INSTRUCTION MANUAL

640-Series
Tugger®
Cable Pullers
Effective with Serial Code YJ for 115 Volt Pullers
and Serial Code ACR for 220 Volt Pullers

Read and understand all of the instructions and

safety information in this manual before operating
or servicing this tool.

99997657 © 2006 Greenlee Textron Inc. IM 1076 REV 14 2/06

 640-Series Tugger® Cable Pullers

Table of Contents Description

Description ..................................................................... 2 The Greenlee Tugger® cable puller is intended to be
used to pull cable through conduit and in tray. The
Purpose of this Manual .................................................. 2
Tugger will develop 17.8 kilo-Newtons (4000 lb) of
Important Safety Information ....................................... 3-5 pulling force. See a Greenlee catalog for sheaves,
Grounding Instructions ................................................... 6 pulling rope, and other cable pulling accessories rated
for use with the Tugger to create an entire cable pulling
Identification ................................................................... 7 system.
Specifications ................................................................. 8 No single manual can provide instructions for every
Cable Pulling Glossary ................................................... 9 cable pulling application. This manual contains general
Cable Pulling Principles .......................................... 10-18 information for pulling cable. Illustrations of some typical
setups are also provided.
Cable Pulling Systems ........................................... 10
Pulling Theory ........................................................ 11
Cable Pulling Forces ........................................ 12-16
Tailing the Rope .................................................... 17
Safety
Summary of Cable Pulling Principles .................... 18 Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
Planning the Pull .......................................................... 18 and any markings on the tool provide information for
Typical Setups ......................................................... 19-21 avoiding hazards and unsafe practices related to the use
Setup and Operation ............................................... 22-23 of this tool. Observe all of the safety information provided.
Removing Cable ........................................................... 24
Dual Pulling .................................................................. 25
Maintenance ............................................................ 26-28 Purpose of this Manual
Troubleshooting ........................................................... 29 This manual is intended to familiarize operators and
Exploded Views and Parts Lists .............................. 30-39 maintenance personnel with the following Greenlee
640-series cable pullers:
Wiring Diagrams ...................................................... 40-41
120-Volt Models: 640
642
676
686
220-Volt Models: 640-22
642-22
686-22
This manual should be kept available to operating and
maintenance personnel.

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.

KEEP THIS MANUAL

Greenlee / A Textron Company 2 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

IMPORTANT SAFETY INFORMATION

SAFETY
Read and understand all of the
ALERT instructions and safety information
in this manual before operating or
SYMBOL servicing this tool.
This symbol is used to call your attention to hazards Failure to observe this warning will
or unsafe practices which could result in an injury result in severe injury or death.
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.
Do not operate the cable puller in a
hazardous environment. Hazards
include flammable liquids and gases.
Immediate hazards which, if not avoided, WILL Failure to observe this warning will
result in severe injury or death. result in severe injury or death.

Hazards which, if not avoided, COULD 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
Hazards or unsafe practices which, if not avoided, result in severe injury or death.
MAY result in injury or property damage.

Greenlee / A Textron Company 3 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

IMPORTANT SAFETY INFORMATION

Inspect all components of the cable- Locate the puller so that it is close to the conduit.
pulling system. Verify the maximum Rope, cable, or connectors can break under tension,
load-bearing capacity or maximum causing the rope to whip violently.
strength of all structural supports,
Failure to observe this warning could result in severe
pulling system components and
injury or death.
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 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 under-rated rope may break and whip violently.

Use a double-braided composite rope with the
following characteristics:
Do not stand directly under a vertical • Maximum Rated Capacity:
pull. Cable could fall suddenly from at least 17.8 kN (4000 lb)
the conduit, injuring nearby personnel. • Average Breaking Strength:
Failure to observe this warning could at least 71.2 kN (16,000 lb)
result in severe injury or death. 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 • Check the condition of the entire rope before use.
the anti-reversing pawl when the capstan is rotating, A worn or damaged rope can break under tension
shut the puller off and have it repaired by an and whip violently.
authorized Greenlee service center. • Do not maintain a stationary rope on a rotating
Failure to observe this warning could result in severe capstan. The wear generated may cause the rope
injury or death. to break under tension and whip violently.
Failure to observe these warnings could result in
severe injury or death.

Greenlee / A Textron Company 4 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

IMPORTANT SAFETY INFORMATION

Attach the pulling rope to the cable with appropriate Do not operate without chain guards
types of connectors as described in this manual. in place.
Select connectors with a maximum rated capacity Failure to observe this warning could
of at least 17.8 kN (4000 lb). An under-rated con- result in severe injury or death.
nector can break under tension.
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.
Keep hands away from the capstan. • The load may fall.
Rope at the capstan can crush a hand.
Failure to observe this warning could result in severe
Failure to observe this warning could injury or death.
result in severe injury or death.

Inspect puller and accessories before use. Replace

Do not wrap rope around hands, any worn or damaged components with Greenlee
arms, waist or other body parts. replacement parts. A damaged or improperly
Do not stand in spent coils or tailed assembled item can break and strike nearby
rope. Hold rope so that it may be personnel with great force.
released quickly.
Failure to observe this warning could result in
Failure to observe this warning could severe injury or death.
result in severe injury or death.

Entanglement hazard:
Rope, cable, or a connecting device can break
under tension, causing the rope to whip violently. • Do not operate the cable puller while wearing
loose-fitting clothing.
• Do not allow any unnecessary personnel to
remain in the area during the pull. • Retain long hair.
• Do not allow any personnel to stand in line with Failure to observe these warnings could result in
the pulling rope. severe injury or death.
Failure to observe these warnings could result in
serious injury or death.

Wear eye protection when using this

tool.
Do not allow the rope to become overlapped on the Failure to wear eye protection could
capstan. If an overlap begins to develop, relax the result in severe eye injury from
tailing force immediately and shut off the cable puller. flying debris.
Failure to observe this warning could result in severe
injury or death.

Greenlee / A Textron Company 5 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Grounding Instructions
120-Volt Model 220-Volt Model

Electric shock hazard. Electric shock hazard.

