Specialty Tools & Ergonomic Equipment Catalog

Specialty Tools & Ergonomic Equipment Catalog Staff Electric Co., Inc. November 2009 Volume 1, Issue 1

Table of Contents Task Page WIRE PULLING FEEDERS Section 1 3 Through 29 Equipment Checklist Wire Pullers 4 Wire Feeders 8 Reel Jacks 9 Pulling Grips 11 Sheaves 19 Pulling Rope 21 Mule Tape- flat tape 22 Shackles & Slings 24 Cable Pulling lubrication system 28 Safety triggers 29 WIRE CARTS BRANCH CIRCUITS Section 2 30 Through 31 BENDING PIPE Section 3 32 Through 33 THREADING PIPE AND VISES Section 4 34 Through 35 CUTTING PIPE Section 5 36 INSTALLING AND FASTENING PIPE Section 6 37 Through 38 PIPE STORAGE Section 7 39 TERMINATE FEEDERS SWITCHGEAR Section 8 40 Through 42 Cable Cutters Cable Benders Cable Crimpers Impact Wrenches SPECIALTY LADDERS & SCAFFOLDING- Section 9 43 Through 46 MOVING HEAVY EQUIPMENT SWITCHGEAR & TRANSFORMERS-Section 10 47 Genie Lift Machinery Rollers and Jacks Johnson bars and Pinch bars MANUFACTURERS REPRESENTATIVES- Section 11 48

REQUISITION FOR MATERIAL Job Number: Date: Job Name: When Needed: Duration: CHECKLIST - WIRE PULLING EQUIPMENT Quantity WIRE PULLERS Greenlee Ultra Tugger UT8 8,000 lb. Greenlee Ultra Tugger 4 UT4 4,000 lb. Greenlee Ultra Tugger 2 UT2 2,000 lb. Greenlee Floor Mount Tugger Enerpac Tugger WIRE FEEDERS Greenlee Ultra Cable Feeder (#6810) REEL JACKS Reel Jacks Wooden Base Greenlee Ratchet Type (#656) Capacity 3,750 lb. each jack 28 46 5/8 Greenlee Screw Type (#683) Capacity 2,500 lb. each jack 22 54 Height Greenlee Screw Type (#687) Capacity 2,500 lb. each jack 13 28 Height Maxis Jax (MJ707) Capacity 1,500 lb. each jack WIRE PULLING GRIPS Wire Snaggers Greenlee/Kellems Wire Basket Grip Greenlee/Kellems Set Screw Grip Maxis Wire Snaggers PULLING ROPE Specify sizes and type- ¼, 3/8,1/2, 9/16, 5/8, ¾, 1 Muletape (Flat type for PVC to prevent burn through) 200-6000 lbs Sizes 1/8 to 3/4 Polyline WIRE LUBE Polywater J Dyna Blue Greenlee Ideal Yellow 77 CABLE PULLING LUBRICATION SYSTEM Greenlee Ultra Glider (UG5) Soaper Monkey SHEAVES Capacity Hook Sheaves 6 inch 4,000 lb. Hook Sheaves 12, 18, 24 8,000 lb. Twin Yoke Sheave (12, 18, 24 ) 4,000 lb. Feeding Sheaves (2 6 conduit sleeves) 4,000 lb. Manhole Sheaves (10 and 12 ) 4,000 lb. Radius Cable Sheaves (48 ) 4,000 lb. Triple Sheave Cable Guide 6,500 lb. Light Pole Base Sheave (#459) 500 lb. Tray Type Sheaves Straight Cable Tray Rollers Rt Angle Cable Tray Rollers Maxis Safety Triggers Foot Switch for pullers (#TR01) Radios 3

