Gardner Bender CP2000 User manual

1.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.0 Safety Symbol Definitions . . . . . . . . . . . . . . . . . .2
3.0 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
4.0 Product Components . . . . . . . . . . . . . . . . . . . . . .3
5.0 Puller Specifications . . . . . . . . . . . . . . . . . . . . . .3
6.0 Introduction to Cable Pulling . . . . . . . . . . . . . . . .3
7.0 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
8.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
8.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . .5
8.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
RPS-0148 07/02
Instruction Sheet
CP2000: 2000 lb Cable Puller
IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. If shipping damage is found, notify carrier at once. Shipping damage is NOT
covered by warranty. The carrier is responsible for all repair and replacement costs resulting from damage in shipment.
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.
8.3 Pulling Cable . . . . . . . . . . . . . . . . . . . . . . . . .6
9.0 Repair and Maintenance . . . . . . . . . . . . . . . . . . .7
9.1 Shear Pin Placement . . . . . . . . . . . . . . . . . . .7
9.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .7
10.0 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2
1.0 DESCRIPTION
This cable puller is designed to be used together with the
power drive from a portable power threader. The product has
been tested with the Mini-Collins®and Rigid™ pipe threader.
Other brands you may already have can also be used.
Each cable puller application will depend upon your particular
need. In this manual we will cover general procedures as they
apply to our equipment.
Please read and understand this manual before attempting to
use this equipment. Most important is the safety of
the operator.
2.0 SAFETY SYMBOL DEFINITIONS
The symbol below is used to call your attention to instructions
concerning your personal safety. Watch for these symbols.
They point out important safety precautions. They mean
“ATTENTION! Become alert. Your personal safety is
involved.” Read the message that follows and be alert to the
possibility of personal injury or death.
DANGER: Indicates a high probability that death,
severe bodily injury or major property damage could result.
WARNING: Is serious but less inevitable. There is
some probability that death, severe bodily injury or
major property damage could result.
CAUTION: Is less serious but still demands
attention. Indicates a hazard which may result in minor
injury or property damage.
3.0 WARNINGS
This section contains information for your protection,
safety and quick reference. When using an electrical
appliance basic precautions should always be followed,
including the following.
Read all Instructions before using the CP2000.
Always have this manual available for reference at the
job site.
DANGER: Do not allow anyone to operate this
equipment until they have read and understood all
operating and safety instructions.
WARNING: This cable puller is not to be used as a
hoist for lifting, supporting, or transporting people or
loads. Failure to observe these precautions could result
in serious injury.
WARNING: Never stand directly behind the path of a
pulling rope. Keep exposed part of pulling rope as short
as possible. A broken pulling rope can whip with
extreme force.
WARNING: Only operate in well lighted areas.
DANGER: Do not operate in an area that contains
hazardous or combustible material. A fire or explosion
can result.
WARNING: All pulling system components must be
rated to withstand the maximum pull forces.
DANGER: Never stand directly under a vertical pull.
WARNING: Keep the work area clear of
all bystanders.
CAUTION: Check all pulling system parts before
use. Never use worn or defective components.
DANGER: Pulling system components can break
during use. Always protect yourself by wearing gloves,
protective glasses and hard hat.
DANGER: Do not allow anyone to operate this
equipment until they have read and understood all
operating and safety instructions.
WARNING: Only use rope that is rated for the
pulling force required. Check the rope often for damage.
Damaged rope can break and cause eye or other
bodily injury.
DANGER: Electrical equipment must be grounded
while in use to protect the operator from electric shock.
DANGER: Only use extension cords that are rated
and marked for outdoor use.
DANGER: Never use this equipment in rain or
damp locations.
DANGER: Disconnect power before service
or repair.
WARNING: The rope on the capstan can crush your
hand during operation. Do not allow the rope to wrap
around any part of your body. Keep loose clothing,
hands and body away from moving parts.
WARNING: This cable puller is not to be used as a
hoist for lifting, supporting, or transporting people or
loads. Failure to observe these precautions could result
in serious injury.
WARNING: Keep hands and loose objects away
from moving parts during operation. Serious injury
may occur.
CAUTION: This unit contains a pin designed to
shear if maximum recommended load is exceeded. This
sudden shearing action may send a shock to the rope,
possibly causing injury. Avoid such hazards by wearing
leather gloves and never wrap the rope around yourself.

4.0. PRODUCT COMPONENTS
1. 2000 Pound Puller: Adjustable for pulling from all
directions. Includes capstan and guide pulley.