• Do not modify the plug provided • Do not modify the plug provided
with the tool. with the tool.
• Connect this tool to a grounded • Connect this tool to a grounded
receptacle on a 20-amp GFCI- receptacle on a 10-amp GFCI-
protected circuit. protected circuit.
Failure to observe these warnings Failure to observe these warnings
could result in severe injury or death. could result in severe injury or death.

This tool must be grounded. In the event of a malfunction This tool must be grounded. In the event of a malfunction
or breakdown, an electrical ground provides a path of or breakdown, an electrical ground provides a path of
least resistance for the electric current. This path of least least resistance for the electric current. This path of least
resistance is intended to reduce the risk of electric shock. resistance is intended to reduce the risk of electric shock.
This tool’s electric cord has a grounding conductor This tool’s electric cord has a grounding conductor
and a grounding plug as shown. Do not modify the and a grounding plug as shown. Do not modify the
plug. Connect the plug to a corresponding receptacle plug. Connect the plug to a corresponding receptacle
that is properly installed and grounded in accordance that is properly installed and grounded in accordance
with all national and local codes and ordinances. with all national and local codes and ordinances.
Do not use an adapter. Do not use an adapter.

20 Amp/125 Volt 10 Amp/250 Volt

Plug and Receptacle Plug and Receptacle

Plug Receptacle Plug Receptacle

Greenlee / A Textron Company 6 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Identification

12
2
4
6
1
11 5
10
3

9 7

Tugger Identification

1. Entrapment Peg 7. Handle/Cleat

2. Capstan Chain Guard 8. Right-Angle Idler Sheave
3. Guarded ON/OFF Switch 9. Tapered Capstan
and Circuit Breaker 10. Rope Ramp
4. Motor 11. Pivoting Capstan Arm
5. Motor Chain Guard 12. Positioning Peg
6. Force Gauge with ON/OFF Switch
(optional)

Greenlee / A Textron Company 7 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Specifications
Mass/Weight .................................................................................... 30.8 kg (68 lb)
Dimensions:
Length ........................................................................................ 533 mm (21")
Width .......................................................................................... 533 mm (21")
Height ......................................................................................... 305 cm (12")
Power (120-Volt Model) :
Voltage ................................................................................... 120 VAC, 60 Hz
Current ................................................................................................ 17 Amps
Source ............................................................ 20 Amp GFCI-Protected Circuit
Power (220-Volt Model):
Voltage ................................................................................... 220 VAC, 50 Hz
Current ............................................................................................... 7.5 Amps
Source ............................................................ 15 Amp GFCI-Protected Circuit
Maximum Pulling Force ............................................................... 17.8 kN (4000 lb)
Speed:
No load .................................................... 10.7 meters/minute (35 feet/minute)
8900 Newtons (2000 lb) .......................... 4.88 meters/minute (16 feet/minute)
17.8 kN (4000 lb) ....................................... 1.83 meters/minute (6 feet/minute)
Duty Cycle:
0 - 11.1 kN (0 - 2500 lb) ................................................. Continuous Operation
11.1 - 15.6 kN (2500 - 3500 lb)
(alarm will sound) ............................................. 15 minutes on / 15 minutes off
15.6 - 17.8 kN (3500 - 4000 lb)
(alarm will sound) ............................................... 5 minutes on / 15 minutes off
Pulling Rope:
Average breaking strength .................................71.2 kN (16,000 lb) minimum

Greenlee / A Textron Company 8 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Glossary

anchoring system pulling force
any item or group of items that keeps a cable pulling the amount of pulling tension developed by the cable
component in place during the cable pull puller, rated in Newtons (metric) or pounds; a cable
puller is usually described by the maximum pulling force
capstan that it can develop
the hollow cylinder of the cable puller that acts on the
resultant force
pulling rope to generate pulling force
any force that is produced when two or more forces act
coefficient of friction on an object; applies to the sheaves of a cable pulling
system
the ratio that compares two amounts of force:
(1) the force needed to move an object over a surface and
rope ramp
(2) the force holding the object against the surface
a device that works with a tapered capstan; guides the
This ratio is used to describe how the capstan and the rope onto the capstan to help prevent rope overlap
rope work together.
sheave
connector
a pulley that changes the direction of the rope and cable
any item, such as a wire grip, clevis, swivel, or pulling
grip, that connects the rope to the cable stored energy

direct line of pull the energy that accumulates in the pulling rope as it
stretches, described in Newtons-meters (metric) or
the areas next to the pulling rope and along its path; foot-pounds
this includes the areas in front of, in back of, and
underneath the rope support structure

maximum rated capacity any stationary object that a cable pulling system
component is anchored to, such as a concrete floor
the amount of pulling tension that any component (for the floor mount) or an I-beam (for a sheave)
can safely withstand, rated in kilo-Newtons (metric)
or pounds; the maximum rated capacity of every tail
component must meet or exceed the maximum pulling
force of the cable puller the portion of the rope that the operator applies force to;
this is the rope coming off of the capstan, and is not
Newton under the tension of the pull

a metric unit of force, equivalent to .225 pounds of force tailing the rope

pipe adapter sheave the operator’s main function; this is the process of
applying force to the tail of the pulling rope—see the
attaches to conduit for pulling or feeding cable complete explanation under Principles of Cable Pulling

pulling grip wire grip

connects the rope to the cable; consists of a wire mesh connects the rope to the cable; some use a set screw to
basket that slides over the cable and grips the insulation clamp onto the conductors of the cable

Greenlee / A Textron Company 9 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles

Pulling cable is a complex process. This section of Cable Pulling Systems
the manual describes and explains four main topics
Pulling cable requires a system of components. At a
of pulling cable:
minimum, a cable pulling system will include a cable
• each cable pulling system component puller, a cable pulling rope, and connectors to join the
• how these components work together rope to the cable. Most systems will also include, but are
not limited to, a cable puller anchoring system, pulling
• forces that are generated sheaves and sheave anchoring systems.
• procedures for the cable puller operator to follow The cable puller has a maximum amount of pulling force,
While reading through this section of the manual, look which is the amount of pulling tension that it develops.
for components that are shaded in the illustrations. The Every other component of the pulling system has a
shading indicates components that are associated with maximum rated capacity, which is the amount of pulling
the text. tension that it can withstand. The maximum rated
Greenlee strongly recommends that each member of the capacity of every component must meet or exceed the
cable pulling crew review this section of the manual cable puller’s maximum pulling force.
before each cable pull.

