Current Tools 8845 User manual

Model 88 Series Cable Puller
8,000 lb. Maximum Pulling Force
and
Model 8845 Cable Pulling Package
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
10/14 REV. 5
This manual is free of charge. All personnel who operate the Cable Puller or any component of the
Cable Pulling Package 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. All information, specifications and product designs may change due to
design improvements or updates and are subject to change without notice. Current Tools does not
assume any liability for damages resulting from misuse or incorrect application of its products.
Read and understand this material before operating or
servicing the Cable Puller or any of component Cable Pulling
Package. Failure to understand how to safely operate and
service these units may result in serious injury or death.

TABLE OF CONTENTS
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 8
Components Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cable Pulling Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Model 88 Cable Puller and Accessories
Power Requirements
Force Gauge
Mounting Chain Installation
Floor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 15
Safety Information
Installation Instructions
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
Rope Set-Up
Pulling Operation
Common Set-Ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Tandem Pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication
Inspection
ExplodedView – Model 88 Cable Puller . . . . . . . . . . . . . . . . . . 22
Parts List – Model 88 Cable Puller . . . . . . . . . . . . . . . . . . . . . . . 23
ExplodedView – Model 88 Cable Puller Motor . . . . . . . . . . . . 24
Parts List – Part #88-44 Cable Puller Motor . . . . . . . . . . . . . . . 25
Wiring Schematic – Model 88 Cable Puller . . . . . . . . . . . . . . . 26
Wiring Drawing – Model 88 Cable Puller . . . . . . . . . . . . . . . . . 26
2

Hazards or unsafe
p
ractices which, if not avoided, COULD result in serious
personal in
j
ur
y
or death
.
W
ARNIN
G
Hazards or unsafe
p
ractices which, if not avoided, COULD result in minor
personal in
j
ur
y
or propert
y
damage
.
CA
UTI
ON
Immediate hazards which, if not avoided, WILL result in serious
p
ersonal
in
j
ur
y
or death
.
DAN
G
E
R
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
SAFETY ALERTS
3

WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
DANGER
DANGER
This manual should be read and understood by all personnel who operate or service
this Cable Puller or any component of the Cable Pulling Package. Failure to understand
how to operate and service this equipment could result in serious injury or death. This
equipment should only be operated and serviced by qualified personnel.
RETAIN SAFETY INFORMATION
4
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 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.
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 88 Cable Puller into a grounded
receptacle with a 15 amp GFCI protected circuit. Do NOT
modify the plug provided with the Model 88 Cable Puller.
ALWAYS inspect the structural integrity of any supports,
conduit, anchoring system etc. that will hold the cable puller
during the pull. These supports should be able to withstand
the maximum pulling force of the cable puller plus a safety
factor of 3:1. Example: 8,000 lb. puller should be anchored
to a support that can withstand 24,000 lbs. of pull.
IMPORTANT SAFETY INFORMATION
W
ARNIN
G
ALWAYS insure cable puller is properl
y
secured before operating.
ALWAYS attach to su
pp
orts that are at least 2" and not more than the 10" wide
.
See mountin
g
chain installation section of this manual for proper mountin
g
of cable
p
uller and tie-down chain installation
.
OK
T
OO
WID
E

5
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
Pulling Rope should be the only thing to contact the capstan.
NEVER let swivels, grips, etc. come in contact with the capstan.
Keep as much rope confined in conduit as possible. This will
help prevent injury should the rope break and whip violently.
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.
This cable puller is equipped with an anti-reversing pawl.
The pawl will make a clicking sound when the capstan is
rotating. If you can not hear the clicking sound as the capstan
rotates, immediately turn the cable puller off and do not
use until repaired.
ONLYuse 3/4”or larger double-braided composite pulling
rope with an 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. If you need to stop the
pull, turn the cable puller off and tie the rope off to hold it
in place until you restart your pull.
Keep all body parts, hair, loose clothing, etc. away from rotating
parts and pinch points. Keep hands away from capstan.
NEVER allow the rope to overlap on the capstan. If this condition
begins to occur, immediately release the tailing force on the rope
so that the rope can feed back toward the conduit or cable tray.
If this does not remedy the overlap, turn off the cable puller
immediately. There is
no known solution for
rope overlap.
Rope should approach
capstan as shown in
Figure 1.
MAXIMUM
10˚
MAXIMUM
10˚
PULL
DIRECTION
Figure 1
IMPORTANT SAFETY INFORMATION continued . . .

