Current Tools 66 Operating, Maintenance, Safety And Parts Manual

Model 66 Cable Puller with

4 Wheel Mobile Carriage

Operating, Maintenance, Safety

This manual is free of charge. All personnel who operate the Cable
Puller should have a copy of this manual and read and understand
its contents. To request a copy of this manual or replacement safety
decals, or for technical assistance, call or write to the address below.

CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606

800.230.5421 or 864.721-4230 • FAX [phone]

and Parts Manual

2/2019

Read and understand this material before
operating or servicing the Cable Puller. Failure
to understand how to safely operate and service
this unit may result in serious injury or death.

www.currenttools.com

TABLE OF CONTENTS

Safety Alerts ..........................................3

Important Safety Information ...........................4,5

Specifications .........................................6

Features..............................................6

Set-Up and Operating Instructions .................... 7-10

Common Set-Ups.....................................11

Maintenance .........................................12

Exploded View .................................... 13-15

Parts List ..........................................16,17

Wiring Drawing ......................................17

2

SAFETY ALERTS

DANGER

THIS SAFETY SYMBOL is used to call your attention to instructions
that concern your personal safety. It means: ATTENTION! BE AWARE!
THIS IS AN IMPORTANT SAFETY INSTRUCTION!

Read, understand and follow these safety instructions. Failure to
follow these safety instructions may result in injury or death.

Safety Alert

Symbol

Immediate hazards which, if not avoided, WILL result in serious personal
injury or death.

WARNING

Hazards or unsafe practices which, if not avoided, COULD result in serious
personal injury or death.

CAUTION

Hazards or unsafe practices which, if not avoided, COULD result in minor
personal injury or property damage.

3

RETAIN SAFETY INFORMATION

DANGER

DANGER

DANGER

WARNING

DANGER

WARNING

DANGER

DANGER

WARNING

DANGER

WARNING

DANGER

DANGER

DANGER

DANGER

DANGER

DANGER

DANGER
DANGER

This manual should be read and understood by all personnel who operate
or service this Cable Puller. Failure to understand how to safely operate
and service this equipment could result in injury or death. This equipment
should only be operated and serviced by qualified personnel.

IMPORTANT SAFETY INFORMATION

DO NOT operate cable puller in wet or damp locations.
DO NOT expose to rain.
DO NOT operate in an explosive atmosphere.
DO NOT use near energized circuits.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

DO NOT use cable puller as a hoist or for lifting, supporting or
transporting people or loads. Use only for its intended purpose
as a cable puller.

DO NOT wrap rope around any body parts. DO NOT wrap rope
around wrists. Hold rope so that it may be released quickly.

ALWAYS keep rope away from operator’s feet.
DO NOT exceed load rating of cable puller, rope or accessories.
ALWAYS inspect rope before each use.
ALWAYS disconnect cable puller before servicing.
ALWAYS plug the Model 66 Cable Puller into a grounded

receptacle with a 15 amp GFCI protected circuit. DO NOT
modify the plug provided with the Model 66 Cable Puller.

ALWAYS ensure cable puller is properly secured to conduit
and all pins are in place before operating.

Pulling Rope should be the only thing to contact the capstan.
NEVER let swivels, grips, etc. come in contact with the capstan.

Rope must ALWAYS be pulled over a rotating sheave. If a
sheave does not rotate, turn cable puller off immediately and
determine problem before continuing the pull.

Set up the cable puller so that pulling rope ALWAYS contacts
both rollers. (See drawing below.)

YESNO

ROLLERS

ROLLERS

4

IMPORTANT SAFETY INFORMATION continued

DANGER

DANGER

DANGER

DANGER

DANGER

DANGER

DANGER

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

CAUTION

WARNING

DANGER

CAUTION

DANGER

DANGER

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

CAUTION

CAUTION
CAUTION

CAUTION

CAUTION

CAUTION

ONLY use
or a pulling rope with a average breaking strength of 26,000 lbs.

NEVER allow the rope to slip on a rotating capstan for more
than a couple of seconds. The rope will wear in that spot and
the rope could break under pressure.

Keep all body parts, hair, loose clothing, etc. away from
rotating parts and pinch points. Keep hands away from
capstan.

DO NOT allow the rope to overlap on the capstan. If this
condition begins to occur, immediately release the tailing force
on the rope. If this does not remedy the overlap, stop the
puller and run the puller in reverse to unwind the overlap.