Typical Cable Pulling System

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

Cable Pulling Principles (cont’d)

Pulling Theory To accomplish a cable pull, the cable pulling system
must develop more force than the combination of gravity
This section introduces the main ideas involved with
and friction.
pulling cable.
Generating Pulling Force
Pulling Resistance
To generate pulling force, the capstan works as a
The cable puller must overcome two types of resistance:
force multiplier. The operator exerts a small amount
gravity and friction.
of force on the rope. The cable puller multiplies this
Gravity constantly exerts its force on the vertical and generates the pulling force.
portions of the run. When the pulling force is relaxed,
This pulling force is applied to the rope, connectors,
gravity attempts to pull the cable downward. Friction
and cable in order to accomplish the pull. The direction
develops where the cable contacts the sheaves, conduit
of force is changed, where necessary, with pulling
and tray. Friction resists any movement, forward or
sheaves.
backward, and tends to hold the cables in place.

Cable Pulling Theory Illustrated

Friction
Gravity
Pulling Force
17.8 kN
(4000 lb)
Conduit

Weight
of Cable

Tailing
Force

Greenlee / A Textron Company 11 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Cable Pulling Forces At the Cable Puller Anchoring System
This section provides detailed explanations and illustra- The cable puller will exert its maximum pulling force on
tions of the forces that are generated during the cable cable puller’s anchoring system. It is extremely important
pull. These explanations are based on the concepts the anchoring system can withstand this amount of
presented in the previous section, Pulling Theory. force. See the instruction manual provided with your
anchoring system for proper setup or installation.

Pulling Force at the Cable Puller’s Anchoring System

Pulling Force
17.8 kN
(4000 lb)

17.8 kN 17.8 kN
(4000 lb) (4000 lb)
Maximum Maximum

Maximum Pulling Force

at Anchoring System

Greenlee / A Textron Company 12 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d) The following table is based on the formula above.
The input, or tailing force, is constant at 44.5 Newtons
At the Capstan (10 lb). Increasing the number of wraps increases
the pulling force.
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. Number
The resultant force depends upon the number of times Operator’s of Wraps Approximate
the rope is wrapped around the capstan, as shown in the Tailing Force of Rope Pulling Force
formula below.
1 93.4 N (21 lb)
Pulling Force = Tailing Force x e0.0175µø 2 213.5 N (48 lb)
Where: e = the natural logarithm, or 2.7183 3 474.9 N (106 lb)

µ = the coefficient of friction between the 44.5 N (10 lb) 4 1043.8 N (233 lb)
rope and the capstan * 5 2293.7 N (512 lb)
6 5048.9 N (1127 lb)
ø = the number of degrees of wrap of rope
around the capstan 7 11.1 kN (2478 lb)
* The average value for the coefficient of friction when
double-braided composite rope is pulled over a clean This table shows how the capstan acts as a force
dry capstan is 0.125. multiplier. Because the coefficient of friction depends
upon the condition of the rope and capstan, this formula
cannot determine an exact amount of pulling force.

The Capstan as a Force Multiplier

Pulling Force: 17.8 kN (4000 lb)

Tailing
Force

Greenlee / A Textron Company 13 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d) Double-braided composite rope is the only type of rope
recommended for use with the Tugger cable puller.
At the Pulling Rope Select a double-braided composite rope with an
The product of a force (f) moving through a distance (d) average rated breaking strength of at least 71.2 kN
is energy (f x d), and may be measured in Newton- (16,000 lb).
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.

Stored Energy

Stored Energy

Greenlee / A Textron Company 14 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d) When selecting a pulling grip, it is extremely important to
select a grip of the correct (1) type, (2) size, and (3)
At the Connectors maximum rated capacity.
The connectors will be subjected to the cable puller’s 1. Select the correct type based on the descriptions
maximum pulling force. of each type in the Greenlee catalog.
Several types of rope connectors—clevises, swivels, 2. Measure the circumference of the wire bundle.
and rope-to-swivel connectors—are available. Follow (To do this accurately, fasten a tie strap around the
the instructions provided with each to provide a good bundle. Cut off and discard the tail. Then cut the tie
connection. strap and measure its length.) Use the table pro-
Two types of wire connectors—wire grips and pulling vided to find the correct size.
grips—are available. The wire grip uses a set screw 3. See the maximum rated capacities in the Greenlee
to clamp onto the conductors of the cable. The pulling catalog.
grip consists of a wire mesh basket that slides over
the cable and grips the insulation.

A Typical Grip Setup—Clevis and Wire Grip Pulling Grip Size Table

Circumference Range Required Grip Diameter

Maximum inches mm inches mm
Pulling Force
17.8 kN 1.57 - 1.95 39.9 - 49.5 0.50 - 0.61 12.7 - 15.5
(4000 lb)
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
A Typical Grip Setup—Swivel and Pulling Grip 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

Maximum 7.85 - 9.42 199.4 - 239.3 2.50 - 2.99 63.5 - 75.9

Pulling Force
9.42 - 11.00 239.3 - 279.4 3.00 - 3.49 76.2 - 88.6
17.8 kN
(4000 lb) 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

Greenlee / A Textron Company 15 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Cable Pulling Forces (cont’d) Resultant Force Table for the Tugger
(17.8 kN or 4000 lb Maximum Pulling Force)
At the Sheaves
Angle of Change Resultant Force
Sheaves are used to change the direction of the pull. Illustration
A change in direction creates a new resultant force that in Direction in kN (lb)
is greater than the cable puller’s maximum pulling force.
This new resultant force exerts itself on the sheaves,
sheave anchoring system, and support structures 180° 0 (0)
illustrated.
The resultant amount of force depends on the angle of
the change in direction. A brief table is provided here;
for more details, see IM 1363 (99929988). 150° 9.25 (2080)

135° 13.7 (3080)

120° 17.8 (4000)

90° 25.1 (5640)

T T

60° 30.8 (6920)

45° 32.9 (7400)

30° 34.3 (7720)

0° 35.6 (8000)

Typical Resultant Force at Sheave

135°

Resultant Force=
13.7 kN (3080 lb)

