Greenlee 52087815 REV 1 - G1 IM.pdf User manual

OPERATION MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Register this product at www.greenlee.com

G1 Versi-Tugger™

Drill-Powered

Cable Puller

Español................25–46

Français...............47–68

G1 Versi-Tugger™

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

2

Description

The Greenlee G1 Versi-Tugger™ is intended to be used

to pull cable through conduit and in tray. The G1 Versi-

Tugger is an attachment for pistol grip style 12-20V

cordless drills. The G1, coupled with a standard drill

or hammer drill driver such as the Makita XFD07, will

develop up to 1000lbs (4.45kN). Refer to a Greenlee

catalog for sheaves, pulling rope, and other cable

pulling accessories to create an entire cable pulling

system. No single manual can provide instructions for

every possible cable pulling application; this manual

contains general information necessary to accomplish

cable pulls of many different setups.

Safety

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This instruction manual

and any markings on the tool provide information for

avoiding hazards and unsafe practices related to

the use of this tool. Observe all of the safety

information provided.

Purpose of this Manual

This manual is intended to familiarize all personnel with

the safe operation and maintenance procedures for the

Greenlee G1 Versi-Tugger Drill-Powered Cable Puller.

Keep this manual available to all personnel.

Replacement manuals are available upon request at no

charge at www.greenlee.com.

All specications are nominal and may change as design

improvements occur. Greenlee Tools, Inc. shall not be liable for

damages resulting from misapplication or misuse of its products.

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

registered trademark of Greenlee Tools, Inc.

KEEP THIS MANUAL

Table of Contents

GENERAL SAFETY ................................................3–4

SPECIFIC SAFETY .................................................5–7

CABLE PULLING OVERVIEW

Cable Pulling Glossary ............................................... 8

Planning the Pull ......................................................... 8

FUNCTIONAL DESCRIPTION

Identication ......................................................... 9-10

Specications ........................................................... 11

OPERATION

Mounting Cordless Drill to Puller .............................. 12

Head and Boom Operation .......................................... 13

Puller Operation .................................................. 14-15

Spooling Pulling Line/Mule Tape ................................... 14

Capstanning ................................................................... 15

Mounting a Monopod .................................................... 16

Attaching a Boom Extension ........................................ 17

EXPLODED VIEW AND PARTS LISTS

G1 Versi-Tugger Puller ........................................ 19-21

G1 Versi-Tugger™

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

3

GENERAL SAFETY RULES

WARNING Read all safety warnings, instructions,

illustrations and speciﬁcations provided with this

power tool. Failure to follow all instructions listed below

may result in electric shock, re and/or serious injury.

SAVE ALL WARNINGS AND INSTRUCTIONS FOR

FUTURE REFERENCE.

The term "power tool" in the warnings refers to your

mains-operated (corded) power tool or BATTERY

operated (cordless) power tool.

WORK AREA SAFETY

Keep work area clean and well lit. Cluttered or dark

areas invite accidents.

Do not operate power tools in explosive

atmospheres, such as in the presence of ﬂammable

liquids, gases or dust. Power tools create sparks

which may ignite the dust or fumes.

Keep children and bystanders away while operating

a power tool. Distractions can cause you to

lose control.

ELECTRICAL SAFETY

Avoid body contact with earthed or grounded

surfaces, such as pipes, radiators, ranges and

refrigerators. There is an increased risk of electric

shock if your body is earthed or grounded.

Do not expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of

electric shock.

PERSONAL SAFETY

Stay alert, watch what you are doing and use

common sense when operating a power tool. Do

not use a power tool while you are tired or under the

inﬂuence of drugs, alcohol or medication. A moment

of inattention while operating power tools may result in

serious personal injury.

Use personal protective equipment. Always wear eye

protection. Protective equipment such as dust mask,

non-skid safety shoes, hard hat, or hearing protection

used for appropriate conditions will reduce

personal injuries.

Prevent unintentional starting. Ensure the switch is

in the off-position before connecting to power source

and or BATTERY pack, picking up or carrying the tool.

Carrying power tools with your nger on the switch

or energising power tools that have the switch on

invites accidents.

