Elliott Tube Tugger Manual

www.elliott-tool.com
Tube & Pipe Cleaners Tube Testers Tube Plugs Tube Removal Tube Installation
Tube Tugger®
Semi-Continuous Tube Extractor
Operating and Maintenance Instructions

Tube Tugger 3
Table Of Contents
Introduction .......................................................................................................... 4
Safety Instructions................................................................................................ 5
Start-Up................................................................................................................ 7
Quick Reference Diagram .................................................................................... 8
Operating Instructions.......................................................................................... 9
Tool Changeover ................................................................................................ 11
Tool Selection Chart / Specications ................................................................. 12
Troubleshooting.................................................................................................. 14
Warranty ............................................................................................................. 15

4 Tube Tugger
INTRODUCTION
Thank you for purchasing this Elliott product. More than 100 years of experience have been employed
in the design and manufacture of this control, representing the highest standard of quality, value and
durability. Elliott tools have proven themselves in thousands of hours of trouble free eld operation.
If this is your rst Elliott purchase, welcome to our company; our products are our ambassadors.
If this is a repeat purchase, you can rest assured that the same value you have received in the past
will continue with all of your purchases, now and in the future.
The Tube Tugger® has been designed for the following types of equipment:
Chillers
Heat Exchangers
Fin Fan Coolers
Surface Condensers
If you have any questions regarding this product, manual or operating instructions, please call Elliott
at [phone] toll free (USA only) or [phone], or fax us at [phone]
for immediate service.

Tube Tugger 5
SAFETY INSTRUCTIONS
Every effort has been made to ensure the operation of the Elliott Tube-Tugger is safe,
although it is impossible to remove all possibilities of accidents.
It is very important that all operators of this machine are fully aware of the following safety
considerations.
1. If you are unfamiliar with the Elliott Tube-Tugger, read this Operation Manual
thoroughly before use.
2. Always wear safety glasses, protective gloves, safety shoes and protective clothing.
3. Do not allow other people in the area of the machine unless they are wearing suitable
protective clothing and equipment.
4. As the machine is hydraulically driven, hydraulic oil leaks from the ram and hose
connections are possible. If hydraulic oil is leaked, clean-up oil immediately
to avoid slippery oor surfaces.
5. The Elliott Tube-Tugger stroke is controlled by a manual control on the hydraulic power
source. It is important to read and understand the manual for the hydraulic power source.
6. Ensure all hydraulic connections are properly made and that the hydraulic hoses
are in good condition.
7. Always be aware of hydraulic power shut off valve.
8. Always shut down the hydraulic power supply before changing tooling.
9. Do not operate the machine if there appears to be damage to the machine,
if screws are loose or missing, or if performance appears to be unsatisfactory.
10. Never use the Tube-Tugger, or any other power tool when under the inuence
of medication, drugs or alcohol that decrease concentration and impair operator control.
11. DO NOT attempt to adjust or service the rod end relief valve on a double-acting cylinder or
ram. If oil leakage is detected from this relief valve, discontinue use of the cylinder or ram
immediately and contact your nearest Authorized Hydraulic Service Center. If improperly
adjusted, the cylinder or ram could develop excessive pressure and cause the cylinder, hose
or couplers to burst which could cause serious injury or death.
12. When extending a cylinder or ram under load, always ensure that the coupler(s) or port
thread(s) has (have) not been damaged or do(es) not come in contact with any rigid
obstruction. If this condition does occur, the coupler’s attaching threads may become
stripped or pulled from the cylinder or ram resulting in the instantaneous release of high
pressure hydraulic uid, ying objects, and loss of the load. All of these possible results could
cause serious injury or death.
13. Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut
off the pump and release all pressure. Never attempt to grasp a leaking pressurized hose with
your hands. The force of escaping hydraulic uid could cause serious injury.