2. Switch Clamp: Attaches over the switch on the power drive.
3. Pipe Threader‚ Power Drive (not included):Provides
the power for puller operations. It attaches to the drive
adaptor on the puller body. See it's manual for additional
operating information.
5.0 PULLER SPECIFICATIONS
6.0 INTRODUCTION TO CABLE PULLING
Each cable pulling operation can be different. Only
experienced personnel should be responsible for setup and
operation of this equipment. During a cable pull, very high
forces can be developed. Any failure of the components of
the system can be dangerous.
WARNING: All pulling system components must be
rated to withstand the maximum pull forces.
Safe and efficient cable pulling will require knowledge of the
following subjects.
1. Planning
Each operation will need its own special set up. Selection of
the proper sheaves, ropes and puller is critical.
Planning the length of the pull is another important
consideration. Cable weight and internal conduit bends will
create resistance to the pull. Size of conduit and cables
already present must be considered. To keep the pulling
force within equipment specifications, shorter pulls may
be required.
2. Installation
Make sure the puller is secured in place. Fastening the puller
to the floor can be accomplished by using the four through
holes on the puller base. Position the puller so the force is
parallel to the conduit. When securing components to other
objects, make sure they can support the pulling force.
3. Safe Operation
Know what the limits of your puller are. Always check
equipment for damage prior to operation.
WARNING: All pulling system components must be
rated to withstand the maximum pull forces.
CAUTION: Check all pulling system parts before
use. Never use worn or defective components.
Thoroughly inspect the work area. Make sure ample space is
available for equipment and personnel. Check for secure
footing and ventilation of any combustible gasses.
WARNING: Only operate in well lighted areas.
DANGER: Do not operate in an area that contains
hazardous or combustible material. A fire or explosion
can result.
Capstan Theory
The capstan uses the friction of the pulling rope to multiply
force. The total pulling force is determined by:
1. Number of wraps of rope on the capstan.
2. Tailing force the operator applies to the rope.
With the full 5 wraps of rope on the capstan, the operator can
easily generate sufficient pulling force for most applications.
For the best operator control during cable pulling, use the
fewest rope wraps needed to maintain an even pull. Only add
more rope wraps to the capstan if the operator needs
additional leverage. Never add or remove wraps from a
moving capstan.
3
Puller Specifications
Weight* 65 lb
Maximum Extended Height 116"
Maximum Arm Reach 70"
Continuous Pull Force 2000 lbs
Breakout Pull Force 2500 lbs
Power Source Portable Pipe Threader
Drive Speed 25 rpm
Pulling Speed 18 fpm
Required Rope Diameter 1⁄2"
Required Rope Type Double Braided Polyester
*Without power drive or foot switch.
Figure 1. 2000 Pound Puller
Figure 3. Mini-Collins®Power Drive (not included)
Figure 2. Switch Clamp
Tab
Power Switch
Forward/Reverse
Switch
Leg Extension
Clevis Pin
Foot

WARNING: The rope on the capstan can crush your
hand during operation. Do not allow the rope to wrap
around any part of your body. Keep loose clothing,
hands and body away from moving parts.
During normal pulling operations, the cable resistance will
constantly change. This will require the operator to change
his tailing force in response. The operator can relax this force
completely and stop the pull at any time. The capstan
requires some tailing force before it will pull. This assures
complete operator control. Do not continue to hold the rope
on the capstan if it starts to slip. Rope wear from friction and
heat will result. This could cause the rope to break. Turn off the
motor and secure the rope.
On a vertical pull, resistance to the force of gravity will tend to
reverse the pull. The weight of the cable will increase as the
vertical height of the pull increases due to the added cable
length. Resistance created by friction will require more pulling
force, but will not reverse the pull.
DANGER: Never stand directly under a vertical pull.
Using Sheaves
Sheaves are used to change the direction of pull and reduce
the friction load. When you install a sheave, make sure the
sheave support can withstand the total force. The force on
the sheave can be as high as double the pulling force. See
Figure 5.
WARNING: All pulling system components must be
rated to withstand the maximum pull forces.
Pulling Rope
WARNING: Only use rope that is rated for the
pulling force required. Check the rope often for damage.
Damaged rope can break and cause eye or other
bodily injury.
The pulling rope is a very important part of the cable pulling
system. Use a rope with a low stretch factor that has a load
rating greater than the total estimated pulling forces expected.
WARNING: Never stand directly behind the path of a
pulling rope. Keep exposed part of pulling rope as short
as possible. A broken pulling rope can whip with
extreme force.