Some components of the cable pulling package exceed 50 lbs.
and will require more than one person to lift, transport, and
assemble.
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.
Do NOT mount the Model 88 Cable Puller to square columns
or I-beams. The mounting chains will not tighten properly on
these structures.
The ONLY approved method to secure the Model 88 Cable Puller
is with the 2 mounting chains provided. Do NOT attempt to use
any other object to secure the cable puller.
Inspect mounting chains for wear before each installation.
NEVER alter the mounting chains or handle.
When making a vertical cable pull, keep the area underneath
the cable pull clear of all personnel.
Do NOT alter this cable puller. Doing so will void the warranty.
Guards and safety features are provided for your protection.
Do NOT use an extension cord longer than 100 ft. Extension
cord should be a minimum of 12 gauge wire with ground.
6
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
IMPORTANT SAFETY INFORMATION continued . . .
FI
GU
RE 2
A
FI
GU
RE 2
B
N
O
OK
Never ti
g
hten chain as shown in Fi
g
ure 2A. This causes side loadin
g
of the chain and can result in failure of the chain or screw causin
g
components to come loose and possibl
y
cause serious in
j
ur
y
or
death. Fi
g
ure 2B shows the proper ali
g
nment of screw and chain
for ti
g
htenin
g
.
W
ARNIN
G
Figure 2BFigure 2A

CAUTION
CAUTION
CAUTION
Wear eye protection when operating cable puller.
Inspect all components of the pulling system before begin-
ning any cable pull. This includes the cable puller and any
accessories ( sheaves, swivels. etc. ) Replace any worn or
defective components.
Be careful during assembly and disassembly of the pulling
system components. Have control of components before
removing any pins.
7
IMPORTANT SAFETY INFORMATION continued . . .
SPECIFICATIONS —Model 88 Cable Puller
Model No.88 Cable Puller
width –20 1/2”
length –24 3/4”
height –16”
weight –101 lbs. (includes two mounting chains)
maximum pulling force –8,000 lbs.
speeds (approx.) no load –16 ft/min.
4,000 lbs. –9 ft/min.
6,000 lbs. –7 ft/min.
motor –120 volts AC, 60 hertz, 15 amps
FEATURES
•Heavy duty all welded unitized steel frame
•Permanently mounted force gauge allows operator to monitor the pulling force
•Circuit breaker on/off switch —helps protect motor
•Safety pawl on capstan sprocket to prevent reverse rotation
•Tapered capstan to help avoid rope overlap
•Simple design provides for easy maintenance —only one guard covers all
sprockets and chains
•Tailing rope safety roller for operator safety —lets operator stand out of the
direct line of tight pulling rope
•Three handles for carrying or positioning puller
•Simple electrical system for easy maintenance

C
AP
S
TA
N
C
HAI
N
G
U
AR
D
HAN
D
L
E
F
O
R
CE
GA
U
G
E
OFF
/
ON CIRCUI
T
BREAKER
S
WIT
CH
M
O
T
OR
P
O
WE
R
CO
R
D
REAR
T-HAN
D
L
E
M
OU
NTIN
G
C
HAIN
S
S
AFET
Y
R
O
LLE
R
FEATURES continued . . .
8
Figure 3

CAT. NO. KEY DESCRIPTION PULLER PULLER WITH FLOOR MOUNT WT.
ONLY
88 8845
88 ACable puller with chains 1 1 101
8045 Bfloor mount 116
COMPONENTS LISTING
9
A
B
Cable Puller Package

