Gardner Bender CP10K Service Manual
10,000 lb. Cable Puller
Service/Repair Manual
CP10K
SAFETY ISSUES
IMPORTANT – USER SAFETY AND
PROTECTION: In setting up systems to
fit your operations, care must be taken
to select the proper components and
design to insure that all safety measures
have been taken to avoid the risk of
personal injury and property damage
from your application or system.
GARDNER BENDER is not
RESPONSIBLE FOR DAMAGE OR
INJURY CAUSED BY UNSAFE USE,
MAINTENANCE OR THE APPLICATION
OF ITS PRODUCTS. Please contact
Gardner Bender for guidance when
you are in doubt as to the proper safety
precautions to be taken in designing and
setting up your particular application.
Technical Support # 1-800-624-4320.
1.0 Safety Symbol Definitions . . . . . . . . . . . . . . . . . 2
2.0 Warning Labels on Product. . . . . . . . . . . . . . . . 2
3.0 Key Safety Information ...................2
4.0 CP10K Instruction Sheet . . . . . . . . . . . . . . . . . . 2
5.0 Required Tools and Test Equipment . . . . . . . . . 2
6.0 Parts Identification ......................3
US Patent: 8,434,741 B2
7.0 Motor, Guage & Wiring
Troubleshooting Guide ................. 4–5
8.0 Hydraulics ............................. 6
9.0 Boom-B Lock Pin Assembly ..................7
10.0 Motor, Capstan, and Pull Meter ............ 8
11.0 Replacement Parts Guide . . . . . . . . . . . . . . 9–13
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1.0 SAFETY SYMBOL DEFINITIONS
!
!
!
The instruction manual and labels applied to the product provide
information for avoiding injury or death from unsafe practices
related to setting up and operating this machine. It is critical that all
personnel involved with the use of this machine understand these
hazards and unsafe practices. The three levels (Danger, Warning, and
Caution) define the severity of the hazard.
DANGER: Immediate hazards that if not avoided WILL result
in severe injury or death.
WARNING: Serious injury or death COULD occur if proper
attention is not observed.
CAUTION: Injury or property damage MAY occur if proper
attention is not observed.
12. Do not wear jewelry or loose-fitting clothes. Long hair, clothing,
body parts and gloves should be clear of moving parts.
13. Always use all personal safety equipment, including eye
protection and a hard hat.
14. Do not wrap rope around legs, arms or torso of body.
15. Do not plug Power Cord directly into power source. Power
Cord must be plugged into the Footswitch.
4.0 CP10K
INSTRUCTION SHEET
Instruction Sheet IS-164
These Service instructions are intended to be used by a qualified
personal at Authorized Gardner Bender Service Centers. Users
of this product should see the CP10K instruction sheet IS-164 for
installation, operation, and maintenance information.
2.0 WARNING LABELS
ON PRODUCT
The product has safety related labels securely adhered to it in
several locations. They serve to highlight the areas of this machine
that have the potential to cause injury if the operator does not use
caution. The labels include internationally recognized symbols
that are described below.
Read and understand the instruction sheet before
!
setting up or operating this machine.
Body parts are in danger of being crushed by
moving or moveable parts.
Body parts are in danger of being entangled in rope.
Read instruction sheet before operation.
3.0 KEY SAFETY INFORMATION
1. Do not use the cable puller for any other purpose or
application beyond its intended use. It is intended for pulling
wire or cable through fixed conduit, with the conduit adaptor
engaged in the conduit and fastened to the cable puller.
2. Do not operate the cable puller in poorly lit areas.
3. Do not exceed the maximum rated 10,000 lbs. pulling force.
4. Inspect all cable puller components prior to operation.
5. Keep the pull rope away from the operator’s feet. Gather the
tailing rope in an area where the operator or crew cannot
become entangled.
6. Never stand directly under a vertical pull or directly in line with
pull rope under tension.
7. Never use general purpose rope; always use double braided
polyester rope and inspect the rope for damage after each
pull. Do not use damaged rope for pulling cable.
8. Do not allow the rope coils to overlap on the Capstan.
9. Keep bystanders away from operations. Distractions increase
chances of injury.
10. Do not use the cable puller while under the influence of drugs,
alcohol or medication.
11. Do not operate near water or other liquids.
5.0 REQUIRED TOOLS AND
TEST EQUIPMENT
• 3/8"–1-1/4", 1/2" Drive Socket Set
• 1-1/16" Box-end Wrench
• 11/16" Box-end Wrench
• 7/16" Box-end Wrench
• 10" Adjustable Wrench
• E-Ring Install Tool
– A-230
– A-210
– A-200
• SAE Allen Wrench Set
• Pliers
• 3/8" Socket Allen Wrench
• 3/16" Flat Head Screwdriver
• #2 Phillips Screwdriver
• 3/8" Socket Allen Wrench
• Battery Operated Continuity Instrument
DANGER: Make certain that the motor and foot switch are
unplugged prior to performing any repair or service efforts.