During the pull, all personnel must stand to the side of the
cable puller and out of the direct line of tight pulling rope.

The cable puller must be attached to steel conduit or schedule
40 PVC conduit only. When attached to PVC conduit, the
conduit MUST be supported within 2" of the end.

ALWAYS inspect pins to be sure they are fully inserted through
holes and have spring clips properly attached. DO NOT
substitute any other object for factory supplied pins.

When making a vertical cable pull, keep the area underneath
the cable pull clear of all personnel.

Keep fingers away from adjustment holes and pivoting parts.
Fingers can be severed by pivoting parts.

Keep as much rope confined in conduit as possible. This will
help prevent injury should the rope break and whip violently.

DO NOT alter this cable puller. Doing so will void the warranty.
Guards and safety features are provided for your protection.

Wear eye protection when operating the cable puller.
Inspect all components of the cable puller before beginning

any cable pull. Replace any worn or defective components.
Be careful during assembly and disassembly of the cable

puller. Have control of components before removing any pins.
DO NOT use an extension cord longer than 100 ft. Extension

cord should be a minimum of 12 gauge wire with ground.
Some components of the pulling package exceed 50 lbs. and

will require more than on person to lift.
The motor, gear box and capstan may heat up during the pull.

Be careful.
ALWAYS pull in the direction of the arrows on top of the

capstan.

3

⁄4" or larger double-braided composite pulling rope,

5

SPECIFICATIONS

model no. — 66 Cable Puller mounted on 4 Wheel Carriage
width — 25"
depth — 42"
height — 46"
fully extended length — 93"
weight — 190 lbs. – Cable puller mounted

on 4 wheel carriage
maximum pulling force — 6,000 lbs.
speeds — no load
Low – 12 ft./min.
High – 44 ft./min.
motor — 120 volts AC, 60 hertz, 13 amps

pulling rope —

3

⁄4" or larger double braided composite pulling

rope, or a pulling rope with a minimum

breaking strength of 26,000 lbs.

FEATURES

• Integral heavy-duty 2 speed motor

• Quick-release conduit couplings

• 4 wheel carriage contains all
components (see photo 1 at right)

• Tapered capstan

• Integral foot switch

• Permanently lubricated vent-free
gear box

• Easy mobility of complete puller with
4 wheel carriage

• Foot switch storage pocket
(see photo 2 below)

Photo 1

Photo 2

6

SET-UP AND OPERATING INSTRUCTIONS

Adjustable

boom

Model 66 Cable Puller

shown pinned for

transport on 4 wheel

mobile carriage.

Extension

arm

From the transport position,

1

remove the extension arm locking
retainer pin.

With the swivel casters brakes disengaged,

3

lift the motor end of the puller so that the
adjustable boom touches the floor.

Remove the puller mount locking

2

retainer pin.

Continue to lift the motor end and pull

4

the carriage until the extension arm is
straight. Reinsert the extension arm
locking retainer pin to secure the tube,
making sure to secure the pin with the

7

attached clip.

SET-UP AND OPERATING INSTRUCTIONS continued

Next, to position the adjustable boom to

6

the desired length for the pull, remove
the locking retainer pin that goes
through the adjustable boom and re-pin

Raise the boom to a comfortable

5

working height for adjusting the nose
unit and insert the puller mount locking
retainer pin, making sure to secure the
the pin with the attached clip.

at the desired length, making sure to
secure the pin with attached clip. NOTE:

The adjustable boom can be removed
and turned for either an up pull or a
down pull.

Nose unit

The angle of the nose unit can be

7

adjusted for multiple pulling angles
by removing the angle adjustment
pin on the adjustable boom. Select
the angle needed for the pull and re­insert the pin, making sure to secure
the pin with the spring clip.

Coupling adapter

An additional angle adjustment

8

can be made on the nose unit
coupling adapter. Remove the
angle adjustment pin and adjust
the coupling adapter to the
desired angle. Re-insert the angle
adjustment pin, making sure to
secure the pin with the spring clip.

8

SET-UP AND OPERATING INSTRUCTIONS continued

DANGER

The standard couplings for the model # 66 puller are stored

9

on the puller frame. Choose the correct size coupling for
the conduit you are pulling in and insert into the coupling
adapter by pushing the receiver plate of the coupling into
the coupling adapter until the spring loaded pawl "snaps"
into the receiver plate. See figures 9A through 9C.