Remove any adjusting key or wrench before turning

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

a rotating part of the power tool may result in

personal injury.

Do not overreach. Keep proper footing and balance

at all times. This enables better control of the power

tool in unexpected situations.

Dress properly. Do not wear loose clothing or

jewelry. Keep your hair, clothing and gloves away

from moving parts. Loose clothes, jewelry or long hair

can be caught in moving parts.

If devices are provided for the connection of dust

extraction and collection facilities, ensure these are

connected and properly used. Use of dust collection

can reduce dust-related hazards.

Do not let familiarity gained from frequent use of

tools allow you to become complacent and ignore

tool safety principles. A careless action can cause

severe injury within a fraction of a second.

POWER TOOL USE AND CARE

Do not force the power tool. Use the correct power

tool for your application. The correct power tool will

do the job better and safer at the rate for which it

was designed.

Do not use the power tool if the switch does not turn

it on and off. Any power tool that cannot be controlled

with the switch is dangerous and must be repaired.

Disconnect the plug from the power source and/

or remove the BATTERY pack, if detachable, from

the power tool before making any adjustments,

changing accessories, or storing power tools. Such

preventive safety measures reduce the risk of starting

the power tool accidentally.

Store idle power tools out of the reach of children

and do not allow persons unfamiliar with the power

tool or these instructions to operate the power tool.

Power tools are dangerous in the hands of

untrained users.

G1 Versi-Tugger™

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

4

Maintain power tools and accessories. Check for

misalignment or binding of moving parts, breakage

of parts and any other condition that may affect the

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

tool repaired before use. Many accidents are caused by

poorly maintained power tools.

Keep cutting tools sharp and clean. Properly

maintained cutting tools with sharp cutting edges are

less likely to bind and are easier to control.

Use the power tool, accessories and tool bits etc.

in accordance with these instructions, taking into

account the working conditions and the work to

be performed. Use of the power tool for operations

different from those intended could result in a hazardous

situation.

Keep handles and grasping surfaces dry, clean

and free from oil and grease. Slippery handles and

grasping surfaces do not allow for safe handling and

control of the tool in unexpected situations.

SERVICE

Have your power tool serviced by a qualiﬁed repair

person using only identical replacement parts.

This will ensure that the safety of the power tool

is maintained.

GENERAL SAFETY RULES (cont'd)

G1 Versi-Tugger™

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

5

SPECIFIC SAFETY RULES AND SYMBOLS

SAFETY

ALERT

SYMBOL

This symbol is used to call your attention to hazards

or unsafe practices which could result in an injury or

property damage. The signal word, dened below,

indicates the severity of the hazard. The message

after the signal word provides information for pre-

venting or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

Hazards which, if not avoided, COULD result in

severe injury or death.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning will

result in severe injury or death.

Do not operate the cable puller in

a hazardous environment. Hazards

include ammable liquids and gases.

Failure to observe this warning will

result in severe injury or death.

Do not use this tool near live circuits. Shut off and

lock out power when working near existing circuits

Inspect and verify the maximum

load-bearing capacity or maximum

strength of all structural supports,

pulling system components and

anchoring systems before setting

up the puller. Any component that

cannot withstand the maximum cable

pulling forces could break

and strike nearby personnel with

sufcient force to cause severe injury

or death.

Do not allow anything other than the

pulling line to contact the capstan.

A grip, swivel, or other component

could break and strike nearby

personnel with great force.

Failure to observe this warning could

result in severe injury or death.

Do not stand directly under a vertical

pull. Cable could fall suddenly from the

conduit, injuring nearby personnel.

Failure to observe this warning could

result in severe injury or death.

Only use approved pulling lines and inspect pulling

lines before use. Never use pulling lines that are

under rated for the application. Approved pulling lines

include: mule tape, measuring tape, and pulling (poly)

line. DO NOT use strings, lines or rope that are not

intended for cable pulling such as general-purpose

rope. Failure to observe this warning could result in

severe injury or death.