Greenlee / A Textron Company 16 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d)

Tailing the Rope Number of Wraps of Rope Around the Capstan
The rope must be pulled off of the capstan as the pull An experienced operator should choose the number of
progresses. The rope that has left the capstan is the times the rope is wrapped around the capstan.
“tail.” The process of pulling the rope off of the capstan is The proper number of wraps allows the operator to
called tailing the rope. control the progress of the pull with a comfortable
The resistance of the cable varies throughout the amount of effort.
duration of the cable pull. Changes in resistance are due Using too few wraps requires a large tailing force to
to characteristics of the rope, changes in conduit direc- accomplish the pull. Using too few wraps also makes the
tion, and changes in the amount of friction. The “feel” of rope more likely to slip on the capstan. This builds up
the rope provides this information about the pull. This is heat and accelerates rope wear.
called tactile feedback. Adjust the tailing force as neces-
sary to compensate for these changes. Using too many wraps causes the rope to grab the
capstan more tightly. This accelerates rope wear, wastes
Control of the Pull power, and increases the possibility of a rope overlap.
Using too many wraps also reduces tactile feedback, so
Decreasing the tailing force will decrease the pulling you receive less information about the pull. You cannot
force, until the rope slips on the capstan and the pull quickly relax the tailing force when there are too many
stops. This provides a high level of control over the wraps.
progress of the cable pull.
If the rope becomes difficult to tail, add another wrap of
Do not allow the rope to slip on the capstan for more rope. Turn off the puller and release all of the tension in
than a few moments. If it becomes necessary to com- the rope. Add a wrap and resume pulling. Be aware,
pletely stop a pull, shut off the puller and maintain however, that some pulls will require tension to hold
enough tailing force to hold cable in place. Tie the rope the cables in place. In these cases, do not attempt to
off to hold it in place. release all of the tension and add a wrap of rope. You
Amount of Tailing Force will need to anticipate the number of wraps before
starting the pull.
While the rope and cable are under tension, it is impor-
tant to maintain the proper amount of tailing force. Preventing Rope Overlap
Too little tailing force will allow the rope to slip on the Do not allow the rope to become overlapped on the
capstan. This will build up excessive heat and accelerate capstan during a pull.
rope wear, increasing the possibility of breaking the rope. A rope overlap will make it impossible to continue or
The proper amount of tailing force will stop the rope from back out of the pull.
slipping on the capstan and produce a sufficient amount If the rope becomes overlapped, you will lose control of
of pulling force to pull in the rope and cable. the pull—the rope will advance with no tailing force and
Too much tailing force is any amount more than is will not feed off of the capstan. The capstan will not allow
necessary to stop the rope from slipping on the capstan. you to reverse the direction of the rope, so you cannot
Excessive tailing force will not increase the pulling force back out of an overlap.
or pulling speed. Set up the puller properly. The positioning peg, entrap-
ment peg, rope ramp and tapered capstan are intended
to prevent rope overlap. See 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 overlapping 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!

Greenlee / A Textron Company 17 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Cable Pulling Principles (cont’d) Planning The Pull

Summary of Cable Pulling Principles • Pull in a direction that will require the lowest amount of
• A cable pulling system consists of many components pulling force.
that work together to accomplish a pull. • Plan several shorter pulls rather than fewer longer pulls.
• The cable puller is rated by its maximum pulling force; • Locate the puller as close to the end of the conduit as
every other component is rated by its maximum rated possible to minimize the amount of exposed rope
capacity. The maximum rated capacity of every under tension.
component must meet or exceed the maximum pulling • Place each component so that the pulling forces are
force of the cable puller. used effectively.
• The cable puller must overcome two types of resis- • Select an anchoring system: adapter sheaves, which
tance: gravity and friction. The puller’s capstan, the are preferred, or the floor mount.
pulling rope, and the operator tailing the rope work
together to produce pulling force. • Verify that each component has the proper load rating.
• The cable puller exerts force on every component of • Inspect the structural supports. Verify that they have
the cable pulling system, including the anchoring enough strength to withstand the maximum forces that
systems and the support structures. may be generated.
• Energy is stored in a rope when the load causes the
rope to stretch. Failure of the rope or any other compo-
nent 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.

Greenlee / A Textron Company 18 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Typical Setups—using 11147 Adapter Package

Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view of
the meter and quick access to its ON/OFF switch.

Pulling Horizontally in Manhole

Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler

Pulling Horizontally in Manhole

Using Two Booms, Nose Unit,
Elbow Unit and Slip-in Coupler

Greenlee / A Textron Company 19 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Typical Setups—using 11147 Adapter Package (cont’d)

Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view of
the meter and quick access to its ON/OFF switch.

Pulling Up Using One Boom,

Nose Unit and Slip-in Coupler

Pulling Up Using Two Booms, Nose Unit,

Elbow Unit and Slip-in Coupler

Greenlee / A Textron Company 20 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Typical Setups (cont’d)

Setups are shown without force gauge. Place the force gauge so the operator has an unobstructed view
of the meter and quick access to its ON/OFF switch.

Using a Manhole Sheave Using Feeding Sheaves in Manholes

Generator

UNOCCUPIED MANHOLE UNOCCUPIED MANHOLE

ABOVE GROUND UNOCCUPIED MANHOLE

Using a Floor Mount

Greenlee / A Textron Company 21 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Setup and Operation

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 accompanying text. Install the vise chains properly.
• Follow the vise chain tightening instructions
1. Fish the rope through the conduit. carefully. Improperly tightened chains can allow
2. Set up the cable puller mounting. Set it up so that the puller to slide or break loose and strike nearby
the rope will approach the capstan at an angle of personnel.
90° (±5°) as illustrated in Rope Approaching the • Do not allow the vise chains to bind at the corners
Capstan. when mounting the puller to a square or rectangu-
Note: If using an adapter sheave, flexible pipe lar support. The vise chain must be uniformly tight
adapter, or mobile T-boom, see the illustrations in at all points.
this manual. If using a manhole sheave or floor
mount, see the instructions supplied with those items. Failure to observe this warning could result in severe
injury or death.

