puller. Select a double-braided composite rope with an

average rated breaking strength of at least 26,000 lb

(115.6 kN).

Stored Energy

G6 Turbo

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

16

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d)

At the Connectors

The connectors will be subjected to the cable puller’s

maximum pulling force.

Several types of rope connectors—clevises, swivels,

and rope-to-swivel connectors—are available. Follow

the instructions provided with each to provide a good

connection.

Two types of wire connectors—wire grips and pulling

grips—are available. The wire grip uses a set screw

to clamp onto the conductors of the cable. The pulling

grip consists of a wire mesh basket that slides over

the cable and grips the insulation.

When selecting a pulling grip, it is extremely important

to select a grip of the correct (1) type, (2) size, and

(3)maximum rated capacity.

1. Select the correct type based on the descriptions

of each type in the Greenlee 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 pro-

vided to nd the correct size.

3. Refer to the maximum rated capacities in the

Greenlee catalog.

Maximum

Pulling Force

6000 lb

(26.7 kN)

A Typical Grip Setup—Clevis and Wire Grip

Maximum

Pulling Force

6000 lb

(26.7 kN)

A Typical Grip Setup—Swivel and Pulling Grip

Pulling Grip Size Table

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

1.95–2.36 49.5–59.9 0.62–0.74 15.8–18.8

2.36–3.14 59.9–79.8 0.75–0.99 19.1–25.1

3.14–3.93 79.8–99.8 1.00–1.24 25.4–31.5

3.93–4.71 99.8–119.6 1.25–1.49 31.8–37.8

4.71–5.50 119.6–139.7 1.50–1.74 38.1–44.2

5.50–6.28 139.7–159.5 1.75–1.99 44.5–50.5

6.28–7.85 159.5–199.4 2.00–2.49 50.8–63.2

7.85–9.42 199.4–239.3 2.50–2.99 63.5–75.9

9.42–11.00 239.3–279.4 3.00–3.49 76.2–88.6

11.00–12.57 279.4–319.3 3.50–3.99 88.9–101.3

12.57–14.14 319.3–359.2 4.00–4.49 101.6–114.0

14.14–15.71 359.2–399.0 4.50–4.99 114.3–126.7

G6 Turbo

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

17

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d)

At the Sheaves

Sheaves are used to change the direction of the pull.

A change in direction creates a new resultant force

that may be greater than the cable puller’s maximum

pulling force. This new resultant force exerts itself on the

sheaves, sheave anchoring system, and support struc-

tures illustrated.

The resultant amount of force depends on the angle of

the change in direction. A brief table is provided here;

For details on calculating the resultant force for any

angle, refer to IM 1363 (99929988).

Resultant Force Table

(6000 lb or 26.7 kN Pulling Force)

Illustration

Angle of Change

in Direction

Resultant Force

in lb (kN)

180° 0 (0)

150° 3100 (13.8)

135° 4600 (20.4)

120° 6000 (26.7)

90° 8500 (37.8)

60° 10,400 (46.3)

45° 11,100 (49.3)

30° 11,600 (51.6)

0° 12,000 (53.4)

Resultant Force

4600 lb (20.4 kN)

135°

Typical Resultant Force at Sheave

G6 Turbo

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

18

Cable Pulling Principles (cont’d)

Tailing the Rope

The rope must be pulled off of the capstan as the pull

progresses. The rope that has left the capstan is the

“tail.” The process of pulling the rope off of the capstan

is called tailing the rope.

The resistance of the cable varies throughout the dura-

tion of the cable pull. Changes in resistance are

due to characteristics of the rope, changes in conduit

direction, and changes in the amount of friction. The

“feel” of the rope provides this information about the

pull. This is called tactile feedback. Adjust the tailing

force as necessary to compensate for these changes.

Control of the Pull

Decreasing the tailing force will decrease the pulling

force, until the rope slips on the capstan and the pull

stops. This provides a high level of control over the

progress of the cable pull.

Do not allow the rope to slip on the capstan for more

than a few moments. If it becomes necessary to com-

pletely stop a pull, shut off the puller and maintain

enough tailing force to hold cable in place. Tie the rope

off to hold it in place.

Amount of Tailing Force

While the rope and cable are under tension, it is impor-

tant to maintain the proper amount of tailing force.

Too little tailing force will allow the rope to slip on the

capstan. This will build up excessive heat and acceler-

ate rope wear, increasing the possibility of breaking the

rope.

The proper amount of tailing force will stop the rope

from slipping on the capstan and produce a sufcient

amount of pulling force to pull in the rope and cable.

Too much tailing force is any amount more than is nec-

essary to stop the rope from slipping on the capstan.

Excessive tailing force will not increase the pulling force

or pulling speed.

Number of Wraps of Rope Around the Capstan

An experienced operator should choose the number of

times the rope is wrapped around the capstan.