GREENLEE ULTRA TUGGER (UT8 - #6800) WIRE PULLERS 8,000 lb maximum pulling force 6,500 lb continuous pulling force Weight 86 lbs Pulling Speed (ft/min) No Load = 9 ft/min At 2,000 lbs = 11 ft/min At 4,000 lbs = 7.5 ft/min Recommended Rope: 7/8 diameter double braided polyester with 32,000 lb breaking strength ADVANTAGES / BENEFITS Reduce Strains Flexibility Articulating boom can reach hard to get areas Extended boom to pull 10 20 ft of cable out of box COST JUSTIFICATION Time / Labor savings in reduced set up time because of articulating boom feature GREENLEE ULTRA TUGGER 4 (UT4) 4,000 lb maximum pulling force Low speed 2,000 lb maximum pulling force High speed 3,000 lb continuous pulling force low speed Weight 175 lbs 15 amp 120 Volt High Pulling Speed (ft/min) No Load = 26 ft/min At 2,000 lbs = 20 ft/min Low Pulling Speed (ft/min) No Load = 13 ft/min At 2,000 lbs = 10 ft/min Recommended Rope: 9/16 diameter double braided polyester with 16,000 lb breaking strength 12 foot long extension available Sets up in minutes - no need to bolt to floor Foot operated switch and remote force gauge 4

WIRE PULLERS CONTINUED GREENLEE ULTRA TUGGER2 (UT2) 2,000 lb maximum pulling force Pulling Speed (ft/min) At 1,000 lbs = 36 ft/min At 2,000 lbs = 22 ft/min Conduit size 1 inch or larger Recommended Rope: 1/2 polyester with 10,000 lb breaking strength ADVANTAGES / BENEFITS Reduce strains from manual pulling wire can use with branch circuits Small unit to fit in tight areas / electrical closets Very quick set up Fast pulling speeds DISADVANTAGES Limited capacity COST JUSTIFICATION Time / Labor savings in reduced set up time over 8,000 lb Ultra Tugger and faster pulling speeds 5

WIRE PULLERS CONTINUED GREENLEE SUPER TUGGER FLOOR MOUNT (#6001) ENERPAC FLOOR MOUNT 6,500 lb maximum pulling force 4,500 lb continuous pulling force Weight 108 lbs Pulling Speed (ft/min) No load = 16.5 ft/min At 2,000 lbs = 11 ft/min At 4,000 lbs 7.5 ft/min At 5,000 lbs = 6 ft/min Recommended Rope: ¾ double braided composite with 26,000 lb breaking strength DISADVANTAGES Increased set up time for mounting puller and setting up sheaves. Risk of tugger pulling free from floor mount GREENLEE TUGGER FLOOR MOUNT (#640) 4,000 lb maximum pulling force 2,500 lb continuous pulling force Weight 68 lbs Pulling Speed (ft/min) No load = 35 ft/min At 2,000 lbs = 16 ft/min At 4,000 lbs 6 ft/min Recommended Rope: 9/16 double braided composite with 16,000 lb breaking strength 6

WIRE PULLERS CONTINUED ENERPAC (GARDNER BENDER) CABLE PULLER FLOOR MOUNT (#CP800) 8,000 lb capacity Weight 65 lbs Recommended Rope: 3/4 double braided polyester ENERPAC (GARDNER BENDER) MINI BRUTUS CABLE PULLER (CP2000) 2,000 lb maximum pulling capacity Pulling Speed 18 ft/min Adjustable arm extends to 70 Maximum extended height 116 Weight 65 lbs Required Rope Diameter- ½ double braided polyester Power drive unit separate Order Rigid 700 Porta-Pony 7

GREENLEE ULTRA CABLE FEEDER (#6810) WIRE FEEDERS Maximum tractive force = 800 lbs Cable capacity: Six 500 MCM Five 750 MCM Weight: 285 lbs ADVANTAGES / BENEFITS Reduce strains from manually pulling cable off reels Feeds cables at variable speeds to match speed of cable puller Labor savings can be operated by 1 worker with a second worker feeding cable into pipe. Can eliminate two people from pulling off reels, depending upon the situation.. 8

REEL JACKS REEL JACKS WOODEN BASE Capacity 2 tons per jack Height adjustment 12 per hook Lower hook 13 to 25 Middle hook 23 to 35 Top hook 33 to 45 Caution when handling to avoid injury- very heavy and can tip over during setup. GREENLEE RATCHET TYPE (#656) Ratchet mechanism to easily raise / lower height Capacity: 3,750 lbs each jack Reel Diameter: 58 90 Height adjustment: 28 46 5/8 Base: 24 ½ x 23 Weight: 87 lbs GREENLEE SCREW TYPE (#683) Capacity: 2,500 lbs each jack - Reel Diameter: 46 96 Height adjustment: 22 54 Base: 24 x 21 Weight: 42 lbs 9