Rope Approaching the Capstan

3. Install the vise chains as shown.

Vise Chain Installation

90° ±5° A CHAIN

POCKETS

E B

POSITIONER

POSITIONING
BLOCK
D
GRIPPING
FEET

NO

When setting up the flexible pipe

adapter or puller, do not use the vise
chains on a structural support that
is less than 51 mm (2") or more than
NO
254 mm (10") wide. An oversized
or undersized structural support
can allow the puller to slide or break
loose and strike nearby personnel
with sufficient force to cause severe
injury or death.

Greenlee / A Textron Company 22 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Setup and Operation (cont’d)

5. Align the rope ramp and route the rope as illustrated 6. Check the ON/OFF switch on the puller to be sure
in Rope Path, Top View and Rope Path, Side View. it is OFF. Plug the puller into the receptacle of the
Note: Use every component of the rope path—the standard force gauge. Plug the force gauge into an
positioning peg, entrapment peg, rope ramp and tapered appropriate power supply (see Grounding Instruc-
capstan—as shown to help prevent rope overlap. tions in this manual).
Note: If using an extension cord, it must be rated
for the current rating of the puller. Use the shortest
cord possible. Longer cords reduce puller speed.
Rope Path, Top View
7. Position the force gauge so that it can be monitored
by the puller operator.

90° ±5° Duty Cycle Table

Color
Band Pounds of Alarm Duty Cycle
on Meter Pulling Force (in minutes)

Green 0-2500 off continuous

Yellow 2500 - 3500 on 15 on / 15 off
Yellow 3500 - 4000 on 5 on / 15 off
Red over 4000 on puller will stop

Ramp 8. Grasp the tailing end of the rope. Apply a slight

amount of tailing force.
9. Turn the puller ON.
10. Tail the rope, allowing the spent rope to accumulate
Operator Tailing End on the floor between the operator and the puller.
Note: The capstan arm is intended to pivot.
Do not attempt to stop the arm from pivoting.
Rope Path, Side View
11. When the pull is complete, turn the puller OFF.
Tie off the rope to the T-shaped cleat and anchor the
Positioning cable.
Peg

Capstan
Entrapment Arm
Peg

Operator
Tailing End

Greenlee / A Textron Company 23 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Removing Cable
Removing old cable involves the same principles as Puller Placement
installing new cable. However, there are some important
Pulling out old cable is generally accomplished with the
differences.
puller located some distance away from the end of the
Pulling Force conduit. This allows the pulling crew to pull out a long
section of cable before turning off the puller, cutting off
It is difficult to predict the amount of pulling force the cable, and reattaching the grip(s). Mounting the
necessary to remove an old cable. The cable may be cable puller a distance away from the end of the conduit
damaged, and it may break with an unexpectedly low increases the amount of exposed rope, which greatly
pulling force. increases the amount of violent whipping action which
The required pulling forces may be very high: would occur if the rope or other components were
to break.
• The cable has probably “taken a set.” Unlike the new
cable on a reel, cable in conduit has probably been in To isolate the operator from the rope path:
the conduit for years, or perhaps decades. The cable • Locate the puller so that you will stand behind an
will resist bending and straightening as it is pulled obstruction, such as a wall. Set up the puller so that
through the conduit. you will be able to maintain control of the pull. You
• The pulling lubricant has probably hardened, increas- need a clear view of the rope as it feeds onto the
ing pulling resistance. capstan, including several feet of the rope in front of
the capstan. You must be able to turn off the puller
• The insulation may be damaged and the cable may be
before the pulling grip, connector, or swivel contacts
corroded.
the capstan.
• Dirt or other foreign matter may have entered the
• Use an additional pulling sheave to change the
conduit and may have cemented the cable in place.
direction of the tailing rope. Anchor the sheaveso that
Using a Force Gauge you are close enough to maintain control of the pull.
You need a clear view of the rope as it feeds onto the
When pulling old cable out of a conduit, the pulling force capstan, including several feet of the rope in front of
will be highest when starting the pull. Select a cable the capstan. You must be able to turn off the puller
puller and pulling components to meet or exceed the before the pulling grip, connector, or swivel contacts
estimated amount of pulling force necessary to remove the capstan.
the old cable. Because breaking the cable free will
require the largest amount of pulling force, it is neces- Note: Use the additional pulling sheave to change the
sary to use a force gauge to prevent overloading the direction of the tailing rope (after the rope leaves the
system components. For the 120-volt Tugger, use capstan). Do not change the direction of the pulling
the 37171 Force Gauge. For the 220-volt Tugger, rope.
use the 05726 Force Gauge. • Use a longer tailing rope than usual and stand
Carefully monitor the pulling force at the force gauge; away from the puller. Stand as far from the puller as
if the puller is not able to begin the pull, shut off the possible, while maintaining control of the pull. You
puller and disassemble the setup. Start over with a puller need a clear view of the rope as it feeds onto the
and components of a higher force rating. 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.

Greenlee / A Textron Company 24 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

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

Dual Pulling

Greenlee / A Textron Company 25 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Maintenance
Read all instructions thoroughly. Be sure that you Lubricating the Drive Chains (every 20 hours)
understand all of the instructions and have the 1. Remove the right guard (45) and left guard (3).
necessary tools available before dismantling the puller.
2. Lubricate the inside of the chains with 80W-90W
gear oil.
Service Activity Schedule
3. Replace the guards and screws.
Lubricate the drive chains. every 20 hours
Greasing the Drivetrain Shafts (every 20 hours)
Grease the drive chain shafts. every 20 hours
Apply a multipurpose NLGI Grade 2 grease (such as
Inspect the chains and ratchet pawl. every 40 hours Mobilgrease® HP or Amoco Permalub) at the grease
Inspect the commutator brushes. every 40 hours fittings (4 and 64). These fittings are located inside the
capstan housing and under the countershaft (67).

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.

Greenlee / A Textron Company 26 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Maintenance (cont’d)
Inspecting the Chains and Ratchet Pawl Inspecting the Commutator Brushes
(every 40 hours) (every 40 hours)
1. Remove the right guard (45) and left guard (3). 1. Remove two brush caps (101). Remove two
2. Remove the connecting link (41) and #35 chain (40). brushes (102).
3. Remove the capstan retaining screws (2). Remove 2. Measure the brushes. Replace both brushes if either
the lubricating screw (4) and washers (5-9). Remove brush is less than 9mm (3/8") long.
capstan unit (10-19). Remove connecting link (21)
and #50 chain (20).
4. Clean the chains thoroughly with solvent.
5. Lay the chains against a straightedge. Slide one
end of the chain back and forth to check free play.
See illustration below. If free play is more than 9mm
(3/8"), replace the chain. Replace the chain if any
links bind.