Model 66 puller shown pinned

10

together and ready for a pull

Next, move the cable

11

9a 9c9b

YESNO

ROLLERS

puller into position. While
maintaining control of the
boom, remove the puller
mount locking retainer pin
that you installed in step
#5. Fully insert the coupling
into the conduit until the
ring of the coupling sits
flush on the conduit. If
the coupling is not at the
correct angle to fully insert
into the conduit, adjust the angle of the coupling adapter or the
length of the adjustable boom. Lock the two swivel casters and
tighten the coupling thumb screw onto the conduit. Insert the
locking retainer pin through the first available hole in the puller
mount that is on the boom side of the upright (See figure 9D).

NOTE: ALWAYS ensure the locking retainer pin is NOT inserted
into the boom transport hole (see exploded view on page 13)
during a pull.

ROLLERS

WARNING

Set up the
cable puller so that pulling
rope ALWAYS contacts both
rollers. (See drawing at left).

BOOM SIDE

FIRST

AVAILABLE

HOLE

Figure 9D

BOOM SIDE

LOCKING

RETAINER

PIN

9

SET-UP AND OPERATING INSTRUCTIONS continued

The operator may stand on

12

either side of the cable puller.
Place the foot switch on the
side the operator will be
standing. Plug the cord into a
15 amp GFCI protected outlet.

Push the FWD/

13

REV switch to the

forward

position.

Depress the foot switch and

14

check the rotation of the capstan
with the pulling rotation direction
decal on the cable puller.

Next, turn the High/

15

Low speed switch to
the desired position,
“H” or “L”.

To begin the pull, place 2 to 3 wraps of the

16

pulling rope around the capstan. Depress the
foot switch and begin the pull. If the amount
of tension (tailing force) you have to put on
the pulling rope exceeds approximately 10
lbs., then turn the cable puller off and add
one wrap of the pulling rope to the capstan.

NOTE: The Model

Puller

mount

pivot pin

66 puller can be
disassembled from,
and used without the 4
wheel carriage. Remove
the puller mount pivot
pin and lift the puller off
of the carriage.

10

When the pull is completed, pull

17

the ring on the back of the coupling
adapter to separate the coupling from
the coupling adapter. NOTE: Be sure

to loosen the thumb screw if you have
tightened it against the conduit.

66 puller shown in
position for an up
pull without the 4
wheel carriage.

COMMON SET-UPS

WARNING

DANGER

WARNING

DANGER

DANGER

DANGER

UP PULL

WARNING

NEVER allow the rope to slip on a
rotating capstan for more than a couple of seconds.
The rope will wear in that spot and the rope could
break under pressure.

Keep fingers away from
adjustment mount holes and pivoting parts.

Fingers can be severed by pivoting parts.

DOWN PULL

WARNING

the capstan. If this condition begins to occur,
immediately release the tailing force on the rope. If
this does not remedy the overlap, stop the puller and
run the puller in reverse to unwind the overlap.

CAUTION

may heat up during the pull. Be careful.

11

DO NOT allow the rope to overlap on

The motor, gear box and capstan

MAINTENANCE

DANGER

WARNING

Unplug the cable puller before servicing.

CAUTION

DO NOT alter this cable puller. Doing so will void the warranty. Guards and
safety features are provided for your protection.

Capstan

Replace the capstan if it is grooved more than 1⁄16" deep.

Gear Box

The Model 66 Cable Puller has a vent-free gear box and
is factory lubricated for life with synthetic, semi-fluid gear
lubricant with an operating range of +5˚F to +220˚F.

12

EXPLODED VIEW — 66 CABLE PULLER

BOOM TRANSPORT HOLE

EXPLODED VIEW — 4 WHEEL CARRIAGE

PARTS LIST — 4 WHEEL CARRIAGE

ITEM # PART # DESCRIPTION QTY.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

452-27 WASHER–LOCK MEDIUM 3/8 ZINC

452-28 NUT–HEX ZINC (3/8-16)

506-3 WASHER–FLAT 3/8 (USS) ZINC

524-11 3/8-16 × 1.0" HEX HEAD SCREW

66-004 WHEEL

66-119 BASE

66-51 COUPLING–2"

66-52 COUPLING–2 1/2"

66-53 COUPLING–3"

66-54 COUPLING–3 1/2"

66-55 COUPLING–4"

77-016 COTTER PIN–3/16 × 1 1/4" LONG

77-017 WASHER–FLAT 3/4" (SAE)