7.0 ASSEMBLY
1. Extend the CP2000:
Remove the clevis pin from the foot. Raise the leg
extension to release the puller arm from the base. See
Figure 7. Reinstall the clevis pin in the foot to secure the
foot to the leg extension. Rotate the puller arm to a parallel
position. Set the arm extension on an available support.
The arm length can be adjusted by removing the clevis pin.
Slide the arm extension in or out as needed and reinstall
the clevis pin.
2. Install the power drive.
The CP2000 requires a power drive (Figure 8) to supply
the pulling force. The CP2000 puller is designed to use a
portable pipe threader power drive such as the Mini-
Collins®or Rigid™. Other power drives that you may
already have may also be used. Before you install the
power drive on the CP2000 you must depress and secure
the power switch with the clamp provided (Figure 9).
4
Figure 4. Pull
Rope Wrap
Capstan
Operator Tailing Force Pulling Force
5000 lbs.
Support Load
3535 lbs.
Support Load
2500 lbs. Pull
2500 lbs. Load
2500 lbs. Pull
Figure 5. Pull vs. Load
Cleavis Pin
Figure 7. CP2000 Extended
Figure 9. Switch Clamp
Tab
Figure 8. Mini-Collins®Power Drive
Puller Arm
Power Switch
Forward/Reverse
Switch

Install the switch clamp on the power drive handle so the
tab depresses the power switch to the “ON”position. See
Figure 10.
Remove the side handle from the power drive. Slide the
power drive head onto the drive coupler on the puller.
Rotate the power drive to ease installation and clear the
drive cradle. When installed correctly, the power drive will
set into the cradle. See Figure 11.
Put the side handle through the hole in the cradle and
install into the pipe threader. See Figure 12. This will
secure the power drive to the puller. Other power drive
units will require a similar procedure.
3. Install the foot switch (optional - model CP15).
Use of a foot switch with this puller is recommended to
insure optimal operator control. Connect the power drive
cord to the foot switch. Connect the foot switch to a
suitable receptacle or extension cord. Always use
extension cords rated for outdoor use.
DANGER: Electrical equipment must be grounded
while in use to protect the operator from electric shock.
DANGER: Only use extension cords that are rated
and marked for outdoor use.
DANGER: Never use this equipment in rain or
damp locations.
DANGER: Disconnect power before service
or repair.
8.0 OPERATION
8.1 Preparation
Preparing for the pull is a very important part of the operation.
This can affect the safety of all the personnel and prevent
damage to the equipment.
1. Check the conduit and raceway system. Is it secure and
able to withstand the total pulling forces? Is it the proper
size for the cables?
2. Check all the pulling system components. Make sure they
are in good operating condition and have the proper
load rating.
3. Determine the length and direction of each pull segment.
Consider the puller load rating.
4.Inspect the operation area. Is there ample room for all
personnel and equipment? Is the area safe?
WARNING: Only operate in well lighted areas.
DANGER: Do not operate in an area that contains
hazardous or combustible material. A fire or explosion
can result.
5. Make sure there are enough personnel to operate the pull
safely. Clear the area of all other people.
WARNING: Keep the work area clear of
all bystanders.
8.2 Setup
The CP2000 can be adjusted to reach and pull from many
positions. This can reduce the need to install additional
Figure 10. Power Drive Handle
Clamp
Figure 11. Power Drive and Puller Drive
Power Drive Head
Drive Cradle
Puller Drive Coupler
Side Handle
Figure 12. Power Drive Side Handle
5
Side Handle
Power Drive
Figure 13. Foot Switch
Foot Switch

sheaves and extensions. Remove the clevis pin from the foot
and raise or lower the puller arm to the needed height.
Reinstall the clevis pin. Remove the clevis pin from the puller
arm and extend or retract the arm extension as needed.
Reinstall the clevis pin. The puller arm also pivots up and
down to provide additional adjustment. See Figure 14.
Pull Direction
The puller arm sheave can be positioned for either RIGHT,
LEFT, UP or DOWN pulling operations. It is important that the
sheave is in the correct position.
To position the puller arm sheave:
Remove the clevis pin from the puller arm. Remove the arm
extension from the puller arm. Rotate the arm extension to
the needed position and reinsert the arm extension into the
puller arm. Adjust the length of the arm and install the
clevis pin.
To Pull UP:
The puller sheave must be on the upper side of the puller
arm. See Figure 15.
To Pull DOWN:
Puller sheave must be on the upper side of the puller arm.