FREE PLAY

6. Lubricate the chains with 80W-90W gear oil.

7. Remove the ratchet pawl (70) and compression
spring (69). Apply multipurpose NLGI Grade 2
grease (such a Mobilgrease® HP or Amoco
Permalub) to all working surfaces. Replace the
spring and pawl.
8. Assemble the #35 chain (40).
Note: Install the clip of each connecting link so that
the closed end of the clip faces the direction of chain
travel, as shown in the Exploded View.
9. Loosen, but do not remove, the four screws (38)
that secure the motor. Push the motor away from the
#35 sprocket (40) to put tension on the chain.
Tighten the screws (38) to 8 Newton-meters (6 ft-lb).
10. Assemble in reverse order.
11. Plug the puller in and turn the puller ON. Listen for
the clicking noise of the anti-reversing mechanism
(ratchet pawl and compression spring). If you do not
hear this clicking noise, inspect and repair the puller.

Do not operate puller if the anti-reverse mechanism

is not working.
Failure to observe this warning could result in severe
injury or death.

Greenlee / A Textron Company 27 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Maintenance (cont’d)
Replacing the Frame Troubleshooting the Electrical Circuit

Electric shock hazard: Electric shock hazard:

Disconnect the cable puller from Disconnect the cable puller from
the power supply before servicing. the power supply before servicing.
Failure to observe this warning could Failure to observe this warning could
result in severe injury or death. result in severe injury or death.

Replace the frame if it appears damaged. During dis- See the wiring diagram. Use a continuity checker to
assembly, inspect each part. Replace any worn, dam- check the electrical circuit. Lack of continuity in the
aged, or missing parts with Greenlee replacement parts. following procedure indicates that a repair is necessary.
Replace the needle bearings (61) regardless of their 1. Unplug the puller.
appearance.
2. Set the switches to ON.
1. Remove the left guard (3). Remove the lubricating
screw (4), washers (5-9), and capstan unit (10-19). 3. Place the probes of the continuity checker across
the following terminals of the cable puller and force
2. Remove the #50 chain (20). Remove the sprocket gauge. All of these pairs of terminals should have
(22) and washers (7). continuity.
3. Remove the right guard (45). Remove the #35 chain.
4. Remove the retaining ring (46), #50 sprocket (67), To check the switch:
and all items located on the sprocket (39, 43, 44 A and B
and 60-64). Discard the needle bearings (61). C and D (220-volt models only)
5. Remove the switch (52), horn (65), and related
components. To check the connectors:
6. Remove the motor, sheave, ratchet pawl and feet. E and A
7. Assemble items to the new frame in reverse order. F and K
Notes: Replace any components that show signs of G and H
wear or damage.
When replacing the items of the sprocket (67) To check the motor:
assembly, install new needle bearings (61). J and K
Install the clip of each connecting link so that the If the motor fails this check, inspect the motor com-
closed end of the clip faces the direction of chain ponents (brushes, armature, and wires). Replace any
travel, as shown in the Exploded View. parts that are worn or damaged. Replace both brushes
if either brush measures less than 9mm (3/8") long.

Greenlee / A Textron Company 28 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Troubleshooting
Should the puller become inoperative, refer to the troubleshooting table below. While performing any repairs,
inspect the motor, capstan, and drivetrain.

Problem Probable Cause Probable Remedy

Motor will not run. No power at supply circuit. Check power supply with a voltmeter.
See the Specifications section of this
manual.

Faulty switch or wiring. Check the switch and wiring for

continuity.

Motor faulty. Check the motor and wiring for

continuity. Check condition of brushes.
Replace any worn or damaged items.

Replace motor

Capstan does not rotate #50 chain broken. Replace #50 chain.
while motor is running.

#35 chain broken. Replace #35 chain.

Broken sprocket in gearbox or stripped Disassemble puller. See disassembly

shaft in motor. instructions under Inspecting the
Chains and Ratchet Pawl. Replace
any worn or damaged drive
components.

Greenlee / A Textron Company 29 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 33
Torque Specifications
32
1 8 Newton-meters 15
(6 foot-pounds)
220V
has eye
Parts List

2 10.8 Newton-meters
12
(8 foot-pounds)
14
3 13.5 Newton-meters 2 30 31
3 13 29
(10 foot-pounds)

4 20.3 Newton-meters

Greenlee / A Textron Company

28 34
(15 foot-pounds) 11

5 67.8 Newton-meters 35
(50 foot-pounds) 9 36
8 37

1
7
6 11
38 2 46
5
1 38 1
45
10
41
4 5 42 44
1 43

25 27
3 26 40

30
1 23
4 2 47 1
39
220V
52 48 has eye

21 24
1 7 50
22 51 49

60 53
69 54
71
20 70 72
18 73
68
55 5 74
17 61
62 59 56
16 67 63
57
64 57

19 65
1 66 75
65 58 2

4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

640-Series Tugger® Cable Pullers
 640-Series Tugger® Cable Pullers

Parts List (cont’d)

Key Part No. Description Qty

1 90531949 Screw, self-tapping, #10 –16 x .250, Phillips head.......................... 11