752-104 CASTER – SWIVEL

8

8

8

8

2

1

1

1

1

1

1

2

2

2

13

13

EXPLODED VIEW — 66 CABLE PULLER

EXPLODED VIEW — GEAR ASSEMBLY

EXPLODED VIEW — 66 CABLE PULLEREXPLODED VIEW — DRIVE ASSEMBLY

13

14

EXPLODED VIEW — 66 CABLE PULLER

EXPLODED VIEW — BOOM ASSEMBLY

13

15

PARTS LIST — 66 CABLE PULLER

ITEM # PART # DESCRIPTION QTY.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

2-1301-4 NUT–HEX NYLON INSERT (5/16"-18)

2-1501-4 NUT–HEX NYLON INSERT (3/8-16)

280-8B RING–RETAINING H.D. EXT (1.5)

33-1 MOTOR

33-12 PIN–ROLL, 3/16 × 1-7/8

33-19 RING–RETAINING 3/8 EXTERNAL

33-24 PIN 5/8" CLEVIS

33-36 R CLIP

33-45 FOOT SWITCH

33-460 ADAPTER SHAFT

33-460 SCREW SCREW–SOCKET HEAD CAP (M6 × 25 LEFT HAND THREAD)

33-49 KEY 3/16" SQ × 1-1/4"

33-53 SCREW–HEX HEAD CAP GR5 ZINC (3/8-16 × 3/4)

33-699 LEVER–DRILL SWITCH

33-702 BAR–ACTUATOR, SWITCH

33-703 SPACER–DRILL SWITCH

33-706 FOOT SWITCH HOLDER

33-735 CAM–DRILL SWITCH

450-18 STRAIN RELIEF

450-4 POWER CORD

66-001 SCREW–SHOULDER SOCKET (1/2" X 2.75")

66-003 LOCKING RETAINER PIN, ZINC (1/2" X 3")

66-111 NOSE UNIT

66-114 PULLER MOUNT

66-300 66 CART ASSEMBLY

66-125 EXTENSION ARM

66-127 ADJUSTMENT TUBE

66-138 FOOT

66-143 PULLER MOUNT PIN ASSEMBLY

66-2 GEARBOX

66-30 SCREW–HEX FLANGE (3/8-16 × 1)

66-32 SCREW–SOCKET HEAD CAP (M6 × 25)

66-33 SCREW–HEX HEAD CAP GR5 ZINC (7/16-14 × 1.5)

66-37 SCREW–BUTTON HEAD SOCKET (M10 × 30)

66-38 KEY 3/8" SQ X 1-1/4"

66-39 SCREW–HX HD CAP (5/16-18 × 2.75"

66-40 SCREW– SOCKET HEAD CAP (5/16-18 × 2.5")

66-595 CAPSTAN–6K PULLER

66-598 ADAPTER CAP

66-599 CAPSTAN SHAFT

66-600 ROLLER

66-601 GEARBOX MOUNTING BRACKET

66-601A GEARBOX MOUNTING BRACKET

66-605 TUBE CONNECTED WELDMENT

66-643 BACK-UP PLATE

66-66 KEY 3/8" SQ × 4-3/4"

66-660 SELECTOR SWITCH PLATE

66-661 CAPSTAN BEARING WASHER

66-662 CAPSTAN RETAINING WASHER

4

1

2

1

2

1

1

6

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

8

4

2

8

2

2

2

1

1

1

1

1

1

1

1

1

1

1

1

16

PARTS LIST — 66 CABLE PULLER (CONTINUED)

15A PLUG

50

66-663 MOTOR SPACER

ITEM # PART # DESCRIPTION QTY.

51

52

53

54

55

56

57

58

59

66-684 PIN–66 PULLER

66-685 HI/LO WELDMENT

66-695 BRACKET FAB–SWITCH

66-742 HI/LO SWITCH

66-76 WASHER–FLAT 7/16" (SAE)

66-971 LOWER TUBE WELDMENT

77-017A WASHER–FLAT SAE ZINC (1/2)

77-035A ROLL PIN 1/8 × 3/4

9544-16 WASHER, FLAT 5/16"

WIRING DRAWING – FOOT SWITCH

POWER CORD
FROM MOTOR

GREEN

WHITE

2

2

1

1

1

2

1

1

2

3

BLACK

NCC NO

FOOT­SWITCH

BLACK

17