REEL JACKS CONTINUED SMALL GREENLEE SCREW TYPE (#687) Capacity: 2,500 lbs each jack Reel Diameter: 28 56 Height adjustment: 13 28 (Will fit Quad Reels at 19 axle height) Base: 15 x 15 Weight: 22 lbs MAXIS JACK (MJ707) Capacity: 1,500 lbs each jack Reel Diameter: up to 48 NOTE: APPROXIMATE WEIGHT FOR A FULLY LOADED PARALLEL REEL IS 4,300 LBS. (500 FEET OF 600 MCM). ADVANTAGES / BENEFITS Lower profile can pick up a reel off floor without lifting reel up to jack Very easy to pull wire off reel due to roller bearings Small footprint for confined areas Quick and easy set up saves time Locks spindles onto jack so it does not pull off when wire nears end of roll Lever action to raise reel Smaller in size able to collapse and transport easier. Saves time by getting all equipment on 1 cart. DISADVANTAGES Must use an axle with 1 ½ to 2 diameter so reel weight rests on all 4 bearings. Rigid pipe is an acceptable sleeve over smaller axles. 10

PULLING GRIPS WIRE SNAGGERS Rated Capacity: 6,860 lbs 3,000 lb working load for each tool 1/0 5 KV wire ADVANTAGES / BENEFITS Huge labor savings can attach/detach grips in a couple of seconds LIMITATIONS Best with oversized conduit due to large size of gripping head Gripping head system is less flexible than Greenlee Wire Mesh Basket Grip or Set Screw Pulling Grips forces on wire snaggers may increase when pulling over sheaves Do not apply wire lube directly to wire snagger start 12 behind grip point COST JUSTIFICATION Estimate $60.00 - $90.00 labor savings per pull 11

WIRE SNAGGERS 12

PULLING GRIPS MAXIS WIRE SNAGGERS 5 sets of pulling grips from 1/0 to 750 MCM 2 rope clevis 2 protective pulling jackets Use a cam lock head and double braided grip (wire basket) Capacity 4,000 lbs each ADVANTAGES Fast- total head preparation - 2 minutes Disconnect wire from grips in 2 minutes without cutting wire No cutting or weaving of wire to make pulling head Pulling jacket keeps head tight for easier movement through conduit Pulling jacket keeps grips clean and free of soap residue. DISADVANTAGES New Product - Unproven technology on strength of pulling head - Do not use for critical pulls. Verify appropriate conduit size see sizing chart. Insert wire and lock into place Keep Pulling Head Tight Remove Wire- Pull up ring and release cams 13

MAXIS WIRE SNAGGERS Grip Size Guide 14

PULLING GRIPS CONTINUED GREENLEE / KELLEMS WIRE MESH BASKET GRIP For large wire (>1.75 ), the wire basket has the highest capacity rating at 9,600 lbs! CAUTION: Use the correct size wire basket for the size of wire. Failures occur when using the incorrect size. Cat. No. Cable Bundle Max Rated Capacity (lbs) Greenlee Color Code Diameter Range 30474.25 -.49 1,360 Dark Green 30476.50 -.74 2,000 Brown 30478.75 -.99 2,880 Light Blue 30480 1.0 1.24 4,920 Gold 30482 1.25 1.49 6,120 Black 30484 1.50 1.74 6,120 Red 30486 1.75 2.24 9,600 Dark Blue 30502 2.00 2.49 9,600 Yellow 30504 2.50 2.99 9,600 Orange After determining the type of grip needed, measure the diameter of the cable being pulled. If pulling more than one cable of the same diameter, refer to chart on next page for required grip diameter range. If pulling more than one cable of different diameters, bundle cables together, measure the circumference and refer to the chart on bottom of the next page for required grip diameter range. Once the cable diameter or required grip diameter is determined, refer to above chart for type of grip chosen to locate Catalog number. 15

