How To Work A Come Along: A Professional Guide To Ratchet Pullers

A come along, or manual ratchet puller, utilizes a mechanical lever system to multiply human force for tensioning, pulling, or lifting heavy loads by winding wire rope or web strap onto a drum. Successful operation requires strict adherence to Working Load Limit (WLL) specifications, proper anchor point selection, and a methodical cycle of handle operation to ensure mechanical safety and prevent catastrophic equipment failure.

Technical Preparation and Safety Inspection Requirements

Before engaging a come along, operators must verify that the tool is rated for the specific load and that the structural integrity of the anchor points is sufficient to handle the exerted force. A come along is not a precision lifting tool like a chain hoist; it is designed primarily for pulling and tensioning.

• Equipment Checklist:
  
  
  • Ratchet Puller: Inspect for frame deformation, handle straightness, and hook throat integrity.
  • Wire Rope or Strap: Examine for fraying, kinks, crushing, or heat damage.
  • Anchor Points: Ensure the anchor can withstand at least 150% of the tool's maximum rated load.
  • Safety Gear: Wear heavy-duty leather gloves to prevent cable splinters and safety glasses to guard against recoil in the event of failure.
• Mandatory Standards:
  
  
  • Never exceed the stamped WLL on the puller’s nameplate.
  • Ensure the pawl is fully engaged in the ratchet gear teeth before applying load.
  • Verify the load path is linear; side-loading the hook can cause the safety latch to fail or the frame to twist.
• Operational Benchmarks:
  
  
  • Typical Setup Time: 5 to 10 minutes.
  • Estimated Physical Effort: High (manual labor is directly proportional to load weight).
  • Maintenance Requirement: Lubricate the ratchet gear and pawl pivot point with light machine oil annually.

Procedural Workflow for Safe Ratchet Puller Operation

Step 1: Anchor the Puller

Secure the anchor hook to a stable, non-moving structure capable of resisting the intended pulling force. If using a chain or nylon strap as an extension, ensure it is wrapped around an object that will not shear or collapse under tension. Avoid wrapping cables around sharp steel edges; use protective corner guards or softeners to prevent wire rope cutting.

Step 2: Extend the Cable

To release the tension and pull out the cable, move the primary release lever or pawl into the disengaged position. Pull the cable manually until the hook reaches the load. Once attached to the load, pull the cable until it is taut, removing all slack. Re-engage the pawl firmly so that the ratchet gear is locked.

Step 3: Begin the Ratcheting Cycle

Move the handle back and forth to engage the ratchet gear. As you pull the handle, the pawl will click into the next gear tooth, capturing the progress and preventing the load from sliding back. Maintain a steady, rhythmic motion. Do not use cheater bars or extenders on the handle; doing so creates excessive torque that can snap the handle or deform the internal gears.

Warning: Keep your body clear of the "line of fire." If a cable snaps under high tension, it will whip back toward the anchor point with lethal force. Never stand directly in line with the cable.

Step 4: Maintaining Tension or Releasing the Load

Once the load has reached the desired position, keep the tension engaged by leaving the pawl in the locked position. To release tension, you must reverse the handle cycle. Carefully move the release lever to the "down" or "release" position and work the handle incrementally. You must have enough load on the cable to allow the pawl to be moved; if the cable is loose, the release mechanism may jam.

Technical Parameters and Mechanical Capacity Comparison

The following table outlines the correlation between tool size, cable configuration, and intended usage profiles for standard manual pullers.

Common Field Failures and Mechanical Remedies

• Failure: The handle snaps during operation.
  
  
  • Root Cause: Overloading beyond the manufacturer’s WLL or shock-loading the device by jerking the handle.
  • Fix: Replace the shear pin if equipped, or retire the unit if the frame has deformed. Never weld a snapped handle.
• Failure: The pawl fails to catch the gear teeth.
  
  
  • Root Cause: Accumulation of dirt, debris, or dried grease preventing the spring-loaded pawl from seating.
  • Fix: Clean the ratchet gear and pawl assembly with a solvent, then apply a light coating of machine oil to ensure free movement.
• Failure: Cable bird-nesting on the drum.
  
  
  • Root Cause: Winding the cable under zero tension or unevenly wrapping it across the drum width.
  • Fix: Unspool the cable completely and rewind it under constant tension, using a gloved hand to guide the wraps evenly.

Frequently Asked Questions

Can I use a come along to lift a load vertically?

While many come alongs are marketed for pulling, they are generally not designed for overhead lifting. Using a tool not rated for lifting (lacking a mechanical load brake) can lead to uncontrolled load descent, causing severe injury.

What is the purpose of the two-pawl system?

Higher-end come alongs utilize a two-pawl system where one pawl is always engaged while the other moves to the next tooth. This ensures the load is held securely at every point in the handle stroke, preventing the tool from jumping or slipping during heavy operation.

How do I prevent the cable from kinking?

Always keep the cable under tension when retracting. If you allow the cable to become slack, it will overlap itself on the drum, leading to crushing damage and permanent kinks that significantly reduce the cable's structural capacity.

What should I do if the release lever is stuck under load?

The release lever is designed to be under load-bearing pressure when locked. If it feels jammed, apply slightly more tension to the handle to take the pressure off the pawl, then flip the lever to the release position while slowly reciprocating the handle.

Maintain Your Lifting Rigging

Regular inspection of your come along components is the most effective way to prevent equipment fatigue and maintain site safety. Ensure that your gear is stored in a dry, covered environment to prevent oxidation of the steel cable and degradation of the internal mechanical pawls.