G1 Versi-Tugger™

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

6

SPECIFIC SAFETY RULES AND SYMBOLS (cont'd)

An under-rated rope may break and whip

violently. Use a cable pulling rope with the

following characteristics:

• Maximum Rated Capacity:

at least 1500 lb (6.7 kN)

• Average Breaking Strength:

at least 6000 lb (26.7 kN)

• Rope Diameter Range: 1/4" to 1/2"

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.

Attach the pulling rope to the cable with appropri-

ate types of connectors. Select connectors with

a maximum rated capacity of 1500 lb (6.7 kN). An

under-rated connector can break under tension.

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 wrap rope around hands,

arms, waist or other body parts.

Do not stand in spent coils or tailed

rope. Hold rope so that it may be

released quickly.

Failure to observe this warning could

result in severe injury or death.

Rope, cable, or a connecting device can break under

tension, causing the rope to whip violently.

• Do not allow any unnecessary personnel to remain

in the area during the pull.

• Do not allow any personnel to stand in line with the

pulling rope.

Failure to observe these warnings could result in

serious injury or death.

• Do not allow the rope to overlap on the capstan.

If the rope approaches the top of the angled part

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

does occur, shut off the puller immediately.

Failure to observe these warnings could result in

severe injury or death.

Only use the G1 Versi-Tugger with approved pistol

grip style 12V-20V cordless drills. Do not use the G1

Versi-Tugger with corded drills, right angle cordless

drills, D-handle or spade handle cordless drills,

impact drills, or pistol grip style cordless drills whose

voltage is rated higher than 20V.

DO NOT exceed maximum rated pull force of 1000

lb. 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.

G1 Versi-Tugger™

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

7

SPECIFIC SAFETY RULES AND SYMBOLS (cont'd)

Inspect puller and accessories before use. Replace

any worn or damaged components with Greenlee

replacement parts. A damaged or improperly assem-

bled item can break and strike nearby personnel with

great force.

Failure to observe this warning could result in severe

injury or death.

Entanglement hazard:

• Do not operate the cable puller while wearing

loose-tting clothing.

• Retain long hair.

Failure to observe these warnings could result in

severe injury or death.

Wear eye protection when using this

tool.

Failure to wear eye protection could

result in severe eye injury from ying

debris.

Wear gloves when using this tool.

Failure to wear gloves could result in

severe injury from ying debris.

Do not alter or modify the G1 VersiTugger in any

way. This includes but is not limited to artically

reinforcing components or using drive keys not

provided by Greenlee.

Do not pin or x trigger in ON position. Do not mount

or attach puller to any object.

G1 Versi-Tugger™

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

8

CABLE PULLING OVERVIEW

Cable Pulling Glossary

Anchoring system

any item or group of items that keeps a cable pulling

component in place during the cable pull

Capstan

the tapered cylinder of the cable puller that acts on the

pulling rope to generate pulling force

Connector

any item, such as a wire grip, clevis, swivel, or pulling

grip, that connects the rope to the cable

Direct line of pull

the areas next to the pulling rope and along its path;

this includes the areas in front of, in back of, and

underneath the rope

Maximum rated capacity

the amount of pulling tension that any component

can safely withstand, rated in kilonewtons (metric)

or pounds; the maximum rated capacity of every

component must meet or exceed the maximum pulling

force of the cable puller

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

Sheave

a pulley that changes the direction of the rope and cable

Support structure

any stationary object that a cable pulling system

component is anchored to, such as a concrete oor

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

Tail

the portion of the rope that the operator applies force

to; this is the rope coming off of the capstan, and is not

under the tension of the pull

Tailing the rope

the operator’s main function; this is the process of

applying force to the tail of the pulling rope—refer to the

complete explanation under “Cable Pulling Principles”

Wire grip

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

clamp onto the conductors of the cable

Planning the Pull

• Pull in a direction that will require the lowest amount

of pulling force.

• Plan several shorter pulls rather than fewer longer

pulls.

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

as possible to minimize the amount of exposed rope

under tension.

• Place each component so that the pulling forces are

used effectively.

• Verify that each component has the proper

load rating.

• Inspect the structural supports. Verify that they have

enough strength to withstand the maximum forces

that may be generated.