2 90539222 Screw, cap, 3/8 – 16 x 2.75 skt head ................................................ 4
3 50353020 Guard, left .......................................................................................... 1
4 50255215 Screw unit, lubricating ....................................................................... 1
5 90516036 Washer, lock, .643 x 1.08 x .156 spring ............................................ 1
6 50299387 Washer, flat, .687 x 2.00 x .125 ........................................................ 1
7 50258966 Washer, flat, 1.28 x 1.75 x .125 fiber ................................................ 4
8 90526449 Washer, flat, .625 x 1.00 x .031 ........................................................ 1
9 90526457 Washer, flat, .625 x 1.00 x .062 ........................................................ 1
10 50355414 Capstan unit ...................................................................................... 1
11 90501349 Pin, dowel, .375 x 2.00 ...................................................................... 4
12 50352911 Ramp ................................................................................................. 1
13 90525876 Screw, cap, 5/16 –18 x .875, socket button head............................. 3
14 90516028 Washer, lock, .323 x .586 x .078 spring ............................................ 3
15 50353055 Arm, capstan ..................................................................................... 1
16 50353225 Bearing, ramp .................................................................................... 1
17 50353187 Plate unit, anti-rotation ...................................................................... 1
18 50353101 Washer, flat, 4.80 x 8.00 x .060 thrust .............................................. 1
19 50353209 Washer, flat, 4.80 x 8.00 x .060 backing ........................................... 1
20 50353446 Chain, roller, #50 ............................................................................... 1
21 90531957 Master link for #50 chain ................................................................... 1
22 50352946 Sprocket, #50, 48 teeth ..................................................................... 1
23 50354302 Current transformer unit (120-volt model) ......................................... 1
50357670 Current transformer unit (220-volt model) ......................................... 1
24 90539311 Screw, self-tapping, #10 x .500 ......................................................... 2
25 50352920 Frame unit, puller .............................................................................. 1
26 90516699 Nut, hex 1/4 – 20 ............................................................................... 1
27 50232584 Grip, rubber, .600 x 1.00 x 4.50 ........................................................ 1
28 50353233 Spacer, .284 x .440 x .75 .................................................................. 1
29 50352962 Plate, motor mounting ....................................................................... 1
30 90539206 Screw, cap, 1/4 – 20 x 1.37, socket button head.............................. 1
31 90541243 Bushing, strain relief .......................................................................... 2
32 91864852 Connector, wire, twist-o (120-volt model only).................................. 1
33 90539567 Clamp, cushioned support ................................................................. 1
34 50354353 Motor, electric (120-volt) .................................................................... 1
50357646 Motor, electric (220-volt) .................................................................... 1
35 50353136 Sprocket, #35, 12 teeth ..................................................................... 1
36 90533186 Washer, flat, .211 x .625 x .047 ........................................................ 1
37 90527917 Screw, cap, #10 – 32 x .375 button ................................................... 1
38 90516672 Screw, cap, 1/4 – 20 x .625, button socket....................................... 7
39 50179160 Washer, flat, 1.00 x 1.50 x .031 fiber ................................................ 2
40 50353454 Chain, roller, #35 ............................................................................... 1
41 90537300 Master link for #35 chain ................................................................... 1

Greenlee / A Textron Company 31 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Parts List (cont’d)

Key Part No. Description Qty

42 50352954 Sprocket, #35, 60 teeth ..................................................................... 1

43 90539192 Washer, shim, 1.00 x 1.50 x .062 ...................................................... 3
44 90539184 Washer, shim, 1.00 x 1.50 x .032 ...................................................... 1
45 50353012 Guard, right ....................................................................................... 1
46 90513010 Retaining ring, .987, Truarc # 5160-98 ............................................. 1
47 90514602 Screw, self-tapping, #10 – 32 x .375 Phillips (120-volt model only) .. 1
48 90507509 Washer, lock, .200 x .373 x .023 (120-volt model only) .................... 1
49 50371703 Power cord (120-volt model) ............................................................. 1
50057251 Power cord (220-volt model) ............................................................. 1
50 90522036 Screw, machine, #6 – 32 x .250 ........................................................ 2
51 50297082 Guard, switch .................................................................................... 1
52 91863880 Circuit breaker (120-volt model) ........................................................ 1
91868017 Circuit breaker (220-volt model) ........................................................ 1
53 90541243 Bushing, strain relief .......................................................................... 1
54 91862639 Nut, lock ............................................................................................ 1
55 90539214 Screw, shoulder, .620 x 1.75 x 1/2 – 13 ............................................ 1
56 50353110 Sheave .............................................................................................. 1
57 50296647 Foot ................................................................................................... 4
58 90505794 Screw, cap, 1/4 – 20 x .500 socket head .......................................... 8
59 90527941 Nut, hex 1/2 – 13 ............................................................................... 1
60 50179047 Spacer, 1.06 x 1.19 x .560 ................................................................ 1
61 90514599 Needle bearing, 1.00 x 1.31 x 1.00 ................................................... 2
62 50353349 Washer, flat, 1.01 x 1.75 x .062 thrust .............................................. 1
63 50353330 Spacer, 1.01 x 1.19 x .312 ................................................................ 1
64 90512715 Grease fitting ..................................................................................... 1
65 50354310 Horn (120-volt model) ........................................................................ 1
50359169 Horn (220-volt model) ........................................................................ 1
66 50354337 Bracket, horn mounting ..................................................................... 1
67 50353128 Countershaft ...................................................................................... 1
68 50256173 Key, square, .250 x .760, .................................................................. 1
69 50163094 Spring, comp, .210 x .300 x 1.62 ...................................................... 1
70 50301020 Pawl, ratchet ...................................................................................... 1
71* 90539656 Screw, cap, 1/4 – 20 x .500 Torx button ............................................ 2
72* 50356577 Washer, flat, .253 x .725 x .070 ........................................................ 2
73* 50296302 Handle unit, vise chain ...................................................................... 2
74* 50356607 Positioner unit, chain ......................................................................... 2
75* 50356615 Screw unit, 36" vise chain ................................................................. 2
Kit
* 50296310 Chain unit (includes one each of the
items marked with an asterisk) .......................................................... 2
Decals For The Tugger
50356623 Decal, read IM (120-volt model)
50358995 Decal, read IM (220-volt model)
99935767 Decal, technical assistance
50353292 Decal, rope ramp
50299360 Decal, capstan rotation

Greenlee / A Textron Company 32 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Greenlee / A Textron Company 33 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Exploded View
Gear-Motor Unit

104

103

105

106 102
101

107
114

113 115
112
111
116
114
109 110
115

108

112
111

117

Greenlee / A Textron Company 34 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Parts List
Motor and Gearbox (120-Volt and 220-Volt Models)

