Current Tools 66 Cable Puller User 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 Mobile Cart
1/15
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 .....................................13,14
Parts List ..........................................15,16
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 insure 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
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IMPORTANT SAFETY INFORMATION continued
5
ONLY use 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.
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 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.
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.
This cable puller exceeds 50 lbs. and will require more than
one person to lift or carry.
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.
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SPECIFICATIONS
6
model no. — 66 Cable Puller (mounted on Mobile Cart)
width — 241⁄2"
depth — 18"
height — 49"
fully extended length — 102"
weight — 115 lbs. – (cable puller only)
— 179 lbs. – (cable puller mounted
on mobile cart)
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 with an average breaking
strength of 26,000 lbs.
FEATURES
• Integral heavy-duty 2 speed motor
• Quick-release conduit couplings
• Mobile Cart with storage for conduit
couplings (see photo 1 at right)
• Tapered capstan
• Integral foot switch
• Permanently lubricated vent-free
gear box
• Lightweight – weighs only 115 lbs.
when assembled and ready for pull.
• Foot switch storage pocket
(see photo 2 below)
Photo 1
Photo 2

7
SET-UP AND OPERATION INSTRUCTIONS
1Remove the transport pins to release the cable
puller (photo 3) and boom section (photo 4) from
the mobile cart.
Photo 3 Photo 4
2Turn the boom section in the direction
needed for the type pull (UP or DOWN). See
common setups on page 11. Re-insert the
pin removed in photo 3 to connect puller
section to boom section.
3Model 66 Cable Puller shown
pinned together and ready for pull.
Model 66 Cable Puller shown
pinned for transport on mobile cart.

8
4Adjust Boom section to desired length
and re-pin. 5Next, to position the extension arm to the desired angle for the pull, remove
the pin that allows the extension arm
to be adjusted to various positions
and re-pin at desired angle. NOTE: If
needed, the extension arm length may
be adjusted. (SEE CLOSE-UP PHOTO
ON BOTTOM OF PAGE 11).
ROLLERS ROLLERS
YESNO
Set up the cable
puller so that
pulling rope
ALWAYS contacts
both rollers. (See
drawing at left).
WARNING
DANGER
CAUTION
7Choose the
conduit coupling
for the size
conduit you will
be connecting
to. Back out the
thumb screw
and insert the
conduit coupling
into the conduit
until the ring of
the conduit coupling sits flush against the
top of the conduit.
NOTE: For a down pull, back out the thumb
screw and insert the conduit coupling into the
conduit until the ring of the conduit coupling
sits flush against the top of the conduit. Then,
to hold the conduit coupling in place, tighten
the thumb screw.
6Complete coupling set stores on
mobile cart as shown above. To store
or remove couplings from cart, loosen
or tighten the provided thumb screw.
SET-UP AND OPERATION INSTRUCTIONS continued

SET-UP AND OPERATION INSTRUCTIONS continued
9
8Next, move the cable puller into position
and attach the extension arm onto the
conduit coupling. You should hear a
”click” as the conduit coupling fits into
the extension arm. If extension arm
is not at the correct angle to attach
to conduit coupling, the angle of the
extension arm may be adjusted. (SEE
STEP #5). Also, the adjustable tube can
be repositioned (SEE STEP #4).
9Operator 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.
Keep fingers away from adjustment mount holes and
pivoting parts. Fingers can be severed by pivoting parts.
WARNING
DANGER
CAUTION
10 Turn the FWD/REV switch to the
forward position.

10
11 Depress the foot switch and check the
rotation of the capstan with the pulling
rotation decal on the cable puller.
12 Next, turn the High/Low speed
switch to the desired position, “H”
or “L”.
13 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. Note that if the rope
is in a “v” shape as shown in photo
13, the pull for the operator is easier
than if pulled at a 90° (or “L” shape).
SET-UP AND OPERATION INSTRUCTIONS continued
14 When the pull is completed, pull the
ring on the back of the extension arm to
separate the conduit coupling from the
extension arm. 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.
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.
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CAUTION
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COMMON SET-UPS
11
UP PULL
Example of extension arm
adjusted to shorter length
DOWN PULL

MAINTENANCE
12
DANGER
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 — 66 CABLE PULLER
13
4
1
9
11
62
17
34
37
28
26
29
45
44 39
30
27 5
49
2
AT TACHES
BEHIND
ITEM 16
18
3
16
33
35
30
36
13
36
25
43
36
12
47
38 38
34
20
23
42
46
43
19
42
50
22
21
8
50
50
8
60
58
31
14
63
41
48
15
6
59
9
40
64
57
32
33
61
30
66
28
31
31
36
10
7
76
76

EXPLODED VIEW — 66 CABLE PULLER
13
EXPLODED VIEW — 66 MOBILE CART
14
52
55
68
67
24
56
65
69
54
53
51
70
36
71
72,73,74
75

