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Ultra Tugger
®
Cable Puller and Pulling Packages
15000-22, 6501-22 and 6505-22
Serial Code AJF
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
52020539 © 2005 Greenlee Textron Inc. 6/05
Español................43
Français ............... 85
Deutsch ............. 127
Italiano .............. 169
Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Table of Contents
Description ..................................................................... 3
Purpose.......................................................................... 3
Important Safety Information ......................................4-7
Grounding Instructions................................................... 8
Identification ..............................................................9-10
Specifications ............................................................... 11
Cable Pulling Glossary ................................................ 12
Cable Pulling Principles:
Cable Pulling Systems ............................................ 13
Pulling Theory.......................................................... 14
Cable Pulling Forces:
At the Cable Puller Anchoring System................ 15
At the Capstan .................................................... 16
At the Pulling Rope ............................................. 17
At the Connectors ............................................... 18
At the Sheaves .................................................... 19
Calculating Hook Load:
One Attachment Point ......................................... 20
Two Attachment Points ....................................... 21
Hook Load ........................................................... 22
Hook Loads Illustrated ........................................ 23
Tailing the Rope:
Control of the Pull................................................ 24
Amount of Tailing Force ...................................... 24
Number of Wraps of Rope around the Capstan ...
24
Preventing Rope Overlap.................................... 24
Summary of Cable Pulling Principles ...................... 25
Planning the Pull .......................................................... 25
Typical Setups:
Pipe Adapter ............................................................ 26
Chain Mount ............................................................ 26
Floor Mount ............................................................. 26
T-Stand .................................................................... 27
Wheeled Carriage.................................................... 28
Setup:
Pipe Adapter .......................................................29-31
T-Stand .................................................................... 32
Wheeled Carriage.................................................... 33
Mounting Components:
Boom with Nose Unit........................................... 34
Booms with Elbow Unit and Nose Unit ............... 35
Slip-in Coupler..................................................... 36
Straddling the Conduit with Slip-in Coupler ........ 36
Chain Mount .......................................................37-38
Floor Mount ............................................................. 39
Installation ........................................................... 39
Operation ..................................................................... 40
Removing Cable .......................................................... 41
Greenlee / A Textron Company 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
KEEP THIS MANUAL
Description
The Greenlee Ultra Tugger
®
cable puller is intended
to be used to pull cable through conduit and in tray.
The Ultra Tugger will develop 22.3 kilo-Newtons
(5000 lbs) of pulling force. See 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.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tools provide information for
avoiding hazards and unsafe practices related to use of
this tool. Observe all of the safety information provided.
Do not operate this tool unless fully trained to do so,
or under trained supervision.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
Greenlee 15000-22 and 6500-22 series Ultra Tugger
cable pullers.
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
Other Publications
Service Manual: 52020540
All specifications are nominal and may change as design improve-
ments occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Ultra Tugger is a registered trademark of Greenlee Textron Inc.
Versi-Boom is a trademark of Greenlee Textron Inc.
Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
Electric shock hazard:
Disconnect the cable puller from the
power supply before servicing.
Failure to observe this warning can
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 prevent-
ing or avoiding the hazard.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
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 flammable liquids and
gases.
Failure to observe this warning will
result in severe injury or death.
Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
Do not allow anything other than the
pulling rope to contact the capstan.
A grip, swivel, or other component
could break and strike operator with
great force.
Failure to observe this warning can
result in severe injury or death.
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 may break and
strike nearby personnel with suffi-
cient force to cause severe injury
or death.
Do not stand directly under a vertical
pull. Cable could fall suddenly from
the conduit.
Failure to observe this warning can
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 can result in severe
injury or death.
An under-rated or worn rope may break and whip
violently. Use a double-braided composite rope
with the following characteristics:
Maximum Rated Capacity:
at least 22.3 kN (5000 lbs)
Average Breaking Strength:
at least 90 kN (20,000 lbs)
Failure to observe this warning can result in severe
injury or death.
Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
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 can result in
severe injury or death.
Attach the pulling rope to the cable with appropriate
types of connectors as described in this manual.
Select connectors with a maximum-rated capacity
of 22.3 kN (5000 lbs). An under-rated connector can
break under tension.
Failure to observe this warning can 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 can
result in severe injury or death.
Shear Point:
Do not put fingers through holes in
elbow unit. Rotating parts may cut
off fingers.