Key Part No. Description Qty

101 91861136 Brush cap .......................................................................................... 2
102 91861098 Brush ................................................................................................. 2
103 91864020 End cap assembly ............................................................................. 1
104 90541243 Bushing, strain relief .......................................................................... 1
105 91863953 Field assembly (120-volt model) ....................................................... 1
91864356 Field assembly (220-volt model) ....................................................... 1
106 90533232 Washer, Belleville 10mm ................................................................... 2
107 91864011 Armature assembly (120-volt model) ................................................ 1
91864364 Armature assembly (220-volt model) ................................................ 1
108 91863988 Gearhousing assembly ...................................................................... 1
109 91861829 Gasket ............................................................................................... 1
110 91863970 First gear assembly ........................................................................... 1
111 90516869 Nut, hex, #10 – 32 full ....................................................................... 4
112 90507509 Washer, lock, #10 internal tooth ........................................................ 4
113 91863961 Gearhousing cover ............................................................................ 1
114 90508688 Screw, cap, 1/4 – 28 x 1.00 skt head ................................................ 6
115 90516745 Washer, lock, 1/4" internal tooth ....................................................... 6
116 91863996 Armature shaft seal ........................................................................... 1
117 91864003 Output gear assembly ....................................................................... 1

Greenlee / A Textron Company 35 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Exploded View
50371711—Force Gauge Unit with Serial Code ZZ (120-Volt Models)

9 10

11

8
8
7

6
12
13
5

1 2 3 4 14

17 15

16

Greenlee / A Textron Company 36 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Parts List
50371711—Force Gauge Unit with Serial Code ZZ (120-Volt Models)

Key Part No. Description Qty

50371711 Force gauge unit
1 50371622 Wire, 12 AWG x 3.00, black .............................................................. 1
2 50371630 Wire, 12 AWG x 7.00, black .............................................................. 1
3 50371649 Wire, 12 AWG x 4.00, green ............................................................. 1
4 50371088 Box .................................................................................................... 1
5 91866847 Receptacle, female ............................................................................ 1
6 90514408 Screw, machine, #8–32 x .375 round head ....................................... 2
7 50371070 Cover ................................................................................................. 1
8 90531949 Screw, self-tapping, #10– 16 x .250 Phillips head............................. 6
9 50353675 Meter (supplied with hardware) ......................................................... 1
10 90522036 Screw, machine, #6–32 x .250 round head ....................................... 2
11 50297082 Guard, switch .................................................................................... 1
12 91863830 Switch, toggle, 120-volt, single-pole (supplied with hardware).......... 1
13 90506332 Nut, hex, #8–32 ................................................................................. 4
14 90541243 Bushing, strain relief .......................................................................... 1
15 50371703 Cord, power, 12 AWG x 6' ................................................................. 1
16 90539346 Bumper, #8–32 machine screw, rubber ............................................ 4
17 91862639 Nut, lock, 1/2" conduit ....................................................................... 1

Decals for the Force Gauge:

50303929 Decal, damp warning
50327186 Decal, adjustment zero
50356674 Decal, identification (120-volt model)

Greenlee / A Textron Company 37 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Exploded View
50057260—Force Gauge Unit with Serial Code ACP (220-Volt Models)

13
12

14

11
11
10

8
7
15
9
6

1 2 3 4 5 16

19
17

18

Greenlee / A Textron Company 38 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Parts List
50057260—Force Gauge Unit with Serial Code ACP (220-Volt Models)

Key Part No. Description Qty

50057260 Force gauge unit
1 50314807 Wire, 14 AWG x 3.00, brown ............................................................. 1
2 50356313 Wire, 14 AWG x 6.00, brown ............................................................. 1
3 50314785 Wire, 14 AWG x 5.00, green with yellow stripe ................................. 1
4 50356321 Wire, 14 AWG x 6.00, blue ................................................................ 1
5 50054872 Box, lower .......................................................................................... 1
6 91869129 Receptacle, remale ........................................................................... 1
7 90502787 Screw, cap, #6–32 x .500 socket head ............................................. 2
8 90506324 Nut, hex, #6–32 ................................................................................. 2
9 90506332 Nut, hex, #8–32 ................................................................................. 4
10 50371070 Box, upper ......................................................................................... 1
11 90531949 Screw, self-tapping, #10–16 x .250 Phillips head .............................. 6
12 50357689 Meter (supplied with hardware) ......................................................... 1
13 90522036 Screw, machine, #6–32 x .250 round head ....................................... 2
14 50297082 Guard, switch .................................................................................... 1
15 91864135 Switch, toggle, 220 V, DPDT ............................................................. 1
16 90541243 Bushing, strain relief .......................................................................... 1
17 50079379 Cord, power, 14 AWG x 6.5' (198 cm) .............................................. 1
18 90539346 Bumper, #8–32 machine screw, rubber ............................................ 4
19 91862639 Nut, lock, 1/2" conduit ....................................................................... 1

Decals for the Force Gauges:

50303929 Decal, damp warning
50327186 Decal, adjustment zero
50057243 Decal, identification (220-volt model)

Greenlee / A Textron Company 39 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Wiring Diagram
Tugger

SECOND POLE —
220-volt model only

A B
BLACK
C D (BROWN)
BLACK BLACK
(BROWN)
J
K Motor
Circuit Board L
WHITE
Horn (BLUE)
Current Transformer Unit
(includes circuit board)
BLACK

E F WHITE
BLACK (BLUE)
(BROWN)
120-Volt Cord
G
GREEN
E F (GREEN with YELLOW stripe)
H
G
220-Volt Cord

Greenlee / A Textron Company 40 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
 640-Series Tugger® Cable Pullers

Wiring Diagram
Force Gauge, 120-Volt Model (50371711)

Power Cord
50371703
Green Meter
50353675

Switch
91863830
Black

Black

Green
White

Receptacle
91866847 Black

Force Gauge, 220-Volt Models (05726)

Green with
Yellow Stripe

Power Cord
50079379

Blue

Brown
Brown

Receptacle Force Meter

91869129 50357689
Brown

Blue

Switch
91864135

Greenlee / A Textron Company 41 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
USA 800-435-0786 Fax: 800-451-2632
815-397-7070 Fax: 815-397-1865
Canada 800-435-0786 Fax: 800-524-2853
International +1-815-397-7070 Fax: +1-815-397-9247

4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070

An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.

www.greenlee.com Printed in USA