Setting up a Greenlee® 640, 6001, 6801 or Ultra Tugger pull and not sure which sheave you need? Feeding sheaves, hook sheaves and pulling grips each do a different job in the pull train — and undersizing a sheave is the fastest way to damage cable jacket or stall a puller. Here's how to pick the right one.
Feeding sheaves: at the conduit mouth
A feeding sheave bolts to the puller and guides cable smoothly into (or out of) the conduit, keeping the bend radius safe. Size it to your conduit and cable bundle:
- 441 3" feeding sheave — smaller conduit runs.
- 441 4" feeding sheave — the everyday middle size.
- 441 5" feeding sheave — bigger bundles, larger conduit.
- Need flexibility? The 441 3"–3-1/2" feeding sheave set covers two sizes with one sheave sleeve adapter.
All 441-series sheaves fit Greenlee 640, 6001, 6801 tuggers and compatible pullers.
Hook sheaves: redirecting the rope
Hook sheaves anchor to the pull point and redirect the rope around corners and down runs. Bigger diameter = gentler bend on the rope and less lost pulling force. All Staten Tools hook sheaves are rated to 6,500 lb:
- 6" hook sheave and 12" hook sheave — tight spaces and lighter pulls.
- 18" hook sheave (652) and 24" hook sheave (652) — long heavy pulls where rope wear matters.
Running older sheaves? The 18"/24" pin upgrade set and 6"/12" pin upgrade set refresh worn pins on Greenlee, Current and Maxis sheaves for a fraction of a new sheave.
Pulling grips and consumables
Between the rope and the cable you need a grip matched to the cable diameter. The 624 pulling grips work with all Greenlee pullers, and the 629 heavy-duty grip kit with clevis adds hardware for repeated heavy pulls. If your tugger's drive chain is stretched or rusty, the 27831 24" replacement chains (Ultra/Super/6801/640/6001) restore full grip on the capstan.
Quick sizing rules of thumb
- Feeding sheave: match to conduit size — cable bundle should never contact the conduit edge.
- Hook sheave: pick the biggest diameter that fits the space; small sheaves eat rope.
- Never exceed the 6,500 lb sheave rating — check your puller's max force setting.
- Replace sheave pins at first sign of wobble; a seized sheave under load is a rope-cutter.
See everything in the cable sheaves & pulling parts collection, all covered by Staten Tools' one-year warranty.
Greenlee® is a registered trademark of Greenlee Tools, Inc. Staten Tools manufactures compatible aftermarket parts and is not affiliated with Greenlee.