6 Tube Tugger
14. Do not subject the hose to potential hazard such as re, sharp surfaces, extreme heat or
cold, or heavy impact. Do not allow the hose to kink, twist, curl, crush, cut, or bend so tightly
that the uid ow within the hose is blocked or reduced. Periodically inspect the hose for
wear, because any of these conditions can damage the hose and possibly result in personal
injury.
15. Do not use the hose to move attached equipment. Stress can damage the hose and possibly
cause personal injury.
16. Keep the cylinder clean at all times. While at a job site, when the cylinder is not in use, keep
the piston rod fully retracted and upside down.
17. Use an approved, high-grade pipe thread sealant to seal all hydraulic connections. PTFE tape
can be used if only one layer of tape is used and it is applied carefully (two threads back) to
prevent the tape from being pinched by the coupler and broken off inside the pipe end. Any
loose pieces of tape could travel through the system and obstruct the ow of uid or cause
jamming of precision-t parts.
18. Always use protective covers on disconnected quick couplers.
SAFETY INSTRUCTIONS

Tube Tugger 7
START-UP
Unpacking:
The Elliott Tube-Tugger is shipped in a carton complete with all accessories listed. On arrival, check
for external damage to the box. If damage is found, notify the carrier and the supplier so insurance
inspectors can examine the box before it is unpacked. When opened, check the contents against
the packing and parts list. Report any damage or shortage to Elliott.
Ensure that there is no packaging material left inside the openings of the machine, especially in the
hydraulic inlets.
Connecting to Hydraulic Power Supply:
The Elliott Tube-Tugger requires a hydraulic power source. The hydraulic power source supplied
by Elliott will be an electric, pneumatic or manual pump.
1. Position the Tube-Tugger and the hydraulic power source on a at surface.
2. Connect counter balance eye bolt and fasten operator side handles.
3. Connect the two 15’ hydraulic hoses to both units.
IMPORTANT: Make sure that the male hose ttings are totally in contact with female tting
shoulder on the tube pulling cylinder before threading down the locking tting. Otherwise
the cylinder‘s relief valve will activate and release a fog of hydraulic uid and the cylinder
will remain idle.
4. Before operating the pump, all hose connections must be tightened with the proper tools. Do
not overtighten. Connections should only be tightened securely and leak-free. Overtightening
can cause premature thread failure or high pressure ttings to split at pressures lower than
their rated capacities
5. Follow the directions of the Elliott hydraulic pump manual to assure that hydraulic pump
is working properly.
6. Cycle the Tube-Tugger several strokes to eliminate any air in the hydraulic lines.
NOTE: The hydraulic hoses are pre-charged with oil by the factory.
7. The Tube-Tugger is ready for tool installation.
Removing the Hydraulic Hoses:
1. Neutralize the pressure before removing the hydraulic hoses.
NOTE: On the hydraulic power units with remote control, ip the switch on the top of the
hydraulic pump from “Remote” to “Off”. Cycle both “Advance” and “Retract” switches on the
remote control, to neutralize the pressure.

8 Tube Tugger
QUICK REFERENCE DIAGRAMS
QUICK REFERENCE DIAGRAMS
Collet Holder / Adapter Package 16-130210
Diagram B
Tube-Tugger Tooling
Diagram C
Page 4 Elliott Tube-Tugger TM-36 TM-36 Elliott Tube-Tugger Page 5
START-UP
Unpacking
The Elliott Tube-Tugger is shipped in a carton complete with all accessories listed. On
arrival, check for external damage to the box. If damage is found, notify the carrier
and the supplier so insurance inspectors can examine the box before it is unpacked.
When opened, check the contents against the packing and parts list. Report any
damage or shortage to Elliott.
Ensure that there is no packaging material left inside the openings of the machine,
especially in the hydraulic inlets.
Connecting to Hydraulic Power Supply
The Elliott Tube-Tugger requires a hydraulic power source. The hydraulic power
source supplied by Elliott will be an electric, pneumatic or manual pump.
1. Position the Tube-Tugger and the hydraulic power source on a flat surface.
2. Connect counter balance eye bolt and fasten operator side handles.
3. Connect the two 15ʼ hydraulic hoses to both units. Important: Make sure that the
male hose fittings are totally in contact with female fitting shoulder on the tube
pulling cylinder before threading down the locking fitting. Otherwise the cylinderʻs
relief valve will activate and release a fog of hydraulic fluid and the cylinder will
remain idle.
4. Follow the directions of the Elliott hydraulic pump manual to assure that hydraulic
pump is working properly.
5. Cycle the Tube-Tugger several strokes to eliminate any air in the hydraulic lines.
NOTE: The hydraulic hoses are pre-charged with oil by the factory.
6. The Tube-Tugger is ready for tool installation.
Removing the Hydraulic Hoses
1. Neutralize the pressure before removing the hydraulic hoses.
NOTE: On the hydraulic power units with remote control, flip the switch on the top of the hydraulic
pump from “Remote” to “Off”. Cycle both “Advance” and “Retract” switches on the remote control,
to neutralize the pressure.
Nosepiece
Pulling Spear
Collet Set O-Ring
(2) Hex. Socket Set Screw
M8 x 1.25 x 12
Nosepiece Adapter
16-130207
Screw-In Holder Base
16-130208
Release Fork
16-130206
Thrust Washer
P1067AE
Compression Spring
16-170303
Threaded Cap
16-181005
Spanner Wrench
16-120022
Hydraulic
Cylinder
17RH303
Collet Holder
/
Adapter Package
16-130210
Nosepiece Adapter
16-130207
Diagram A
Counter Balance
Eye Bolt
Bracket Assembly
80RH303-1
Operator
Side-Handles
Seal Kit # 17-300077
Adjustable Spanner Wrench
16-120025