FAILURE TO OBSERVE THESE CAUTIONS MAY RESULT IN
DAMAGING MACHINE MOTOR OR SEVERE INJURY.
DANGER: Check for overhead wires prior to unfolding the
boom structure.
FAILURE TO OBSERVE THESE DANGERS WILL RESULT IN
SEVERE INJURY OR DEATH
WARNING: If you do not place your hands as instructed, then
you may crush your hand or fingers. If you do not observe the
machine warning labels, you may crush your hand or fingers.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH
2
6.0 PARTS IDENTIFICATION
1. Steering Handles
2. Caster Wheels & Brakes
3. Hydraulic Pump
4. Main Boom
5. Boom-A
6. Boom-B
7. Boom-A Lock Pin
8. Pulley-A Housing
9. Boom-B Lock Pin
10. Boom-B Extension
11. Boom-B Extension
Lock Pin
1
12. Pulley-B Housing
13. Pulley-B Housing
Lock Pin
14. Pull Orientation Pivot
15. Pull Orientation Pin
16. Conduit Adaptors
17. Power Cord
18. Footswitch
19. Pull Meter & Switch Box
20. Capstan
21. Motor
22. Pin Clips
9
8
18
16
14
21
15
6
13
10
11
7
12
22
3
5
4
20
19
17
2
3
7.0 MOTOR, GUAGE & WIRING TROUBLESHOOTING GUIDE
The CP10K utilizes a DC Permanent Magnet motor. AC power from the wall socket is routed through the Pull Meter & Switch Box
(Item 19) and a Bridge Rectifier in the circuit converts the AC voltage supply to a DC voltage supply to support the motor.
7.1 GENERAL TROUBLESHOOTING
If the capstan does not rotate, there are several possible reasons outlined below.
1. Mechanical Failure
A. Capstan/shaft key is missing
B. Internal gearbox failure
2. Electrical System Failure
A. Source Voltage Failure
B. Foot Switch Failure
C. Pull Meter Switch failure
D. Wiring Circuit Failure
E. Bridge Rectifier Failure
F. Motor Failure
DANGER: All electrical troubleshooting can be successfully
completed with the cable puller disconnected from the voltage supply.
DO NOT CONNECT THE CABLE PULLER TO POWER WHEN
TROUBLESHOOTING ELECTRICAL SYSTEM FAILURES.
FAILURE TO OBSERVE THIS DANGER WARNING WILL RESULT IN
SEVERE INJURY OR DEATH.
7.2 MECHANICAL FAILURE TROUBLESHOOTING
A. If the motor runs when power is applied, but the capstan does not rotate, then confirm that the Capstan/shaft key is intact. See
Section 10.0, Figure 3.
B. If the motor runs when power is applied and the Capstan/shaft key is intact, the Capstan is not rotating due to an internal
gearbox failure. Replace the gear motor or have it serviced.
7.3 ELECTRICAL SYSTEM FAILURE
A. Source Voltage Failure
Check for correct 120 volt AC voltage supply at the wall socket and extension cord if utilized.
B. Foot Switch Failure
Plug the foot switch into a 120 AC volt voltage supply. Do not connect the Foot Switch to the Cable Puller. With the foot switch
depressed to the on position, check the output plug for correct 120 AC voltage supply. Replace the Footswitch if necessary.
C. Pull Meter Switch Failure
Unplug the Cable Puller and Foot Switch from the voltage supply. !! IMPORTANT !!
Remove the 2 screws holding the Pull Meter & Switch Box cover in place.
Carefully pull the cover, including the pull meter away from the box as shown in Figure 1.
Use the probes of a continuity instrument to touch the two switch terminals (WITH NO POWER APPLIED) and check the
operation of the switch. The instrument should indicate continuity with the switch in the on position. The instrument should
indicate no continuity with the switch in the off position. Replace the Switch if necessary.
D. Wiring Circuit Failure
Re-assemble the Pull Meter & Switch Box cover if you removed it in step C.
Make certain that there is no voltage supply to the system.
Remove Pull Meter and Switch Box cover. See Figure 1. This will expose the Bridge Rectifier.
Use a continuity instrument to check for continuity between the Pull Meter & Switch Box plug and the two terminals on the
Bridge Rectifier marked “AC”. Note: the Pull Meter & Switch Box switch has to be in the ON position to allow continuity. The
wiring circuit is okay if each of the plug posts has continuity to one of the Rectifier AC terminals.
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