The proper number 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 tighter. This accelerates rope wear, wastes

power, and increases the possibility of a rope overlap.

Using too many wraps also reduces tactile feedback,

so you receive less information about the pull. You

cannot quickly relax the tailing force when there are too

many wraps.

If the rope becomes difcult to tail, add another wrap

of rope. Turn off the puller and release all of the tension

in the rope. Add a wrap and resume pulling. Be aware,

however, that some pulls will require tension to hold

the cables in place. In these cases, do not attempt to

release all of the tension and add a wrap of rope. You

will need to anticipate the number of wraps before start-

ing the pull.

Preventing Rope Overlap

Do not allow the rope to become overlapped on the

capstan during a pull.

A rope overlap will make it impossible to continue

or back out of the pull.

If the rope becomes overlapped, you will lose control

of the pull —the rope will advance with no tailing force

and will not feed off of the capstan. The capstan will not

allow you to reverse the direction of the rope, so you

cannot back out of an overlap.

Set up the puller properly. The rope ramp and tapered

capstan are intended to prevent rope overlap. Refer

to the instructions in the “Operation” section of this

manual.

Every wrap of the rope must remain in direct contact

with the capstan. During the pull, take great care to

prevent the incoming rope from riding up and overlap-

ping the next wrap. If an overlap begins to develop,

immediately relax the tailing force on the rope so that

the rope can feed back toward the conduit or tray.

When the rope resumes its normal path, apply tailing

force and continue the pull.

There is no suggested remedy for a rope overlap.

Do not allow the rope to overlap!

G6 Turbo

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

19

Cable Pulling Principles (cont’d)

Summary of Cable Pulling Principles

• A cable pulling system consists of many components

that work together to accomplish a pull.

• The cable puller is rated by its maximum pulling

force; every other component is rated by its maximum

rated capacity. The maximum rated capacity of every

component must meet or exceed the maximum

pulling force of the cable puller.

• The cable puller must overcome two types of resis-

tance: gravity and friction. The puller’s capstan, the

pulling rope, and the operator tailing the rope work

together to produce pulling force.

• The cable puller exerts force on every component

of the cable pulling system, including the anchoring

systems and the support 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 rope overlap to develop.

Planning the Pull

• Pull in a direction that will require the lowest amount

of pulling force.

• Plan several shorter pulls rather than fewer longer

pulls.

• Locate the puller as close to the end of the conduit

as possible to minimize the amount of exposed rope

under tension.

• Place each component so that the pulling forces are

used effectively.

• Select an anchoring system: boom mount or

oor mount.

• Verify that each component has the proper load

rating.

• Inspect the structural supports. Verify that they have

enough strength to withstand the maximum forces

that may be generated.

G6 Turbo

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

20

Removing Cable

Removing old cable involves the same principles as

installing new cable. However, there are some important

differences.

Pulling Force

It is difcult to predict the amount of pulling force

necessary to remove an old cable. The cable may be

damaged, and it may break with an unexpectedly low

pulling force.

The required pulling forces may be very high:

• The cable has probably “taken a set.” Unlike the new

cable on a reel, cable in conduit has probably been in

the conduit for years, or perhaps decades. The cable

will resist bending and straightening as it is pulled

through the conduit.

• The pulling lubricant has probably hardened,

increasing pulling resistance.

• The insulation may be damaged and the cable may be

corroded.

• Dirt or other foreign matter may have entered the

conduit and may have cemented the cable in place.

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, which greatly

increases the amount of violent whipping action which

would occur if the rope were to break.

To isolate the operator from the rope path:

• Locate the puller so that you will stand behind an

obstruction, such as a wall. Set up the puller so that

you will be able to maintain control of the pull. You

need a clear view of the rope as it feeds onto the

capstan, including several feet of the rope in front of

the capstan. You must be able to turn off the puller

before the pulling grip, connector, or swivel contacts

the capstan.

• Use an additional pulling sheave (if necessary)

to change the direction of the tailing rope. Anchor

the sheave so that you are close enough to maintain

control of the pull. You need a clear view of the rope

as it feeds onto the capstan, including several feet of

the rope in front of the capstan. You must be able to

turn off the puller before the pulling grip, connector, or

swivel contacts the capstan.

Note: Use the additional pulling sheave to change the

direction of the tailing rope (after the rope leaves the

capstan). Do not change the direction of the pulling

rope.

• Use a longer tailing rope than usual and stand away

from the puller. Stand as far from the puller as pos-

sible, while maintaining control of the pull. You need

a clear view of the rope as it feeds onto the capstan,

including several feet of the rope in front of the

capstan. You must be able to turn off the puller before

the pulling grip, connector, or swivel contacts the

capstan.

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Greenlee G6 Turbo Tugger Cable Puller Manuel utilisateur

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