CABLE PULLING BASICS
Model 88 Cable Puller and Accessories
The Model 88 Cable Puller has a maximum pulling force of 8,000 lbs.
Therefore, all of the accessories used to make a cable pull with this unit
must be rated to meet or exceed the forces generated. This includes, but
is not limited to pulling rope, sheaves, swivels, grips, etc. Be aware that
the pulling force on a sheave and its anchoring system can be as great as
twice the pulling force generated by the cable puller.
Power Requirements
The Model 88 Cable Puller motor is rated at 120 volt – 60 hz – 15 amps.
10
ALWAYS plu
g
the Model 88 Cable Puller into a
g
rounded receptacle with
a 15 am
p
GFCI
p
rotected circuit
.
DO NOT modif
y
the plug provided with the Model 88 Cable Puller. If needed
,
have a 15 amp GFCI receptacle installed b
y
a qualified electrician
.
W
ARNIN
G
If an extension cord is used, it should be a minimum of 12
g
au
g
e wire with
g
round and a maximum len
g
th of 100 ft
.
CA
UTI
ON
Do NOT exceed load ratin
g
of cable puller, rope, or accessories.
W
ARNIN
G
Inspect all components of the pulling s
y
stem before beginning an
y
cable pulling.
This includes the cable puller and an
y
accessorie
s
(
sheaves, swivels. etc.
)
Replace an
y
worn or defective components
.
CA
UTI
ON

11
CABLE PULLING BASICS continued . . .
Force Gauge
The Model 88 Cable Puller is equipped with an integral force gauge.
To calibrate the force gauge, run the puller for 1 minute with no load.
While the puller is running (with no load), use adjustment screw on face
of force gauge to set needle to zero pounds of force.
The operator should always monitor the force gauge throughout the entire
cable pull. The force gauge has 3 color sections to help you identify operating
conditions. These sections are:
Color Condition
Green Puller can be run continuously
Yellow 50% duty cycle; 15 minutes on / 15 minutes off
Red Overload Condition –Do NOT operate puller
Correct overload condition or set up a tandem pull
(See page 21. )
Mounting Chain Installation
The Model 88 Cable Puller is designed to be mounted using the two mounting
chains provided. The handles on the chains should provide sufficient leverage
to tighten the chains securely. No other tools are needed. Be sure to check the
mounting chains for kinks and twists before you tighten them. See Warning
below for proper mounting chain installation.
Figure 4BFigure 4A

ALWAYS insure cable puller is properl
y
secured before operating.
ALWAYS attach to su
pp
orts that are at least 2" and not more than the 10" wide
.
OK
T
OO
WID
E
DAN
G
ER
12
A
D
C
B
Figure 5
A–Loosen the mounting chain
handle so that only 3 or 4 threads
remain engaged.
B–Wrap the chain around the
floor mount, conduit or structural
support sufficient to handle
the pulling forces.
C–Pull the loose end of the mounting
chain tight and hook the closest
chain link into the recessed area.
D–Tighten the chain handle.
Repeat this process for second
mounting chain.
Be sure threads do not bottom out before chain becomes ti
g
ht.
W
ARNIN
G
CABLE PULLING BASICS continued . . .

13
CABLE PULLING BASICS continued . . .
ALWAYS inspect the structural integrit
y
of an
y
supports, conduit, anchoring
s
y
stem etc. that will hold the cable puller during the pull. These supports
should be able to withstand the maximum pullin
g
force of the cable puller
plus a safet
y
factor of 3:1. Example: 8,000 lb. puller should be anchored to
a support that can withstand 24,000 lbs. o
f
pull
.
W
ARNIN
G
Do NOT mount the Model 88 Cable Puller to s
q
uare columns or I-Beams.
The mounting chains will not tighten properl
y
on these structures
.
W
ARNIN
G
1.
The onl
y
approved method to secure the Model 88 cable puller is with
the 2 mountin
g
chains provided with the Model 88 cable Puller. Do NOT
attempt to use an
y
other ob
j
ect to secure the puller
.
2.
Inspect mountin
g
chains for wear before each installation
.
3
. NEVER alter the mounting chains or handle
.
W
ARNIN
G