PULLING GRIPS CONTINUED GREENLEE / KELLEMS WIRE MESH BASKET GRIP (continued) SELECT THE SIZE OF GRIP NEEDED: CABLES WITH SAME DIAMETER IN ONE GRIP* 2 CABLES 3 CABLES DIA. EACH DIA. EACH IN./(mm) IN./(mm) 4 CABLES DIA. EACH IN./(mm) 5 CABLES DIA. EACH IN./(mm) REQUIRED GRIP DIAMETER IN./(mm).30-.38/(7.6-9.7).25-.31/(6.4-7.9).22.27/(5.6-6.9).19-.24/(4.8-6.1).50-.61/(12.7-15.5).38-.14/(9.7-11.2).31-.36/(7.9-9.1).27-.31/(6.9-7.9).24-.29/(6.1-7.4).62-.74/(15.7-18.8).44-.59/(11.2-15.0).36-.49/(9.1-12.4).31-.42/(7.9-10.7).29-.38/(7.4-9.7).75-.99/(19.1-25.1).59-.75/(15.0-19.1).49-.63/(12.4-16.0).42-.54/(10.7-13.7).38-.48/(9.7-12.2) 1.00-1.25/(25.4-31.5).75-.90/(19.1-22.9).63-.76/(16.0-19.3).54-.65/(13.7-16.5).48-.58/(12.2-14.7) 1.25-1.49/(31.8-37.8).90-1.07/(22.9-27.2).76-.89/(19.3-22.6).65-.77/(16.5-19.6).58-.67/(14.7-17.0) 1.50-1.74/(38.1-44.2) 1.07-1.22/(27.2-31.0).89-1.02/(22.6-25.9).77-.88/(19.6-22.4).67-.77/(17.0-19.6) 1.75-1.99/(44.5-50.5) 1.22-1.53/(31.0-39.9) 1.02-1.28/(25.9-32.5).88-1.10/(22.4-27.9).77-.96/(19.6-24.2) 2.00-2.49/(50.8-63.2) 1.53-1.83/(38.9-46.5) 1.28-1.53/(32.5-38.9) 1.10-1.32/(27.9-33.5).96-1.16/(24.2-29.5) 2.50-2.99/(63.5-75.9) 1.83-2.14/(46.5-54.4) 1.53-1.79/(38.9-45.5) 1.32-1.54/(33.5-39.1) 1.16-1.35/(29.5-34.3) 3.00-3.49/(76.2-88.6) 2.14-2.44/(54.4-62.0) 1.79-2.05/(45.5-52.0) 1.54-1.76/(39.1-44.7) 1.35-1.54/(34.3-39.1) 3.50-3.99/(88.9-101.3) 2.44-2.75/(62.0-69.9) 2.05-2.30/(52.0-58.4) 1.76-1.98/(44.7-50.3) 1.54-1.74/(39.1-44.2) 4.00-4.49/(101.6-114.0) 2.75-3.06/(69.9-77.7) 2.30-2.56/(58.4-65.0) 1.98-2.20/(50.3-55.9) 1.74-1.93/(44.2-49.0) 4.50-4.99/(114.3-126.7) * Split grips require the next larger size MEASURE THE CIRCUMFERENCE OF THE WIRE BUNDLE CIRCUMFERENCE RANGE REQUIRED GRIP DIAMETER INCH mm INCH mm 1.57-1.95 39.9-49.5.50 -.61 12.7-15.5 1.95-2.36 49.5-59.9.62 -.74 15.8 18.8 2.36 3.14 59.9 79.8.75 -.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 1.258 1.49 31.8 37.8 4.71 5.50 119.6 139.7 1.50 1.74 38.1 44.2 5.50 6.28 139.7 159.5 1.75 1.99 44.5 50.5 6.28 7.85 159.5 199.4 2.00 2.49 50.8 63.2 7.85 9.42 199.4 239.3 2.50 2.99 63.5 75.9 9.42 11.00 239.3 279.4 3.00 3.49 76.2 88.6 11.00 12.57 279.4 319.3 3.50 3.99 88.9 101.3 12.57 14.14 319.3 359.2 4.00 4.49 101.6 114.0 16

