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Current Tools 8085, Operating, Maintenance, Safety And Parts Manual

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Current Tools 8085 Operating, Maintenance, Safety And Parts Manual Download Page 33

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.

WARNING

DO NOT mount the Model 88 Cable Puller to square columns or I-Beams. 
The mounting chains will not tighten properly on these structures.

WARNING

OK

TOO WIDE

ALWAYS insure cable puller is properly secured before operating. ALWAYS  
attach to supports that are at least 2" and not more than the 10" wide.

WARNING

33

1. The only approved method to secure the Model 88 cable puller is with 

the 2 mounting chains provided with the Model 88 cable Puller. DO NOT
attempt to use any other object to secure the puller.

2. Inspect mounting chains for wear before each installation.

3. NEVER alter the mounting chains or handle.

WARNING

CABLE PULLING BASICS

continued . . . 

Summary of Contents for 8085

Page 1: ...anual 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 ...

Page 2: ...ling Basics 30 33 Specifications Model 88 Cable Puller 34 Features Model 88 Cable Puller 34 35 Operating Instructions Model 88 Cable Puller 36 39 Maintenance Model 88 Cable Puller 40 Exploded View Model 88 Cable Puller 41 Parts List Model 88 Cable Puller 42 Motor Exploded View Model 88 Cable Puller 43 Motor Parts List Model 88 Cable Puller 44 Wiring Schematic Wiring Diagram 45 Component Parts List...

Page 3: ...damage CAUTION Immediate hazards which if not avoided WILL result in serious personal injury or death DANGER 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 de...

Page 4: ... 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...

Page 5: ...uple 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 t...

Page 6: ...el 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 DO NOT use screw on couplings when pulling in PVC conduit Screw on couplings may detach and cause serious injury or death When pulling in PVC conduit ONLY use slip in couplings...

Page 7: ...placed but must meet the following specifications 4 minimum to 10 maximum only use 2 schedule 40 pipe or 2 rigid conduit these two tubes must be equal in length When using elbow unit nose unit and both sets of boom tubes factory supplied boom tubes may be replaced but must meet the following specifications 4 minimum to 10 maximum 3 minimum to 10 maximum only use 2 schedule 40 pipe or 2 rigid condu...

Page 8: ...ng DO NOT allow the puller and boom to hang from slip in or screw on couplings The couplings may break causing injury The mobile carriage or T stand should support the weight of the cable puller Inspect all components of the pulling system before beginning any cable pull This includes the pulling system cable puller boom etc and any accessories sheaves swivels pins etc Replace any worn or defectiv...

Page 9: ...ional optional optional 1 1 1 4 5 lbs 10 8097 3 Slip In Coupling 3 1 1 1 1 1 1 5 5 lbs 11 8097 3 5 Slip In Coupling 3 1 2 1 1 1 optional 1 1 6 5 lbs 12 8097 4 Slip In Coupling 4 1 1 1 1 1 1 8 lbs not shown 8097 5 Slip In Coupling 5 optional optional optional optional optional optional 9 lbs 13 8099 Coupling Adapter 1 1 1 1 1 1 8 lbs not shown 8098 2 Screw On Coupling 2 optional optional optional 1...

Page 10: ... screw on or slip in couplings From the information in this section choose and install a coupling that will meet your pulling requirements Screw On Couplings Screw On Couplings which thread onto the end of rigid or IMC conduit are provided for conduit sizes 3 3 1 2 and 4 Screw On couplings are the only approved coupling when making a pull from overhead because they will support the weight of the b...

Page 11: ... this is the couplings can be straddled on conduit sizes smaller than 2 1 2 However the largest conduit you can straddle using a slip in coupling is 4 by using the 5 optional slip in coupling Also when straddling conduit with a slip in coupling you can NOT pull down from overhead because it will NOT support the weight of the boom When using a slip in coupling to straddle the conduit the coupling m...

Page 12: ... 2 Slide the Coupling Adapter onto the coupling receiver plate until the spring loaded pawl snaps into place See Figure 12b 12 CONDUIT MUST NOT EXTEND PAST END OF COUPLING CONDUIT SLIP IN COUPLING SHOWN STRADDLING CONDUIT STRUCTURE CAPABLE OF SUPPORTING 8 000 LBS Bottom of coupling must be seated against a structure capable of supporting 8 000 lbs WARNING PULL RING COUPLING COUPLING ADAPTER figure...