Tube Tugger 9
OPERATING INSTRUCTIONS
The Tube-Tugger has been designed for efcient use and optimum productivity. The unit is small,
lightweight and portable.
The Tube-Tugger will extract tubes with outside diameters ranging from 5/8” to 1-1/4”. Standard OD
collet jaws and nosepieces are available for 5/8”, 3/4”, 7/8”, 1” and 1-1/4” OD tubes.
Pulling spears are sized for the tube ID. Twenty-ve standard spear sizes are available.
The tool selection guide for the Tube-Tugger is listed on page 12.
1. Determine the OD and ID of the tubes to be extracted.
2. Select the proper tools: Nosepiece, pulling spear and collet set (See Page 12).
3. Install the correct nosepiece and collet set on the Tube-Tugger.
4. Thread the spear into the tube ID using adapter with an impact drive or by hand.
NOTE: Be careful not to impact the spear too deep, as this will cause difculty in extracting
the tubes.
5. Secure Tube-Tugger to counter balance.
6. Position the Tube-Tugger over the spear and hold against the tube sheet.
7. Initiate the stroke of the Tube-Tugger. When the Tube-Tugger has reached its maximum
stroke, initiate the return stroke, keeping the Tube-Tugger in contact with the tube sheet.
Repeat until the tube end is visible from the back end of the collet holder.
8. Once the spear has passed through the collet jaws, stop the Tube-Tugger and remove the
spear from the tube.
9. Continue the extraction until the tube is fully extracted from the vessel. Once the tube is
pulling freely the operator may hand pull the tube through the collet jaws to speed up the
extraction process.
NOTE: The release fork may be used to fully open the collet jaws if required.
10. Repeat steps 4 to 9 until all tubes are extracted.

10 Tube Tugger
OPERATING INSTRUCTIONS (CONT.)
Tube-Tugger in operation.
Diagram D
Tube-Tugger secured to counter balance
and positioned over the spear.
Spear being impacted into tube.
INTRODUCTION
Thank you for purchasing this Elliott product. The design and manufacture of this
machine represents the highest standard of quality, value and durability. Elliott tools
have proven themselves in thousands of hours of trouble free field operation.
If this is your first Elliott purchase, welcome to our company; our products are our
ambassadors. If this is a repeat purchase, you can rest assured that the same value you
have received in the past will continue with all of your purchases, now and in the future.
The Elliott Tube-Tugger®is a portable continuous tube extractor for removing or
extracting tubes from heat exchangers, condensers and chillers. This tube extractor is
hydraulically driven and powered by a separate hydraulic power source: Manual, electric
or pneumatic.
We at Elliott would like you to be completely satisfied with this machine and therefore
recommend that this instruction manual be thoroughly read prior to use.
This machine has been designed and manufactured to the highest standards, using the
latest in materials and technology. If the guidelines and maintenance schedules in this
manual are followed, the Elliott Tube-Tugger will provide many years of trouble free
operation.
Elliott Tool Technologies Ltd shall not be liable for errors contained herein or for incidental or consequential damage in connection
with the furnishing, performance, or use of this material.
Page 2 Elliott Tube-Tugger TM-36 TM-36 Elliott Tube-Tugger Page 7