PULLING GRIPS CONTINUED GREENLEE / KELLEMS SET SCREW GRIPS Minimum cable diameter 3/8 Use to pull in 2 or larger conduit #629 6,500 lb capacity for 2 grip system or 3,250 lbs per grip ADVANTAGES / BENEFITS Versatility can be used on a variety of wire sizes DISADVANTAGES CAUTION: THE GRIP HEAD SHOULD NOT BE MORE THAT 60% FILLED NOR LESS THAN 40% FILLED TO ASSURE THAT THE SET SCREW DOES NOT PROJECT ABOVE THE SURFACE OF THE GRIP BODY WHEN THE SET SCREWS ARE TIGHTENED DOWN. 17

PULLING GRIPS CONTINUED SWIVELS FOR PULLING GRIPS Connect grip and pulling rope Eliminates winding and tangling of rope and cable during pull, thereby reducing pulling forces Swivels required on all pulling with > 4,000 lb pulling forces as calculated using Greenlee Cable Pull Tension Estimator Software as part of pre-plan. GREENLEE # MAX RATED CAPACITY (LBS) Overall Diameter Minimum Pipe Size OPENING DIAMETER 39106 2,250 7/8-3/8 39107 5,000 1 1/4 - ½ 39108 7,000 1 3/8 2 9/16 39109 10,000 1 5/8 2.5 5/8 39110 15,000 2 3 ¾ 39111 25,000 2 3/8 4 1 FLEXIBLE MANDREL Use for cleaning out mud, dirt from duct before installation of cable Use in conduit with tight bends to evaluate conduit opening Order by size of duct. Sizes available form 2 6 WIRE BRUSH DUCT Flat steel bristles for maximum cleaning of sand, dirt from duct Order by size of duct. Sizes available from 2 6 18

WIRE PULLING FEEDERS Sheaves Hook Type Sheaves 4,000 lb Capacity- 6 inch Hook Sheaves 8,000 Capacity Sizes available: 12, 18 and 24 Right-Angle Twin Yoke Sheave 4,000 Capacity Sizes available: 12, 18 and 24 Feeding Sheaves 4,000 Capacity Sizes available: 2 6 conduit sleeve Manhole Sheaves Sizes available: 10 ft and 12 ft long #671 10 feet long with 4,000 lb. Capacity #6072 12 feet long with 6,500 lb. capacity Radius Cable Sheave- #631 4,000 lb capacity 48 inch radius 19

WIRE PULLING FEEDERS Sheaves Light Pole Base Sheave #459 Mounts directly to light pole bolt pattern Allows users to install wires into bases while pulling horizontally. 500 lb capacity Tray Type Sheaves # 658, 659 Helps roll and guide tray pulls 5 sheave Straight Cable Tray Rollers- #2024S Fits cable trays 36 wide Right Angle Cable Tray Rollers # 2036R Fits cable trays 36 wide Triple Sheave Cable Guide- #6036 Capacity: 6,500 lbs Weight 28 lbs Adjustable center sheave for 19-1/2 or 36 radius 21-7/8 high, 24 long, 7-3/8 wide with 5 sheaves 20

GREENLEE PULLING ROPE Double braided inner core with an extra double braided outer jacket for added strength and less stretch Rot and mildew resistant Lowest stretch 4:1 Safety Factor Select a rope with a maximum rated capacity that meets or exceeds the cable pullers maximum pulling force. Rope Diameter Rope Greenlee Max Rated Average Length Cat. No. Capacity Breaking Strength 3/8 rope 300, 600, 1,200 450, 451,452 1200 lbs 3,700 lbs ½ rope 300, 600 455, 456 2,200 lbs 10,000 lbs (for UT2 puller) 9/16 rope 300, 600, 1,200 35283, 35284, 35285 4,000 lbs 16,000 lbs (for UT4 & 640 Puller) ¾ rope 300 600, 1,200 35098, 35100, 35101 6,500 lbs 26,000 lbs 7/8 Rope (for 6800 (UT8) ultra tugger) 300 600, 1,200 34136, 34137, 34138 8,0000 lbs 32,000 lbs 21

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CLEVIS & SHACKLE INFORMTION FROM MCMASTER CARR 24