PARTS LIST — 66 CABLE PULLER
15
6000 LB PULLER
ITEM # PARTS DESCRIPTION QTY PART#
1............................................................. MOTOR .............................................. 1...........................33-1
2.......................................................... GEAR BOX............................................ 1...........................66-2
3..................................................... ADAPTER SHAFT ...................................... 1.......................33-460
4..................................................... CAPSTAN SHAFT ...................................... 1.......................66-599
5....................................................... ADAPTER CAP......................................... 1.......................66-598
6.............................................................SPACER .............................................. 1.......................33-703
7...................................................... BOTTOM PLATE ....................................... 1.......................33-934
8............................................................. ROLLER .............................................. 2.......................66-600
9.............................................NUT-5⁄16-18 NYLON INSERT .............................. 4....................2-1301-4
10.......................................................PIN, 5⁄8" CLEVIS ........................................ 1.........................33-24
11.......................................................LOWER FRAME........................................ 1.......................66-971
12....................................................EXTENSION TUBE..................................... 1.......................66-608
13...................................................ADJUSTABLE TUBE .................................... 1.......................66-609
14.................................................. CAM-DRILL SWITCH.................................... 1.......................33-735
15..............................................BAR-ACTUATOR, SWITCH ............................... 1.......................33-702
16......................................TOP GEAR BOX MOUNTING PLATE ....................... 1.......................66-601
17................................. BOTTOM GEAR BOX MOUNTING PLATE................... 1.................... 66-601A
18.......................................... CONNECTOR TUBE BRACKET............................ 1.......................66-605
19.....................................................EXTENSION ARM ...................................... 1.......................66-638
20........................................................... CAPSTAN............................................. 1.......................66-595
21...............................................................PAWL ................................................ 1...................... 33-485
22............................................................. SPRING .............................................. 1.........................33-22
23............................................................... RING................................................. 1.........................33-23
24............................................................... CART ................................................ 1.......................66-973
25.............................................................SPACER .............................................. 2.......................66-663
26........................................................HI/LO SWITCH......................................... 1.......................66-742
27..........................................................HI/LO STEM........................................... 1.......................66-685
28.............................................ROLL PIN-SPRING 1⁄8" X 3⁄4".............................. 2.................... 77-035A
29...................................................... BACK UP PLATE ....................................... 1.......................66-643
30........................................SCREW-HEX FLANGE 3⁄8"-16 X 1" ......................... 8.........................66-30
31....................................................FLAT WASHER-5⁄16" .................................... 2.....................9544-16
32......................................... SCREW-SOC. HD. CAP M6 X 25........................... 4.........................66-32
33................................SCREW-HEX HD. CAP-7⁄16-14 x 1-1⁄2" (GR. 5)................. 2.........................66-33
34..................................... EXT.RETAINING RING-1-1⁄2" (HEAVY) ...................... 2...................... 280-8B
35..................................... SCREW-BUTTON SOC. CAP M10x20 ...................... 4.........................66-35
36.............................................................. R-CLIP................................................ 8.........................33-36
37..................................... SCREW-BUTTON SOC. CAP M10x30 ...................... 4.........................66-37
38.....................................................KEY 3⁄8"SQ x 1-1⁄4"...................................... 2.........................66-38
39......................................... SCREW-HEX HEAD 5⁄16-18x2-3⁄4"........................... 2.........................66-39
40..................................... SCREW-SOC. HD. CAP-5⁄16-18 x 2-1⁄2"....................... 2.........................66-40
41...............................................SWITCH BRACKET-DRILL................................ 1.......................66-695
42..................................................... ROLL PIN-5⁄32 x 1" ...................................... 2.........................33-42
43..............................................PIN-1⁄2" x 2-1⁄2" WITH RING ............................... 2.........................33-43
44.......................................................STRAIN RELIEF ........................................ 1.......................450-18
45....................................................... FOOT SWITCH......................................... 1.........................33-45
46........................................ SCREW-HEX HD. CAP-3⁄8-16 x 3⁄4"......................... 1.........................33-53
47.........................................CAPSTAN RETAINING WASHER .......................... 1.......................66-662
48................................................... ROLL PIN -3⁄16x1-7⁄8"..................................... 2.........................33-12
49.................................................... KEY 3⁄16"SQ x 1-1⁄4"...................................... 1.........................33-49
50............................................ PIN- 5⁄8" (DIAMETER) x 5-7⁄8".............................. 3.......................66-684
51........................................................ COUPLING-2" ......................................... 1.........................66-51

16
6000 LB PULLER
ITEM # PARTS DESCRIPTION QTY PART#
52......................................................COUPLING-2-1⁄2"....................................... 1.........................66-52
53........................................................ COUPLING-3" ......................................... 1.........................66-53
54......................................................COUPLING-3-1⁄2"....................................... 1.........................66-54
55........................................................ COUPLING-4" ......................................... 1.........................66-55
56................................................................GRIP ................................................ 2.........................504-1
57...........................................CAPSTAN BEARING WASHER............................ 1.......................66-661
58................................... SCREW-HEX HEAD 10 x 1⁄2SELF DRILL .................... 1.................... 77-033A
59.................................................. 3⁄8" RETAINING RING.................................... 1 .........................33-19
60........................................................POWER CORD ......................................... 1.........................450-4
61............................................. SELECTOR SWITCH PLATE .............................. 1.......................66-660
62......................................................CORD RETAINER....................................... 1.........................66-62
63....................................................... LEVER-ON/OFF ........................................ 1.......................33-699
64.......................................... WIRE/FOOT SWITCH HANGER ........................... 1.......................33-706
65............................................................... AXLE................................................. 1 .......................66-974
66.....................................................KEY 3⁄8"SQ x 4-3⁄4"...................................... 1.........................66-66
67..............................................................WHEEL............................................... 2.........................510-2
68......................................................... COTTER PIN........................................... 2.......................501-14
69..................................................... WASHER, 3⁄4SAE....................................... 4.......................77-017
70.............................................. SCREW – SPADE THUMB................................ 5.........................66-56
71.................................................................PIN .................................................. 1.......................66-981
72............................................................... STOP ................................................ 1...................... 670-6A
73............................................................FERRULE ............................................. 1.........................670-6
74......................................................CABLE 1⁄16" x 10" ....................................... 1.........................33-27
75............................................................... RING................................................. 1.......................8099-3
76....................................................WASHER – 7⁄16 SAE ..................................... 2.........................66-76
WIRING DRAWING
PARTS LIST — 66 CABLE PULLER continued
FOOT-
SWITCH
15A PLUG
POWER CORD
FROM MOTOR
BLACK
NCC NO
BLACK
GREEN
WHITE