Rotate the entire puller arm upside down to position the puller
sheave to the bottom. The power drive will be held in the
cradle by its handle. See Figure 16.
DANGER: Never stand directly under a vertical pull.
To pull to the RIGHT:
Rotate the puller arm to the right.
To pull to the LEFT:
Rotate the puller arm to the right as you would for a right pull.
Rotate the entire puller arm upside down to position the puller
sheave to the left. The power drive will be held in the cradle
by its handle.
Puller Position
To position the puller sheave, adjust the puller arm according
to the previous instructions in the “HEIGHT AND REACH
ADJUSTMENT”section in this manual. Set the puller sheave
for the direction of the pull. Align the puller sheave with the
conduit opening. Rest the puller arm securely on the conduit
in the access box.
NOTE: Additional adapters may be needed if the puller arm
cannot contact the conduit. The puller foot may be fastened
to the floor for added stability if needed.
WARNING: All pulling system components must be
rated to withstand the maximum pull forces.
8.3 Pulling Cable
This section of this manual will only cover the cable pulling
operation of the CP2000 unit. We will assume that the conduit
has been cleaned and tested for obstructions and the rope is
fed and connected securely to the cable. Position observers
at critical points of the pull and have clear communication
with them.
To Start the Pull:
Position the rope over the sheave on the puller. Wrap the
tailing end of the rope once (1) around the capstan. Grasp the
tailing rope firmly and well behind the capstan.
WARNING: Never stand directly behind the path of a
pulling rope. Keep exposed part of pulling rope as short
as possible. A broken pulling rope can whip with
extreme force.
Depress and hold the foot switch. Apply a medium pulling
force to the tailing rope. If the pull will not begin, release the
foot switch. Apply an additional wrap of tailing rope to the
capstan and repeat. Only add one (1) wrap at a time up to a
total of five (5). For the best operator control during cable
pulling, use the fewest rope wraps needed to maintain an
even pull. Only add more rope wraps to the capstan if the
operator needs additional leverage. Never add or remove
wraps from a moving capstan.
Completing the Pull:
Allow the tailing rope to coil on the floor between you and the
puller as the pull continues. Never allow the rope to
Figure 14. Height and Reach Adjustment
Figure 15. Set Up for Upward Pulls
Figure 16. Set Up for Downward Pull
Clevis Pin
Clevis Pin
Base
6
Puller Sheave

accumulate behind or around your legs. If you loose control of
the pull, the rope can be pulled back violently toward
the capstan.
WARNING: The rope on the capstan can crush your
hand during operation. Do not allow the rope to wrap
around any part of your body. Keep loose clothing,
hands and body away from moving parts.
During normal pulling operations, the cable resistance will
constantly change. This will require the operator to change
his tailing force in response. The operator can relax this force
completely and stop the pull at any time. The capstan
requires some tailing force before it will pull. This assures
complete operator control. Do not continue to hold the rope
on the capstan if it starts to slip. Rope wear from friction and
heat will result. This could cause the rope to break. Turn off the
motor and secure the rope.
CAUTION: This unit contains a pin designed to
shear if maximum recommended load is exceeded. This
sudden shearing action may send a shock to the rope
possibly causing injury. Avoid such hazards by wearing
leather gloves and never wrap the rope around yourself.
The CP2000 is equipped with a shear pin that will shear at
2500 lbs (1134kg) pulling force. This is for added protection
for the operator and equipment. Do not attempt a pulling
operation that exceeds this limit. If this should occur, secure
the rope and repair the unit. See Section 9.0 Repair and
Maintenance section in this manual.
On a vertical pull, resistance to the force of gravity will tend to
reverse the pull. The weight of the cable will increase as the
vertical height of the pull increases due to the added cable
length. If your equipment fails during a vertical pull the entire
cable and rope can fall. Resistance created by friction will
require more pulling force, but will not reverse the pull.
Always securely tie the rope when the pull is complete.
DANGER: Never stand directly under a vertical pull.
9.0 REPAIR AND MAINTENANCE
9.1 Shear Pin Placement
1. Remove the power drive from the CP2000 arm:
•Unthread the side handle from the power drive.
•Rotate the power drive up and slide it off from the
drive coupler.
2. Remove the drive coupler from the puller arm.
3. Remove the two (2) setscrews from the drive coupler.
4. Insert a small size punch into the setscrew hole and push
the shear pin completely out. Be careful. Do not damage
the internal threads.
NOTE: Use a wheel puller to remove the drive coupler from
the shaft, if it needs replacement. Use only mild steel .25 dia.
21⁄2" long as shear pin replacement. Use the punch to install a
new shear pin and reassemble the unit.
9.2 Lubrication
Monthly:
•Apply EP 80/90 gear lube to the arm pivot thru the hole in
the shaft.
•Apply EP 80/90 gear lube to the puller sheave thru the hole
in the sheave.
•Apply high temperature bearing grease to the grease fitting
in the end of the capstan.
•Use a dry silicone spray as needed to lubricate the arm
extension and leg extension. This will also protect
against rust.
NOTE: Lubricate the power drive as per specifications of
drive manufacturer.
10.0 PARTS LIST
Figure 17. CP2000 Right View
Capstan
Rope Wrap
Tailing Rope
7
Figure 18. Power Drive
Side Handle
Drive Coupler

Set Screw
Shear Pin
Drive Coupler
Figure 19. Shear Pin Replacement
CP2000 Repair Parts Listing
Part # Description
CP2000-1 Wheel Kit
CP2000-2 Capstan
*see note Key - Idler Shaft
*see note Set Screw, 5⁄16" - 18 x 3⁄8"
CP2000-3 Conduit Adapter Arm
CP2000-4 11⁄2" Conduit Coupling
CP2000-5 2" Conduit Coupling
CP2000-6 Shear Pin, 1⁄4"
CP2000-7 Warning Label Kit
CP2000-8 Frame Adjustment Pin
CP2000-9 Switch Clamp Assembly
*Note: Comes with replacement capstan, #CP2000-2.

Gardner
Bender
RPS-0148 07/02
PO Box 3241 •Milwaukee, WI 53201-3241 •414-352-4160 •Fax [phone]
6615 Ordan Drive •Mississauga, Ontario L5T 1X2 •905-564-5749 •Fax [phone]
WARRANTY: Gardner Bender warrants its product
against defects in workmanship and materials for 1
year from date of delivery to user. Chain is not
warranted. Warranty does not cover ordinary wear
and tear, abuse, misuse, overloading, altered products
or use of improper fluid.
WARRANTY RETURN PROCEDURE: When question
of warranty claim arises, send the unit to the nearest GB
Authorized Service Center for inspection, transportation
prepaid. Furnish evidence of purchase date. If the claim
comes under the terms of our warranty the Authorized
Service Center will REPAIR OR REPLACE PARTS
AFFECTED and return the unit prepaid.
PARTS AND SERVICE: For quality workmanship and
genuine Gardner Bender parts, select an Authorized
GB Service Center for your repair needs. Only
repairs performed by an Authorized Service Center
displaying the official GB Authorized sign are backed
with full factory warranty. Contact Gardner Bender
[phone] for the name of the nearest GB
Authorized Service Center.
REPAIR AND SERVICE INSTRUCTIONS: For repair service and parts contact your nearest Gardner Bender
Service Center. The Gardner Bender Service Center will provide complete and prompt service on all Gardner
Bender products. For closest service center please visit our website @ www.gardnerbender.com.
WARNING
PRECAUTIONS COULD RESULT IN SERIOUS INJURY.
OR LOADS. FAILURE TO OBSERVE THESE
FOR LIFTING, SUPPORTING, OR TRANSPORTING PEOPLE
THIS CABLE PULLER IS NOT TO BE USED AS A HOIST
5-459
CAUTION
AND NEVER WRAP THE ROPE AROUND YOURSELF.
INJURY. AVOID SUCH HAZARDS BY WEARING LEATHER GLOVES
ACTION MAY SEND A SHOCK TO THE ROPE POSSIBLY CAUSING
RECOMMENDED LOAD IS EXCEEDED. THIS SUDDEN SHEARING
THIS UNIT CONTAINS A PIN DESIGNED TO SHEAR IF MAXIMUM
5-461
WARNING
MAKE SURE ALL PINS ARE IN PLACE AND SECURE
DURING OPERATION. SERIOUS INJURY MAY OCCUR.
WARNING
SERIOUS INJURY MAY OCCUR.
PARTS DURING OPERATION.
OBJECTS AWAY FROM MOVING
KEEP HANDS AND LOOSE
5-460
CP2000-1 Wheel Kit CP2000-2 Capstan CP2000-3 Conduit Adapter Arm
CP2000-4 11⁄2" Conduit Coupling CP2000-6 Shear Pin, 1⁄4"
CP2000-7 Warning Label Kit CP2000-8 Frame Adjustment Pin CP2000-9 Switch Clamp Assembly
CP2000-5 2" Conduit Coupling