Page 13: ...tions continue below Mobile Carriage For added convenience and mobility a mobile carriage is included in the package 1 Locate the mobile carriage frame and the 2 axles Insert the axles through the hub washers on the mobile carriage frame Slide the four pneumatic tires onto the axles and secure with four cotter pins See Figure 13 13 Some components weigh more than 50 lbs and will require more than ...

Page 14: ...ket on the mobile carriage See Figure 14b 3 Next attach the Model 88 Cable Puller to the puller mount using the chains provided See Figure 14C Refer to the mounting chains installation instructions on pages 31 33 4 You are now ready for the Boom Assembly beginning on page 17 14 PULLER MOUNT RECEIVER TUBES FACE THIS DIRECTION BOTH SIDES OF PULLER MOUNT BRACKET MUST BE OUTSIDE THE MOBILE CARRIAGE BR...

Page 15: ...two sets of holes in the T Stand bracket with the two sets of holes in the puller mount bracket Attach the T Stand to the puller mount with 2 pins 8091 5 and secure with spring clips See Figure 15b NOTE Both sides of the T Stand bracket must be inside the puller mount bracket See Figure 15c 15 PULLER MOUNT BRACKET figure 15a PIN BOTH POSITIONS PULLER MOUNT T STAND figure 15b figure 15c ASSEMBLY IN...

Page 16: ...he chains provided See Figure16b For mounting chains installation instructions refer to pages 31 33 of this manual NOTE T Stand ALWAYS has both puller mount pins 8091 5 installed and will pivot on floor 5 You are now ready for Boom Assembly beginning on page 17 16 PIVOT PULLER MOUNT T STAND figure 16a figure 16b ASSEMBLY INSTRUCTIONS continued ...

Page 17: ...re 17b 17 Be careful during assembly and disassembly of the boom components Keep pins in place to avoid uncontrolled movement of boom components Have control of boom components before removing any pins CAUTION 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 WARNING ALWAYS check...

Page 18: ...COUPLING COUPLING ADAPTER TOP PIN REMOVED 3 Remove the top puller mount pin 8091 5 This will allow the cable puller and boom assembly to pivot on the mobile carriage Next with the coupling and coupling adapter in place See pages 10 12 the mobile carriage and Boom Assembly may now be positioned so that any 2 sets of holes in the nose unit align with the 2 sets of holes on the coupling adapter Using...

Page 19: ... 5 at an appropriate angle for the pull and slide the elbow unit onto the 4 boom tubes as shown in Figure 19 Be sure the elbow unit remains pinned at all times except to adjust the boom angle See Warning below Check the sight holes to insure the boom tubes are completely inserted and tighten the hex bolts on each side of the elbow unit See Figure 19 19 figure 19 ASSEMBLY INSTRUCTIONS continued ...

Page 20: ... ensure the boom tubes are completely inserted and tighten the hex bolt on each side of the elbow unit See Figure 20b 7 The nose unit may now be mounted to the end of the 3 boom tubes Check the sight holes to ensure the boom tubes are completely inserted and tighten the hex bolt on each side of the nose unit See Figure 20c ELBOW UNIT 4 BOOM TUBES 3 BOOM TUBES NOSE UNIT figure 20a figure 20b figure...

Page 21: ...the nose unit to the coupling adapter and secure pins with four spring clips READY FOR AN UP PULL CONDUIT COUPLING COUPLING ADAPTER When using the elbow unit the pulling rope must contact both the sheaves in the boom Boom may collapse if this warning is not observed WARNING The sides of the coupling adapter must both be inside the nose unit side plates COUPLING COUPLING ADAPTER NOSE UNIT WARNING f...

Page 22: ... The couplings may break causing injury The mobile carriage or T stand should support the weight of the cable puller CAUTION When using one set of boom tubes and nose unit factory supplied boom tubes may be replaced but must meet the following specifications 4 minimum to 10 maximum only use 2 schedule 40 pipe or 2 rigid conduit these two tubes must be equal in length When using elbow unit nose uni...

Page 23: ...tion and Slip In Coupling Up Pull using Mobile Carriage both Boom Sections and Slip In Coupling straddling conduit Down Pull using Mobile Carriage both Boom Sections and Screw On Coupling Horizontal Pull from man hole with both Boom Sections and Slip In Coupling ...

Page 24: ... manhole using Mobile Carriage both Boom Sections and Slip In Coupling Horizontal Pull using T Stand one Boom Section and Screw On Coupling Up Pull using T Stand one Boom Section and Slip In Coupling COMMON SET UPS continued ...

Page 25: ...25 Horizontal Pull using floor mount COMMON SET UPS continued Current Tools ...

Page 26: ... to the Mobile Carriage To Lock align both sets of holes on the puller mount with both sets of holes on the Mobile Carriage Insert pins 8091 5 and secure with spring clips If both sections of standard boom tubes are used fold forward section back as shown See Figure 26 26 WARNING 10º Maximum Tip Hazard DO NOT lean unit more than 10 º Keep unit under control when transporting figure 26 ...

Page 27: ...oncrete 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 27 CAUTION Current Tools place close to conduit ALWAYS place the flo...

Page 28: ...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...

Page 29: ...ing for a single cable puller two cable pullers may be used in tandem to make the pull See figure 29 below Be sure to use a separate rope and set of accessories for each cable puller Each set of rope and accessories should meet or exceed each cable pullers maximum pulling force 29 figure 29 ...

Page 30: ...r motor is rated at 120 volt 60 hz 15 amps 30 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 If needed have a 15 amp GFCI receptacle installed by a qualified electrician WARNING If an extension cord is used it should be a minimum of 12 gauge wire with ground and a maximum length of...

Page 31: ...ee page 29 Mounting Chain Installation The Model 88 Cable Puller is designed to be mounted using the two mount ing 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 A D B C figure 31 A Loosen the mounting chain handle so that only 3 o...

Page 32: ... bottom of cable puller as shown FIGURE A FIGURE B NO OK Never tighten chain as shown in Figure A This causes side loading of the chain and can result in failure of the chain or screw causing components to come loose and possibly cause serious injury or death Figure B shows the proper alignment of screw and chain for tightening WARNING figure 32 CABLE PULLING BASICS continued ...

Page 33: ...quare columns or I Beams The mounting chains will not tighten properly on these structures WARNING OK TOO WIDE ALWAYS insure cable puller is properly secured before operating ALWAYS attach to supports that are at least 2 and not more than the 10 wide WARNING 33 1 The only approved method to secure the Model 88 cable puller is with the 2 mounting chains provided with the Model 88 cable Puller DO NO...

Page 34: ...el 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...

Page 35: ...CAPSTAN CHAIN GUARD HANDLE FORCE GAUGE OFF ON CIRCUIT BREAKER SWITCH MOTOR POWER CORD REAR T HANDLE MOUNTING CHAINS SAFETY ROLLER 35 FEATURES figure 35 ...

Page 36: ...at a 90º angle 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 36b 36 TO OPERATOR BLACK ROLLER 90º MAXIMUM 10 MAXIMUM 10 PULL DIRECTION figure 36b figure 36a OPERATING INSTRUCTIONS Model 88 Cable Puller DO NOT operate cable puller in wet or damp locations Do NOT expose to rain DANGER DO NOT operate i...

Page 37: ...round 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 Rope should approach capstan as shown in figure 36b ALWAYS use black roller to guide rope so that operator stands at 90º angle to the cable puller and out of the direct line of tight pulling rope See figure 36a A...

Page 38: ...er 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 WARNING 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 pressu...

Page 39: ...as possible This will help prevent injury should the rope break and whip violently WARNING When making a vertical cable pull keep the area underneath the cable pull clear of all personnel WARNING 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 d...

Page 40: ...Puller exploded view TENANCE Inspection Important After the first 5 hours of operation remove the cover and inspect both chain tensioners Adjust as needed Front and Rear Chain Inspection Every 40 hours of operation the front and rear drive chains should be removed and inspected for excessive wear or binding Motor Brushes Inspect the two motor brushes every 30 hours Replace if less than 3 8 long Al...

Page 41: ... CABLE PULLER 38 52 13 32 53 15 51 32 14 11 51 17 16 18 16 32 51 17 22 23 20 19 52 51 24 25 42 33 26 12 7 3 8 10 6 4 54 INCLUDED WITH ITEM 45 29 30 2 5 53 27 27 50 45 39 1 48 31 28 9 29 21 28 49 46 37 39 47 34 35 40 39 41 44 38 ...

Page 42: ...23 40 Chain Master Link 1 77 032 24 40 Sprocket Motor 1 88 69 25 Motor Shaft Retaining Ring 1 88 25 26 Jackshaft Sprocket Weldment 1 88 19 27 Jackshaft Phenolic Washer 2 88 70 28 Roller Bearning Jackshaft 2 88 35 29 Inner Race Jackshaft 2 88 36 30 Pawl 1 88 27 31 Pawl Spring 1 88 26 32 Hex Nut 3 88 71 33 Safety Roller 1 88 18 34 Socket Head Shoulder Bolt 1 280 2D 35 Power Cord 1 450 4 37 Washer Ph...

Page 43: ...43 MODEL 88 CABLE PULLER MOTOR EXPLODED VIEW 100 101 102 103 104 105 106 107 121 122 103 103 123 108 109 110 112 113 111 119 120 118 117 114 116 115 ...

Page 44: ...ate 1 88 44G 107 Gear Box Housing 1 88 44H 108 Fan Screen 1 88 44I 109 Threaded Stud 4 88 44J 110 Middle Motor Housing 1 88 44K 111 Field 1 88 44L 112 Screw 2 88 44O 113 Lock Washer 2 88 44N 114 End Cap Housing 1 88 44P 115 Motor Brush 2 88 44Q 116 Brush Cap 2 88 44R 117 Screw 4 88 44S 118 Set Screw 2 88 44T 119 Brush Holder 2 88 44U 120 Motor Cord 1 450 4 121 Output Shaft Gear Assembly 1 88 44W 1...

Page 45: ...WIRING DRAWING MODEL 88 CABLE PULLER 45 WIRING SCHEMATIC MODEL 88 CABLE PULLER ...

Page 46: ... 1 2 IMC Rigid Conduit 1 3 8098 4 Screw On Coupling for 4 IMC Rigid Conduit 1 SLIP IN COUPLINGS ITEM CATALOG DESCRIPTION QTY not shown 8097 2 5 Slip In Coupling for 2 1 2 EMT IMC Rigid Conduit optional 1 8097 3 Slip In Coupling for 3 EMT IMC Rigid Conduit 1 2 8097 3 5 Slip In Coupling for 3 1 2 EMT IMC Rigid Conduit 1 3 8097 4 Slip In Coupling for 4 EMT IMC Rigid Conduit 1 not shown 8097 5 Slip In...

Page 47: ...RIPTION QTY 1 8099 1 Spring 1 2 8099 2 Pawl 1 3 8099 3 Pull Ring 1 4 8099 799 coupling adapter weldment 1 BOOM TUBES 8095 8096 ITEM CATALOG DESCRIPTION QTY 1 8095 3 Boom Tube 2 2 8096 4 Boom Tube 2 2 1 3 2 1 4 COMPONENT PARTS LISTING continued ...

Page 48: ...OBILE CARRIAGE 8091 ITEM CATALOG DESCRIPTION QTY 1 8091 1 Axle 2 2 77 016 Pin Cotter 3 16 x 1 25 4 3 8091 2 Pneumatic Tire 4 4 8091 3 Frame 1 5 8091 W Decal Warning 1 6 8091 455 Pin Sheave 3 4 Dia X 8 5 8 2 7 406 3 Spring Clip 4 1 COMPONENT PARTS LISTING continued ...

Page 49: ... QTY 1 8045 Floor Mount 1 2 8045 W Decal Warning 1 not shown 8045 3 Anchor Bolt 4 1 2 COMPONENT PARTS LISTING continued PULLER MOUNT 8092 ITEM CATALOG DESCRIPTION QTY 1 8092 1 Frame 1 2 8092 2 Cap Screw 1 2 13 x 1 2 3 8092 W Decal Warning 1 2 1 3 ...

Page 50: ...upling 3 4 Dia x 7 3 8 2 7 8094 W Decal Warning 1 ELBOW UNIT 8093 ITEM CATALOG DESCRIPTION QTY 1 8093 1 Elbow Weldment 1 2 8093 2 Elbow Pivot 1 3 8093 3 Pin Sheave 1 Dia x 8 1 8 1 4 8093 4 Roll Pin 2 5 8092 2 Cap Screw 1 2 13 x 1 4 6 812 1 Sheave Unit 12 1 7 8093 5 Pin Elbow 3 4 Dia x 8 1 8 1 8 406 3 Spring Clip 2 9 8093 W Decal Warning 1 2 5 7 3 6 4 1 6 1 5 7 8 2 3 4 9 COMPONENT PARTS LISTING con...

Page 51: ...51 STORAGE BOX ITEM CATALOG DESCRIPTION QTY 1 101 Metal Storage Box 1 not shown 506 Casters 1 2 8890 101 W Decal Warning 1 2 1 COMPONENT PARTS LISTING continued ...

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