Greenlee 2001 User manual

2001-Series
Easy Tugger®Cable Pullers
Effective with Serial Code VL for 115 Volt Pullers
and Serial Code VA for 220 Volt Pullers
99978245 © 2006 Greenlee Textron Inc. IM 979 REV 9 2/06
INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose .......................................................................... 2
Important Safety Information .......................................3-5
Grounding Instructions ................................................... 6
Identification ................................................................... 7
Specifications ................................................................. 8
Cable Pulling Glossary ................................................... 9
Cable Pulling Principles ............................................... 10
Cable Pulling Systems........................................... 10
Pulling Theory ........................................................ 11
Cable Pulling Forces ........................................ 12-16
Tailing the Rope .................................................... 17
Summary of Cable Pulling Principles .................... 18
Planning the Pull .......................................................... 18
Typical Setups.........................................................19-21
Setup and Operation ...............................................22-23
Removing Cable........................................................... 24
Dual Pulling .................................................................. 25
Maintenance............................................................26-28
Troubleshooting ........................................................... 29
Exploded Views and Parts Lists ..............................30-34
Wiring Diagrams........................................................... 35
Table of Contents Description
The Greenlee Easy Tugger®cable puller is intended to
be used to pull cable through conduit and in tray. The
Easy Tugger will develop 8.89 kilo-Newtons (2000 lb)
of pulling force. See a Greenlee catalog for sheaves,
pulling rope, and other cable pulling accessories rated
for use with the Easy Tugger to create an entire cable
pulling system.
No single manual can provide instructions for every
cable pulling application. This manual contains general
information for pulling cable. Illustrations of some typical
setups are also provided.
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
This manual is intended to familiarize operators and
maintenance personnel with Greenlee 2001-series
Easy Tugger cable pullers.
Keep this manual available to all personnel.
KEEP THIS MANUAL
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.
Mobilgrease is a registered trademark of Mobil Oil Corporation.

Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
IMPORTANT SAFETY INFORMATION
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.
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.
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.
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 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

Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
IMPORTANT SAFETY INFORMATION
Inspect all components of the cable-
pulling system. 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 great force.
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.
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.
An underrated rope may break and whip violently.
Use a double-braided composite rope with the
following characteristics:
• Maximum Rated Capacity:
at least 8.89 kN (2000 lb)
• Average Breaking Strength:
at least 35.6 kN (8000 lb)
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.
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.
• 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.
X

Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
IMPORTANT SAFETY INFORMATION
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 great force.
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.
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.
Failure to observe this warning could result in
serious 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.
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 from the capstan.
Rope at the capstan can crush a hand.
Failure to observe this warning could
result in severe injury or death.
Do not operate without chain guards
in place.
Failure to observe this warning could
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 at least 8.89 kN (2000 lb). An underrated con-
nector can break under tension.
Failure to observe this warning could result in severe
injury or death.
Wear eye protection when using this
tool.
Failure to wear eye protection could
result in severe eye injury from
flying debris.
Entanglement hazard:
• Do not operate the cable puller while wearing
loose-fitting clothing.
• Retain long hair.
Failure to observe these warnings could result in
severe injury or death.

Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
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 receptacle
that is properly installed and grounded in accordance
with all national and local codes and ordinances.
Do not use an adapter.
220-Volt Model
20 Amp/125 Volt
Plug and Receptacle
ReceptaclePlug
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 receptacle
that is properly installed and grounded in accordance
with all national and local codes and ordinances.
Do not use an adapter.
10 Amp/250 Volt
Plug and Receptacle
ReceptaclePlug
Electric shock hazard.
• Do not modify the plug provided
with the tool.
• Connect this tool to a grounded
receptacle on a 10-amp GFCI-
protected circuit.
Failure to observe these warnings
could result in severe injury or death.
120-Volt Model

Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
Identification
5. Hole for Vise Chain
6. Vise Chain Pocket
7. Power Cord
8. Tapered Capstan
1. Capstan Chain Guard
2. Handle
3. Guarded ON/OFF Switch
and Circuit Breaker (not shown)
4. Motor
Easy Tugger Identification
1
2
7
4
6
8
5

Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
Weight ................................................................................................... 19.8 kg (44 lb)
Dimensions:
Length ................................................................................................. 381 mm (15")
Width.....................................................................................................483 cm (19")
Height ................................................................................................. 241 cm (9.5")
Power (120-Volt Model) :
Voltage............................................................................................ 120 VAC, 60 Hz
Current .......................................................................................................... 8 Amps
Source .................................................................... 20 Amp GFCI-Protected Circuit
Power (220-Volt Model):
Voltage............................................................................................ 220 VAC, 50 Hz
Current .......................................................................................................... 4 Amps
Source .................................................................... 10 Amp GFCI-Protected Circuit
Maximum Pulling Force....................................................................8.89 kN (2000 lb )
Speed:
No load .............................................................. 6.7 meters/minute (22 feet/minute)
8.89 kN (2000 lb) ............................................. 3.35 meters/minute (11 feet/minute)
Duty Cycle:
0 - 6.22 kN (0 - 1400 lb) ......................................................... Continuous Operation
6.22 - 8.89 kN (1400 - 2000 lb) ................................. 10 minutes on / 10 minutes off
Pulling Rope:
Average Breaking Strength............................................ 35.6 kN (8000 lb) minimum
Specifications

Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
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 under-
neath 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
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
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)
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
Cable Pulling Glossary

Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2001-Series Easy Tugger Cable Pullers
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
Tailing
Force