G1 Versi-Tugger™

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

9

FUNCTIONAL DESCRIPTION

Identiﬁcation

1. Boom Assembly

2. Capstan and Capstan Wall Assembly

3. Frame and Gearbox Assembly

4. Handle Assembly

5. Drill Strap

Note: for detailed exploded views, please see the Exploded Views and Parts

Lists section of this manual or refer to the G1 Versi-Tugger Service Manual.

1

2

4

5

3

G1 Versi-Tugger™

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

10

Identiﬁcation (cont’d)

Assembly Components

6. Capstan

7. Capstan Wall

8. Capstan Wall Knob

9. Boom

10. Boom Adapter

11. Puller Head

12. Puller Head Sheave

13. Frame

14. Handle

15. Gearbox

16. Input Shaft

17. Drill Strap

18. Monopod Adapter

12

9

8

18

6

13

15

16

10

14

7

11

17

G1 Versi-Tugger™

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

11

Speciﬁcations

Weight (with boom) ................................................................................. 13.8 lb (6.3 kg)

Dimensions

Length (with boom) .........................................................................32.1 in (81.5 cm)

Width .................................................................................................9.7 in (24.6 cm)

Height .............................................................................................. 10.5 in (26.7 cm)

Fits conduit sizes .............................................................................................. 1/2"–4"

Compatible Pulling Rope/Line ........... Pulling line (poly line), polyaramid and polyester

measuring tape (mule tape), pulling rope 1/4” to 1/2”

LOW HIGH

No-Load Speed* (Spooling 430 Poly line) 83 ft/min (25.3 m/min) 308 ft/min (93.9 m/min)

*Assumes drill output in low-speed = 500RPM and high-speed = 2000RPM Note:

pull speed is dependent on cordless drill performance

Pulling Force

Max/Peak ..................................................................................................... 1,000 lb

Constant ................................................................................................. up to 600 lb

Only use the G1 Versi-Tugger with approved pistol grip style 12V-20V cordless

drills. Do not use the G1 Versi-Tugger with corded drills, right angle cordless drills,

D-handle or spade handle cordless drills, impact drills, or pistol grip style cordless

drills whose voltage is rated higher than 20V.

G1 Versi-Tugger™

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

12

Mounting Cordless Drill to Puller

Use of the drill strap with the G1 is mandatory for safe operation. Failure to observe this warning could

result in injury.

1. Loosen the cordless drill chuck enough to accept

the input shaft.

2. Tighten the cordless drill chuck onto the input shaft.

Ensure the drill chuck is fully seated on the three

ats of the input shaft.

3. Wrap the end of the hook and loop drill strap

around the hand grip of the cordless drill and the

end of the puller frame.

4. Insert the strap end through the buckle on the

opposite side of the frame as the drill. Pull the end

of the drill strap through the buckle.

5. Cinch the strap tight and fasten the hooks on the

strap end to the loops on the body of the strap.

6. Ensure that the strap is free of damage and dirt and

that the hooks are fully engaged with loops of the

drill strap.

Cordless Drill

Input Shaft

Drill Strap Buckle

End of Puller Frame

Drill Strap

OPERATION

Cordless Drill

Drill Strap Buckle

Male

"hook & loop"

Hooks

Drill Strap Looped

Back Through Buckle

Input Shaft

End of Puller Frame

Only use the G1 Versi-Tugger with approved pistol

grip style 12V-20V cordless drills. Do not use the G1

Versi-Tugger with corded drills, right angle cordless

drills, D-handle or spade handle cordless drills,

impact drills, or pistol grip style cordless drills whose

voltage is rated higher than 20V.

G1 Versi-Tugger™

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

13

Head and Boom Operation

The G1 Versi-Tugger is equipped with a multi-position

head and boom system. The puller head has 5 positions

and the boom has 4 positions.

To adjust the position or orientation of the boom or

puller head:

• Remove the respective quick release pin

• Reorient the component to its desired position

• Reinsert the quick release pin.

No matter the situation, always ensure that the conduit

engagement notch properly interfaces with the conduit

or conduit nut. In addition, always orient the head so

the rope or pulling line is not rubbing on the edge of the

conduit, or on stationary components of the puller.