Tube Tugger 11
TOOL CHANGEOVER
Changing the Nosepiece:
1. Loosen socket screws in nosepiece adapter with Allen wrench.
2. Remove nosepiece from nosepiece adapter.
3. Insert new nosepiece into nosepiece adapter.
4. Make sure that the socket screw engages into slotted ring of the nosepiece.
5. Tighten socket screw to lock in nosepiece.
Changing the Collet Set:
6. Engage spanner wrench into threaded cap and loosen cap.
7. Unthread cap from rear of Tube-Tugger.
8. Remove compression spring and thrust washer.
9. Remove set of collet jaws from Tube-Tugger.
10. Lubricate new set of collet jaws on the OD of the jaws.
11. Insert new set of collet jaws into Tube-Tugger.
12. Insert thrust washer and compression spring.
13. Thread cap onto Tube-Tugger.
14. Secure cap rmly using spanner wrench and release fork.
TABLE OF CONTENTS
Introduction ...................................................................... 2
Safety............................................................................... 3
Start-up ............................................................................ 4
Quick Reference Diagram................................................ 5
Operation ......................................................................6-7
Tool Changeover ............................................................. 8
Tool Selection Guide / Specifications .............................. 9
TOOL CHANGEOVER
Changing The Nosepiece:
1. Loosen socket screws in nosepiece adapter with Allen wrench.
2. Remove nosepiece from nosepiece adapter.
3. Insert new nosepiece into nosepiece adapter.
4. Make sure that the socket screw engages into slotted ring of the nosepiece.
5. Tighten socket screw to lock in nosepiece.
Changing The Collet Set:
Thrust Washer
Collet Set
Diagram E
Socket Screw
Nosepiece
Nosepiece
Adapter
Threaded Cap
Compression Spring
1. Engage spanner wrench into threaded cap and loosen cap.
2. Unthread cap from rear of Tube-Tugger.
3. Remove compression spring and thrust washer.
4. Remove set of collet jaws from Tube-Tugger.
5. Lubricate new set of collet jaws on the OD of the jaws.
6. Insert new set of collet jaws into Tube-Tugger.
7. Insert thrust washer and compression spring.
8. Thread cap onto Tube-Tugger.
9. Secure ca
p
firml
y
usin
g
s
p
anner wrench and release fork.
Page 8 Elliott Tube-Tugger TM-36 TM-36 Elliott Tube-Tugger Page 1

12 Tube Tugger
TOOL SELECTION CHART / SPECIFICATIONS
Tube OD BWG
Spear Minimum Spear
*Diameter
Maximum Spear
*Diameter Male Sq.
Size Nose Piece *Collet Set with O-Ring
29” Reach 48” Reach Inch mm Inch mm
5/8”(15.9mm)
7 TT625-7 TT625-7-48 0.245 6.2 0.385 9.8
1/2” 80-40125N062 80-40125C062
8-9 TT625-8 TT625-8-48 0.280 7.1 0.432 11.0
10-12 TT625-10 - 0.342 8.7 0.482 12.2
13-15 TT625-13 - 0.425 10.8 0.545 13.8
16-18 TT625-16 - 0.485 12.3 0.589 15.0
19-24 TT625-19 - 0.531 13.5 0.615 15.6
3/4” (19.1mm)
7 TT750-7 TT750-7-48 0.370 9.4 0.528 13.4
5/8”
80-40125N075 80-40125C075
8-9 TT750-8 TT750-8-48 0.405 10.3 0.576 14.6
10-12 TT750-10 TT750-10-48 0.467 11.9 0.625 15.9
13-15 TT750-13 TT750-13-48 0.550 14.0 0.685 17.4
16-18 TT750-16 TT750-16-48 0.610 15.5 0.727 18.5
19-24 TT750-19 TT750-19-48 0.656 16.7 0.750 19.1
7/8” (22.2mm)
7 TT875-7 TT875-7-48 0.495 12.6 0.653 16.6
80-40125N087 80-40125C087
8-9 TT875-8 TT875-8-48 0.530 13.5 0.701 17.8
10-12 TT875-10 TT875-10-48 0.592 15.0 0.750 19.1
13-15 TT875-13 TT875-13-48 0.675 17.1 0.810 20.6
16-18 TT875-16 TT875-16-48 0.735 18.7 0.852 21.6
19-24 TT875-19 TT875-19-48 0.781 19.8 0.875 22.2
1” (25.4mm)
7 TT1000-7 TT1000-7-48 0.620 15.7 0.778 19.8
3/4” 80-40125N100 80-40125C100
8-9 TT1000-8 TT1000-8-48 0.655 16.6 0.826 21.0
10-12 TT1000-10 TT1000-10-48 0.717 18.2 0.875 22.2
13-15 TT1000-13 TT1000-13-48 0.800 20.3 0.935 23.7
16-18 TT1000-16 TT1000-16-48 0.860 21.8 0.977 24.8
19-24 TT1000-19 TT1000-19-48 0.906 23.0 1.000 25.4
1-1/4” (31.8mm)
7 TT1250-7 TT1250-7-48 0.870 22.1 1.028 26.1
1” 80-40125N125 80-40125C125
8-9 TT1250-8 TT1250-8-48 0.905 23.0 1.076 27.3
10-12 TT1250-10 TT1250-10-48 0.967 24.6 1.125 28.6
13-15 TT1250-13 TT1250-13-48 1.050 26.7 1.185 30.1
16-18 TT1250-16 TT1250-16-48 1.110 28.2 1.227 31.2
19-24 TT1250-19 TT1250-19-48 1.156 29.4 1.250 31.8
* O-Ring number P8309-225 is supplied with all Collet Sets.
Elliott highly recommends using P8788 Spear Lubricant with your spears to greatly increase spear life.