Failure to observe this warning can
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.
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 can 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 can 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 can result in severe
injury or death.
Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
IMPORTANT SAFETY INFORMATION
Wear eye protection when using this
tool. Failure to wear eye protection
can result in severe eye injury from
flying debris.
Inspect puller and accessories before use. Replace
any worn or damaged components with Greenlee
replacement parts. A damaged or improperly
assembled item can break and strike nearby
personnel with sufficient force to cause severe
injury or death.
Entanglement hazard:
Do not operate the cable puller while wearing
loose-fitting clothing.
Retain long hair.
Failure to observe this warning can result in severe
injury or death.
When using the wheeled carriage to transport the
Ultra Tugger:
Keep personnel out of the path of transport.
Evaluate the terrain over which the carriage is
to move. If in doubt, obtain additional help and
move the carriage slowly.
Do not transport over inclines of more than 10°.
Do not transport the carriage with boom tubes
longer than the supplied 3' and 4' tubes.
10°
Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Grounding Instructions
Electric shock hazard:
Connect this tool to a grounded
receptacle on a 16-amp GFCI-
protected circuit.
Failure to observe these warnings
can 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 to the operator.
This tool’s electric cord has a grounding conductor and a
grounding plug as shown. Connect the plug to recep-
tacle that is properly installed and grounded in accor-
dance with all national and local codes and ordinances.
Do not use an adapter.
16-Amp / 230-Volt Plug and Grounded Receptacle
ReceptaclePlug
This tool is equipped with a European-style electrical
plug. The electrical plug can be replaced with a compat-
ible plug for the country in which the tool will be used.
The electrical plug should be replaced by a qualified
electrician. Do not use an adapter.
Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Identification
Ultra Tugger Cable Puller
1. Motor (under shroud) 7. Right Angle Sheave
2. Circuit Breaker / I/O Switch 8. Rope Ramp
3. Mounting Plates 9. Hitch Clip
4. Rope Tie-Off 10. Gearbox
5. Adjustable Sheave Bracket 11. Mounting Pin (2)
6. Tapered Steel Capstan 12. Force Gauge with
Remote I/O Switch
1
2
3
4
5
6
7
9
11
Lift Point
Lift Point
10
8
12
Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Identification (cont’d)
Versi-Boom™ Components
1. Elbow Unit 9. Wheeled Carriage
2. Sight Hole 10. Slip-in Coupler
3. 4' Boom Tube 11. Nose Unit
4. Sight Hole 12. Mounting Pins
5. Boom Mount 13. Hitch Pin Clips
6. T-Stand 14. 3' Boom Tube
7. Puller 15. Long Pin
8. Force Gauge
7
1
14
11
1
3
12
10
2
3
5
9
6
4
1
8
Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Specifications
Weight ............................................................................................ 43 kg (95 lb)
Dimensions:
Length..................................................................................... 29 cm (11.5")
Width .......................................................................................... 68 cm (27")
Height ........................................................................................ 25 cm (9.8")
Motor:
Voltage ................................................... 230 VAC, 50/60 Hz, Single Phase
Current Draw at Full Load ............................................................. 9.5 Amps
Sound Level ........................................................................... L
WA 70 at 1 meter
Power Source ...............................230 VAC, 50/60 Hz, 16 Amps, Single Phase
Speed:
No Load ....................................................................... 2.74 m/min (9 ft/min)
5560 Newtons (1250 lb) .............................................. 2.44 m/min (8 ft/min)
11.1 kN (2500 lb) ...................................................... 2.29 m/min (7.5 ft/min)
16.7 kN (3750 lb) ......................................................... 2.13 m/min (7 ft/min)
22.3 kN (5000 lb) ......................................................... 1.83 m/min (6 ft/min)
Pulling Force:
0 - 17.8 kN (0 - 4000 lb) ............................................ Continuous Operation
17.8 kN - 35.6 kN (4000 - 8000 lb)................................. 5 minutes per hour
Pulling Rope:
Required Rope ..................................................... 22.2 mm (7/8") diameter,
double-braided, polyester composite
Average Breaking Strength ............................. 143 kN (32,000 lb) minimum
IP Rating:
Motor ..................................................................................................... IP23
Ultra Tugger and Force Gauge Enclosure ............................................ IP54
Temperature Rating
Transportation and Storage ....................... 55°C to -25°C (131°F to -13°F)
Elevation Rating..............................................1000 m (3280 ft) above sea level
Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
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 kilo-Newtons (metric)
or pounds; the maximum rated capacity of every
component must meet or exceed the maximum pulling
force of the cable puller
Newton
a metric unit of force, equivalent to .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
Cable Pulling Glossary
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 Newtons-meters (metric) or
foot-pounds
support structure
any stationary object that a cable pulling system
component is anchored to, such as a concrete floor
(for the floor 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—see the
complete explanation under Principles of Cable Pulling
wire grip
connects the rope to the cable; some use a set screw to
clamp onto the conductors of the cable
Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
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
Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Cable Pulling Principles (cont’d)
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 direction
of force is changed, where necessary, with pulling
sheaves.
Gravity
Weight
of Cable
Conduit
Friction
Tailing
Force
Pulling Force
35.6 kN
(8000 lbs)
Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Cable Pulling Principles (cont’d)
Pulling Force at the Cable Puller’s Anchoring System
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. Refer to “Typical Setup: Floor Mount” for proper
setup or installation.
35.6 kN
(8000 lbs)
Maximum
35.6 kN
(8000 lbs)
Maximum
Pulling Force
35.6 kN
(8000 lbs)
Maximum Pulling Force
at Anchoring System
Greenlee / A Textron Company 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
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 coefficient 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 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.
Number
Operator’s of Wraps Approximate
Tailing Force of Rope Pulling Force
44.5 N (10 lbs) 1 93.4 N (21 lbs)
44.5 N (10 lbs) 2 213.5 N (48 lbs)
44.5 N (10 lbs) 3 474.9 N (106 lbs)
44.5 N (10 lbs) 4 1043.8 N (233 lbs)
44.5 N (10 lbs) 5 2293.7 N (512 lbs)
44.5 N (10 lbs) 6 5048.9 N (1127 lbs)
44.5 N (10 lbs) 7 11.1 kN (2478 lbs)
The following table is based on the formula above.
The input, or tailing force, is constant at 44.5 Newtons
(10 lbs). Increasing the number of wraps increases
the pulling force.
The Capstan as a Force Multiplier
Pulling Force: 35.6 kN (8000 lbs)
Tailing
Force
Greenlee / A Textron Company 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Cable Pulling Principles (cont’d)
Stored Energy
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 foot-pounds. 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 Ultra Tugger cable
puller. Select a double-braided composite rope with an
average rated breaking strength of at least 143 kN
(32,000 lbs).
Stored Energy
Greenlee / A Textron Company 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
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 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
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
Pulling Grip Size Table
A Typical Grip Setup—Clevis and Wire Grip
A Typical Grip Setup—Swivel and Pulling Grip
Maximum
Pulling Force
35.6 kN
(8000 lbs)
Maximum
Pulling Force
35.6 kN
(8000 lbs)
Greenlee / A Textron Company 19 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
Cable Pulling Principles (cont’d)
Typical Resultant Force at Sheave
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.
Refer to “Calculating the Hook Load” to determine the
resultant force at any angle.
Resultant Force Table for the Ultra Tugger
(22.3 kN or 5,000 lbs Maximum Pulling Force)
Resultant Force=
17.1 kN 3850 lbs)
22.3 kN
(5000 lbs)
135°
Angle of Change Resultant Force
in Direction in kN (lbs)
180° 0 (0)
150° 18.5 (4160)
135° 27.4 (6160)
120° 35.6 (8000)
90° 50.2 (11,300)
60° 61.6 (13,800)
45° 65.8 (14,800)
30° 68.7 (15,400)
0° 71.2 (16,000)
Illustration
Greenlee / A Textron Company 20 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Ultra Tugger
®
Cable Puller and Pulling Packages
R
T
T
θ
Formula 1:
R = 2 x T x SIN ((180 -
θθ
θθ
θ) / 2)
R - the resultant force, or hook load; this force is exerted on the hook, anchoring and structural support
θ - the angle of change in rope direction
T - the tension exerted on the rope by the cable puller
Note: The total load on the support structure = R + the weight of the sheave.
Sheave with One Attachment Point
Cable Pulling Principles (cont’d)
Calculating the Hook Load
One Attachment Point
To calculate the hook load exerted at one attachment
point, use the Reference Table and Formula 1.
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