Although each pulling situation has unique setup

requirements, typical up-pull, down-pull, and side-pull

positions are shown below:

1. Head-Adjustment Pin and Conduit

Engagement Notch

2. Boom Adjustment Pin

3. Up-Pull Head Orientation

4. Down-Pull Head Orientation

5. Side-Pull Orientation

Boom

Adapter

Quick-Release Pin

Orientation

Locking

Hole

Rope or

Pulling Line

Rope or

Pulling Line

Rope or

Pulling Line

Note: The lines on the boom indicate the engagement point of each length when lined up with the top of the

mount. You may need to rotate the boom to engage.

Orientation Locking Holes

Quick-Release Pin

Conduit

Engagement

Notch

G1 Versi-Tugger™

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

14

Puller Setup and Operation

Spooling Pulling Line/Mule Tape

SETUP

1. Anchor pulling line/tape to the capstan. There are two

ways to anchor the line to the capstan listed below:

A. Thread the line through the large hole in the

capstan and tie a knot.

-OR-

B. Take the end of the line and clamp it between

the capstan wall and the capstan. This can be

accomplished by unscrewing the capstan wall

about halfway. Then, take the end of the line

and place it between the capstan wall and the

capstan. Finally, screw the capstan wall rmly into

place against the capstan.

2. Adjust the orientation and position of the head and

boom if necessary, ensure the line/tape is anchored

to the capstan. (see previous page 14 “Head and

Boom Operation”). Remember to fully seat the

conduit engagement notch against the conduit or

conduit nut before beginning to pull.

Capstan Wall

Capstan

Pulling Line

or Mule Tape

OPERATION

1. Once the puller has been set up correctly, the pulling

process can begin.

2. With the cordless drill attached to the G1 Versi-

Tugger (see previous page 13 “Mounting Cordless

Drill to Puller”) and the cordless drill direction set to

the FORWARD or CLOCKWISE spinning position,*

depress the trigger of the cordless drill and the

capstan will begin to spin.

3.

When the capstan spins, the pulling line or mule tape

will begin to spool up.

• DO NOT attempt to touch or shift the line while the

capstan is spinning. If an adjustment is necessary,

stop the drill and then make the adjustment.

• It is recommended that when pulling wire or cable

that the cordless drill be operated in LOW speed

to avoid damage to the cable during the pulling

process. Other low force cable pulling scenarios,

like pulling rope into conduit with pulling line (as

setup for a larger cable pull), can be run in HIGH

speed if desired.

4. When the cable pull is complete, the pulling line or

mule tape can be removed. First separate the pulling

line or mule tape from the wire, cable, or rope that

has been pulled.

5. To remove the pulling line/tape when the pull is

complete, unscrew the knob of the capstan wall. Once

fully unscrewed, remove the wall from the capstan.

6. The spool of line or tape can be removed from the

capstan by grasping the line/tape and sliding it off the

end of the capstan.

7. After the pulling line or mule tape has been removed

from the capstan, screw the capstan wall back onto

the capstan.

*See manufacturer instructions for your drill.

G1 Versi-Tugger™

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

15

Puller Setup and Operation (cont’d)

Capstanning — Pulling Rope or Mule Tape

SETUP

To use the G1 Versi-Tugger to capstan rope (1/4” to 1/2”

diameter), rst set up the puller.

1. Adjust the orientation and position of the head and

boom if necessary, see p. 14 “Head and Boom

Operation”). Remember to fully seat the conduit

engagement notch against the conduit or conduit

before beginning to pull.

Puller Head

Cordless Drill

Rope

Capstan

Conduit

2. Route the rope from the conduit over the puller

head sheave and to the capstan.

Puller

Head Sheave

Cordless Drill

Rope

from Conduit

Capstan

Tail of Rope

3. Wrap the rope in a clockwise direction, as with

conventional cable pullers, around the capstan with

tail end of the pulling rope towards capstan wall.

Cordless Drill

Clockwise

Wraps around

Capstan

Puller

Head

Sheave

Rope

from Conduit

Tail of Rope

OPERATION

4. With the cordless drill attached to the

G1 Versi-Tugger (see p. 13 “Mounting Cordless

Drill to Puller”) and the cordless drill direction set to

the FORWARD or CLOCKWISE* spinning position,

depress the trigger of the cordless drill. The capstan

will begin to spin.