Tube Tugger 13
TOOL SELECTION CHART / SPECIFICATIONS
Puller Specications
Puller Capacity Stroke Diameter
Lengths
Collapsed Extended Across Handles
80-40125
30 Ton (27.2Mt)
3.000” (76.2mm)
6.500” (165.1mm)
12.940” (329.0mm) 15.940” (405.0mm) 18.250”
(464.0mm)
80-40125-6 6.000” (152.4mm) 18.000” (457.0mm) 22.000” (559.0mm)
Hydraulic Pumps
Part Number Pump Type HP
Maximum
Operating
Pressure
(psi)
Power
Requirement
Weight
Repair Kit
Lbs. Kg.
M5773-00 110V Electric
10,000
25 Amps @110V
88 39.9
17-300332
M5776-00 220V Electric 15 Amps @220V
M5775-00 Pneumatic 3 50 cfm @80 psi 91 41.3
80-36102D3 Manual NA 10,000 NA 28 12.7 17-300508

14 Tube Tugger
TROUBLESHOOTING
Problem Cause Solution
Cylinders will not extend or
retract but pump achieves
full pressure.
Hose connector not properly
seated or pressurized.
Disconnect hoses, relieve
pressure in hoses by
depressing ball into a rag on
oor. To relieve pressure in
female connector insert
wooden dowel into tting,
wrap a rag around connector
and tap with a hammer.

WARRANTY
Should any part, of Seller’s own manufacture, prove to have been defective in material or workmanship
when shipped (as determined by Seller), Seller warrants that it will, at its sole option, repair or replace
said part f.o.b., point of manufacture, provided that Buyer noties, in writing, of such defect within
twelve (12) months from date of shipment from the manufacturing plant.
On request of Seller, the part claimed to be defective will be returned, transportation, insurance, taxes
and duties prepaid, to the factory where made, for inspection. Any item, which has been purchased by
Seller, is warranted only to the extent of the original manufacturer’s warranty to Seller.
Seller shall not be liable for any damages or delays caused by defective material or workmanship.
No allowance will be made for repairs or alterations made by others without Seller’s written consent or
approval. If repairs or alterations are attempted without Seller’s consent, Seller’s warranty is void.
THE WARRANTIES PROVIDED IN THE OBLIGATIONS AND LIABILITIES OF SELLER HEREUNDER,
AND THE RIGHTS AND REMEDIES OF BUYER HEREUNDER ARE EXCLUSIVE AND IN SUBSTITUTION
FOR, AND BUYER HEREBY WAIVES ALL OTHER WARRANTIES, GUARANTEES, OBLIGATIONS,
CLAIMS FOR LIABILITIES, RIGHTS AND REMEDIES, EXPRESS OR IMPLIED, ARISING BY LAW OR
OTHERWISE, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY FOR MERCHANTABILITY
AND FITNESS FOR PURPOSE.
Seller’s total liability is limited to the lower of the cost of repair or replacement.

Elliott Tool Technologies, Ltd.
1760 Tuttle Avenue
Dayton, Ohio 45403-3428
Phone: [phone] • [phone]
Fax: [phone]
www.elliott-tool.com
Printed in the USA
©08/2018 Elliott Tool Technologies, Ltd.
TM-36
PL-8
Elliott Tool offers a complete line of
precision tube tools to meet your needs.
Contact us or your local support.
Contact Us
www.elliott-tool.com/support
Locally Supported By: