Current Tools 66 Cable Puller Operating, Maintenance, Safety And Parts Manual

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

800.230.5421 or 864.721-4230 • FAX [phone]
www.currenttools.com

Operating, Maintenance, Safety

and Parts Manual

Model 66 Cable Puller with

4 Wheel Mobile Carriage

10/2018

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.

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.

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

3

SAFETY ALERTS

Safety Alert

Symbol

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.

DANGER

WARNING

CAUTION

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

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

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

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.
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.)

RETAIN SAFETY INFORMATION

4

IMPORTANT SAFETY INFORMATION

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.

ROLLERS

ROLLERS

YES NO

DANGER

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

DANGER

DANGER
DANGER

IMPORTANT SAFETY INFORMATION continued

5

ONLY use

3

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

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.

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

CAUTION

CAUTION
CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

WARNING

WARNING

SPECIFICATIONS

6

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

7

SET-UP AND OPERATING INSTRUCTIONS

2

Remove the puller mount locking

retainer pin.

3

With the swivel casters brakes disengaged,

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

4

Continue to lift the motor end and pull

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
attached clip.

Adjustable

boom

Extension

arm

1

From the transport position,

remove the extension arm locking
retainer pin.

Model 66 Cable Puller

shown pinned for

transport on 4 wheel

mobile carriage.

8

5

Raise the boom to the approximate

angle for the pull and insert the puller
mount locking retainer pin, making
sure to secure the pin with the
attached clip.

6

Next, to position the adjustable boom to

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

8

An additional angle adjustment

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.

7

The angle of the nose unit can be

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.

SET-UP AND OPERATING INSTRUCTIONS continued

Nose unit

Coupling adapter

9

10

Model 66 puller shown

pinned together and ready for
a pull

9

The standard couplings for the model # 66 puller are stored

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.

11

Next, move the

cable puller into
position and fully
insert the coupling
into the conduit
until the ring on 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. NOTE: To help hold the coupling in the

conduit on a down pull, lock the two swivel
casters on the 4 wheel carriage and tighten the
coupling thumb screw onto the conduit.

SET-UP AND OPERATING INSTRUCTIONS continued

ROLLERS

ROLLERS

YES NO

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

WARNING

12

The operator may stand on

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.

9a 9c9b

10

14

Depress the foot switch and

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

15

Next, turn the High/Low

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

16

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

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.

SET-UP AND OPERATING INSTRUCTIONS

continued

17

When the pull is completed, pull

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.

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.

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.

The motor, gear box and capstan
may heat up during the pull. Be careful.

CAUTION

13

Push the FWD/

REV switch to the

forward

position.

WARNING

WARNING

WARNING

NOTE: The Model
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.

Puller

mount

pivot pin

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

COMMON SET-UPS

UP PULL

DOWN PULL

11

MAINTENANCE

12

WARNING

CAUTION

Unplug the cable puller before servicing.

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.

EXPLODED VIEW — 66 CABLE PULLER

13

EXPLODED VIEW — 4 WHEEL CARRIAGE

13

EXPLODED VIEW — 66 CABLE PULLER

13

EXPLODED VIEW — GEAR ASSEMBLY

14

EXPLODED VIEW — 66 CABLE PULLEREXPLODED VIEW — DRIVE ASSEMBLY

EXPLODED VIEW — 66 CABLE PULLER

13

EXPLODED VIEW — BOOM ASSEMBLY

15

PARTS LIST — 66 CABLE PULLER

16

ITEM # PART # DESCRIPTION QTY.

1

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

4

2

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

1

3

280-8B RING–RETAINING H.D. EXT (1.5)

2

4

33-1 MOTOR

1

5

33-12 PIN–ROLL, 3/16 × 1-7/8

2

6

33-19 RING–RETAINING 3/8 EXTERNAL

1

7

33-24 PIN 5/8" CLEVIS

1

8

33-36 SPRING CLIP

6

9

33-45 FOOT SWITCH

1

10

33-460 ADAPTER SHAFT

1

11

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

1

12

33-49 KEY 3/16" SQ × 1-1/4"

1

13

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

1

14

33-699 LEVER–DRILL SWITCH

1

15

33-702 BAR–ACTUATOR, SWITCH

1

16

33-703 SPACER–DRILL SWITCH

1

17

33-706 FOOT SWITCH HOLDER

1

18

33-735 CAM–DRILL SWITCH

1

19

450-18 STRAIN RELIEF

1

20

450-4 POWER CORD

1

21

452-27 WASHER–LOCK MEDIUM 3/8 ZINC

8

22

452-28 NUT–HEX ZINC (3/8-16)

8

23

506-3 WASHER–FLAT 3/8 (USS) ZINC

8

24

524-11 3/8-16 X 1.0" HEX HEAD SCREW

8

25

66-001 SCREW–SHOULDER SOCKET (3/8" × 2.75")

1

26

66-002 LOCKING RETAINER PIN, ZINC (1/2" × 3")

3

27

66-004 10" DIAMETER WHEEL

2

28

66-111 NOSE UNIT

1

29

66-114 PULLER MOUNT

1

30

66-119 PULLER BASE

1

31

66-125 EXTENSION ARM

1

32

66-127 ADJUSTABLE BOOM

1

33

66-138 FOOT WELDMENT

1

34

66-143 PULLER MOUNT PIN ASSEMBLY

1

35

66-2 GEARBOX

1

36

66-30 SCREW–HEX FLANGE (3/8-16 × 1)

8

37

66-32 SCREW–SOCKET HEAD CAP (M6 × 25)

4

38

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

2

39

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

8

40

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

2

41

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

2

42

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

2

43

66-595 CAPSTAN–6K PULLER

1

44

66-598 ADAPTER CAP

1

45

66-599 CAPSTAN SHAFT

1

46

66-600 ROLLER

1

47

66-601 GEARBOX MOUNTING BRACKET

1

48

66-601A GEARBOX MOUNTING BRACKET

1

49

66-605 TUBE CONNECTED WELDMENT

1

50

66-643 BACK-UP PLATE

1

17

PARTS LIST — 66 CABLE PULLER (CONTINUED)

FOOT­SWITCH

15A PLUG

POWER CORD
FROM MOTOR

BLACK

NCC NO

BL

ACK

GREEN

WH

ITE

ITEM # PART # DESCRIPTION QTY.

51

66-66 KEY 3/8" SQ × 4-3/4"

1

52

66-660 SELECTOR SWITCH PLATE

1

53

66-661 CAPSTAN BEARING WASHER

1

54

66-662 CAPSTAN RETAINING WASHER

1

55

66-663 MOTOR SPACER

2

56

66-684 PIN–66 PULLER

2

57

66-685 HI/LO WELDMENT

1

58

66-695 BRACKET FAB–SWITCH

1

59

66-700 COUPLING–2"

1

60

66-701 COUPLING–2-1/2"

1

61

66-702 COUPLING–3"

1

62

66-703 COUPLING–3-1/2"

1

63

66-704 COUPLING–4"

1

64

66-742 HI/LO SWITCH

1

65

66-76 WASHER–FLAT 7/16" (SAE)

2

66

66-971 LOWER TUBE

1

67

752-104 CASTER – SWIVEL

2

68

77-016 COTTER PIN–3/16 × 1-1/4" LONG

2

69

77-017 WASHER–FLAT 3/4" (SAE)

2

70

77-017A WASHER–FLAT SAE ZINC (1/2)

1

71

77-035A ROLL PIN 1/8 × 3/4

2

72

9544-16 WASHER, FLAT 5/16"

3

WIRING DRAWING – FOOT SWITCH