5. Using the hand not operating the drill, pull the

tail of the rope while the capstan is spinning. The

rope will begin to pull the cable and payoff as with

conventional cable pullers.

• If the rope loses engagement on the capstan and

begins to slip, stop the drill and add additional

wraps of the rope to the capstan.

• It is recommended that when pulling wire or cable

that the cordless drill be operated in LOW speed

to avoid damage to the cable during the pulling

process. Other low force cable pulling scenarios

can be run in HIGH speed if desired.

6. When the pull is complete, the rope can

be unwrapped from the capstan in a

counter-clockwise direction.

*See manufacturer instructions.

G1 Versi-Tugger™

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

16

Optional: Mounting a Monopod

Wing Screw

Monopod Adapter

1/2" EMT Conduit

1. Cut a piece of 1/2” EMT conduit to desired length.

2. Insert the conduit into the monopod adapter.

3. Loosen the wing screw until the conduit fully seats

into the bottom of the monopod adapter.

4. Tighten the wing screw until the conduit is held

securely by the wing screw.

* Take care when tightening the wing screw,

overtightening can result in stripping the threads

in the monopod adapter.

G1 Versi-Tugger™

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

17

Optional: Attaching a Boom Extension

Boom Assembly

Boom Adapter

1" Rigid Conduit

1. Select a piece of 1” rigid conduit and cut to

length if necessary. Ensure you leave one

threaded end intact.

2. Remove the boom assembly from the

G1 Versi-Tugger. (See p.14 for additional

instructions.)

3. Thread the 1” rigid conduit into the boom

adapter. (A)

4. Insert the boom assembly into the end of the

conduit not threaded into the G1. (B)

5. Use caution while using a conduit boom

extension as the weight of the G1 Versi-Tugger

will increase signicantly.

A.

B.

G1 Versi-Tugger™

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

18

Troubleshooting

If the puller becomes inoperative, refer to the troubleshooting table below.

Problem Probable Cause Probable Remedy

During a pull, the drill, input

shaft AND capstan stop

spinning

Drill battery is low or empty Replace cordless drill battery.

The drill stalled because the pull

force is too high

Stop using the G1 Versi-Tugger and use a larger

cable puller to nish the cable pull.

During a pull, the frame

begins to bend and contacts

the capstan

Force of the pull exceeded 1000

LB.

Do not exceed maximum force of 1000 lb

to avoid cosmetic damage. Unit is still fully

operable.

Drill and input shaft are spin-

ning but the capstan is NOT

spinning

Output shaft key sheared due to

overload from unapproved drill

or motor

Remove output shaft, replace key and

reassemble output shaft.

Drill is slipping off the

input shaft

Drill chuck was tightened down

onto the diameter of the input

shaft and not the three ats

Remove the drill chuck from the input shaft.

Reattach the drill chuck to the input shaft

and ensure that the teeth of the drill chuck

are mating properly with the three ats of

the input shaft.

Capstan wall is not screwing

into the capstan

Misalignment of the threads

can be caused by interference

between the capstan wall and

the anti-backout tab on the

capstan

Realign the threads of the capstan wall knob to

be on axis with the capstan and ensure that the

anti-backout tab on the capstan is inserted into

the radial slots in the capstan wall. Then thread

the capstan wall knob into the capstan.

The handle is spinning

about the frame

Product was dropped or

forcefully swung by the handle

Use a hex key or Allen wrench to tighten the

handle screw down.

The input shaft is sliding off

the gearbox

Product was dropped too

hard or experienced

signicant vibration

Use a hex key or Allen wrench to tighten the

input shaft screw down.

Line breaks during pull when

exiting conduit

Line is rubbing on edge of

conduit

Ensure pulling head is set up so line does not

rub against edge of conduit and uses roller.

Line breaks near pulling head Line is caught between head

and roller

Position line so it runs over the roller, not

beside it.