FLOOR MOUNT
The Model 8045 Floor Mount is made to fit the Current Tools Model 88
Cable Puller. The floor mount is to be mounted only to a concrete floor
using the method described below.
Safety Information
1. ALWAYS mount to a smooth, flat
concrete floor with a minimum
3000 psi rating.
2. Mount only to a concrete floor.
NEVER mount to cinder blocks, brick, etc.
3. Wedge anchors must be at least 12”away from edge of concrete.
4. ALWAYS use new anchors. NEVER REUSE ANCHORS.
5. Use only 5/8”x 6”wedge anchors or equivalent with a tension
and shear rating of 2,500 lbs. (Current Tools part #8045-3)
6. ALWAYS wear eye protection when installing anchors.
14
CAUTION
Current Tools
place close to conduit
ALWAY
S
p
lace the floor mount close to the conduit. This will reduce the
possibilit
y
of in
j
ur
y
should the rope break. See Figure 6B
.
W
ARNIN
G
Figure 6A
Figure 6B

CAUTION
15
FLOOR MOUNT continued . . .
Installation Instructions
1. Wear safety glasses.
2. Follow the safety instructions provided by the drill manufacturer.
3. Use only 5/8”diameter solid carbide tipped bits that meet ANSI B94-12.
4. Using the floor mount as a template, drill four 5/8”holes a minimum
of 6”deep but not closer than 1 1/4”to the bottom (opposite surface) of
the concrete. Be sure to drill the holes perpendicular to the work surface
and do not ream the holes or let the drill bit wobble.
5. Clean the holes with compressed air and a wire brush. Clean holes are
necessary for proper performance.
6. Assemble the washer and nut on the anchor so the top of the nut is flush
with the top of the anchor.
7. Next, drive the 4 wedge anchors through the 4 floor mount holes and into
the concrete holes making sure the nut and washer rests solidly against
the floor mount.
8. Tighten the anchors with a torque wrench to 75–90 ft. lbs.
Note: If anchor spins, pull up on the anchor using the claw end of hammer
and then torque. If spinning still occurs, Do NOT use this location; reposition
the floor mount and repeat this installation procedure.
9. Place the Model 88 Cable Puller so that the “V”positioning units on the
bottom of the puller legs straddle the floor mount. Mount puller to the
floor mount using the mounting chain installation procedure found on
pages 11, 12, & 13 of this manual.
Figure 7

Rope Set-Up
As shown in the overhead view,
Figure 8A, the pulling rope must
approach the capstan at a 90ºangle.
This will help avoid rope overlap.
Make several wraps of the pulling
rope around the capstan, beginning
at the housing end of the capstan.
See Figure 8A.
Next, guide the pulling rope around
the black safety roller as shown in
Figure 8A. This will enable the operator
to stand at a 90ºangle to the cable
puller and out of the direct line of
tight pulling rope.
Also note the pulling rope should
approach the capstan as indicated
in Figure 8B.
16
TO
OPERATOR
BLACK
ROLLER
90º
MAXIMUM
10˚
MAXIMUM
10˚
PULL
DIRECTION
Figure 8B
Figure 8A
OPERATING INSTRUCTIONS —Model 88 Cable Puller
Do NOT o
p
erate cable
p
uller in wet or dam
p
locations. Do NOT ex
p
ose to rain.
DAN
G
ER
Do NOT o
p
erate in an ex
p
losive atmos
p
here
.
DAN
G
ER
Do NOT use cable puller as a hoist or for liftin
g
, supportin
g
or transportin
g
people or loads. Use onl
y
for its intended purpose as a cable puller.
W
ARNIN
G