Line catches or breaks near

capstan

Line is getting caught between

capstan and frame

Position the line to spool around capstan with

tension so as not to slip between capstan and

frame.

Maintenance

Routinely inspect all aspects and components on the

G1 Versi-Tugger to ensure puller is in proper working

order prior to usage. If parts are missing or broken DO

NOT USE and have the puller serviced at an authorized

Greenlee Repair Center.

The gearbox is prelled with high temperature synthetic

lubricant. Therefore, no maintenance is required on

the gearbox.

G1 Versi-Tugger™

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

19

Exploded View and Parts Lists

Parts List – G1 Versi-Tugger

Key Catalog No. Description Qty

1 G1-R12 Drill Strap ................................................................................................1

2 Gearbox............................. .....................................................................1

2A Button Head Cap Screws (M6 x 18MM)............................. ....................3

3 Frame............................. ......................................................................... 1

4 Boom Adapter............................. ............................................................ 1

4A Boom Adapter Button Head Cap Screws (1/4”-20 x 3/4”) .....................4

5 G1-R18 Monopod Adapter Kit............................. ................................................1

5A Monopod Adapter ................................................................................1

5B Quick-Release Pin w/ Lanyard (1/4” x 2-1/4”) .....................................1

5C Shoulder Screw (1/4” x 1-3/8”) ............................................................ 1

5D Wing Screw (#10-32 x 1/2”) ................................................................. 1

5E Locknut (#10-24)............................. ..................................................... 1

7B

7G

7C

7A

7E

8A

4

8D

8C

5B

4A

8B

9A

9F

9C

5C

9B

9E

9D

2A

3

2

6C

6A

6B

5A

5D

5E

9E

9D

1

10A

10C

10B

7F

7H

7D

7G

G1 Versi-Tugger™

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

20

Parts List – G1 Versi-Tugger (cont'd)

Exploded View and Parts Lists (cont'd)

Key Catalog No. Description Qty

6 G1-R11 Input Shaft Kit ......................................................................................... 1

6A Input Shaft ........................................................................................... 1

6B Key (1/8” x 1/8” x 1/2”)............................. ........................................... 1

6C Set Screw (5/16”-24 x 1/4") ................................................................. 1

7 G1-R14 Boom Assembly Kit................................................................................. 1

7A Puller Head............................. ............................................................. 1

7B Puller Head Sheave .............................................................................. 1

7C Shoulder Screw (1/4" x 2-1/2") ............................................................ 1

7D Locknut (#10-24) .................................................................................. 1

7E Bowtie Cotter Pin (1/16") ..................................................................... 1

7F Clevis Pin (1/4" x 1-1/4") ...................................................................... 1

7G Flange Bushing .................................................................................... 2

7H Quick-Release Pin w/ Lanyard (1/4" x 1-1/16")................................... 1

8 G1-R15 Handle Assembly Kit ............................................................................... 1

8A Handle ................................................................................................. 1

8B Handle Grip .......................................................................................... 1

8C Handle Button Head Cap Screw (1/4” x 7/8”)...................................... 1

8D External Lock Washer (1/4”) ................................................................. 2

9 G1-R16 Capstan Assembly Kit ............................................................................. 1

9A Capstan ................................................................................................ 1

9B Capstan Shaft ...................................................................................... 1

9C Key (3/16” x 3/16” x 1/2”) .................................................................... 1

9D Washer (3/4”) ....................................................................................... 2

9E External Retaining Ring (3/4”) .............................................................. 2

9F Split-Pin (1/4” x 1-3/4”) ........................................................................ 1

10 G1-R13 Capstan Wall Kit ...................................................................................... 1

10A Capstan Wall ........................................................................................ 1

10B Capstan Wall Knob .............................................................................. 1

10C Locknut (3/8”-16) ................................................................................. 1

11 G1-R19 Decal and Warnings Kit (not shown) ....................................................... 1

11A Warning Decal ...................................................................................... 1

11B G1 Capstan Wall Decal ........................................................................ 1

11C G1 Product Info Decal ......................................................................... 1

11D Greenlee Logo Decal ........................................................................... 1

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Greenlee 52087815 REV 1 - G1 IM.pdf User manual

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