17
Pulling Operation
1. Be sure the cable puller power switch is in the offposition.
2. Operator should monitor the force gauge throughout the entire cable pull.
3. Hold the tailing end of the pulling rope and pull slightly. Turn the cable
puller on.
Note: The tailing rope is that portion of the pulling rope that has
passed the capstan and is now excess to the pull. By pulling on the
tailing rope the operator can control and vary the pulling force. It
should require no more than 10 lbs. of tailing force by the operator
to engage the pulling rope on the capstan. If the rope slips on the
capstan, turn the puller off and add an additional wrap of rope
around the capstan. Also note that with the tailing force at a con-
stant pull, each additional wrap of rope around the capstan will
approximately double the pulling force of the cable puller.
ALWAYS use black roller to
g
uide rope so that operator stands at 90
o
an
g
le to the
cable puller and out of the direct line of ti
g
ht pullin
g
rope. See Fi
g
ure 8A
.
ALWAYS wrap rope be
g
innin
g
at housin
g
end of capstan as shown in Fi
g
ure 8A
.
Ro
p
e must a
pp
roach ca
p
stan at a 90oan
g
le. See Fi
g
ure 8A
.
Rope should approach capstan as shown in Fi
g
ure 8B
.
W
ARNIN
G
Rope Requirements: Use onl
y
3/4" or larger double braided composite pulling rope
wi
th
an avera
g
e breakin
g
stren
g
th of 26,000 lbs
.
Be sure to inspect rope for dama
g
e before each cable pull
.
W
ARNIN
G
Wear e
y
e protection when operating cable puller
.
CA
UTI
ON
OPERATING INSTRUCTIONS continued . . .

18
4. As the rope is tailed it should mound on the floor between the
operator and the cable puller.
5. Turn the cable puller switch to the offposition when the pull is completed.
Note:The Model 88 Cable Puller is equipped with a circuit breaker
switch. If the amperage rating of the breaker is exceeded the puller
will stop. Before restarting the pull, allow the motor to cool and
determine the cause for the overload condition. Correct before
restarting the pull.
This cable puller is equipped with an anti-reversin
g
pawl. The pawl will make a clickin
g
sound when the capstan is rotating. if
y
ou can not hear the clicking sound as the
capstan rotates, immediatel
y
turn the cable puller off and do not use until repaired
.
W
ARNIN
G
NEVER allow the rope to overlap on the capstan. If this condition be
g
ins to occur
,
immediatel
y
release the tailing force on the rope so that the rope can feed back toward
t
he conduit or cable tra
y
. If this does not remed
y
the overlap, turn off the cable puller
immediatel
y
. There is no known solution for ro
p
e overla
p
.
W
ARNIN
G
NEVER allow the rope to slip on a rotatin
g
capstan for more than a couple of seconds
.
The rope will wear in that spot and the rope could break under pressure. If
y
ou need
to sto
p
the
p
ull, turn the cable
p
uller off and tie the ro
p
e off to hold it in
p
lace until
y
ou restart
y
our pull
.
W
ARNIN
G
Keep all bod
y
parts, hair, loose clothing, etc. awa
y
from rotating parts and pinch
points. Keep hands awa
y
from capstan.
Do NOT wrap rope around an
y
bod
y
parts. Do NOT wrap rope around wrists
.
ALWAYS keep the tailing rope awa
y
from the operator
’
s
feet
.
W
ARNIN
G
OPERATING INSTRUCTIONS continued . . .

19
Pulling Rope should be the onl
y
thing to contact the capstan. NEVER let swivels, grips,
e
t
c
. come in contact with the ca
p
stan.
W
ARNIN
G
Ro
p
e must ALWAYS be
p
ulled over a rotatin
g
sheave. If a sheave does not rotate
,
turn
cable puller off immediatel
y
and determine the problem before continuing the pull.
W
ARNIN
G
Keep as much rope confined in the conduit as possible. This will help prevent in
j
ur
y
should the rope break and whip violentl
y
.
W
ARNIN
G
When makin
g
a vertical cable pull, keep the area underneath the cable pull clear
of all
p
ersonnel.
W
ARNIN
G
NEVER allow the rope to overlap on the capstan. If this condition be
g
ins to occur,
immediatel
y
release the tailing
f
orce on the rope so that the rope can
f
eed back
toward the conduit or cable tra
y
. If this does not remed
y
the overlap, turn off the
cable puller immediatel
y
. There is no known solution for ro
p
e overla
p.
W
ARNIN
G
OPERATING INSTRUCTIONS continued . . .

20
COMMON SET-UPS
NOTE: When using Manhole Sheave,
always refer to Model 308/310/312 Manhole
Sheave instruction sheet. For a FREE copy
of this instruction sheet, call Current Tools
at 800-230-5421 or write to Current Tools;
PO Box 17026; Greenville, SC 29606