How To Use A Come Along Tool Safely And Efficiently

A come along is a manually operated lever ratchet winch used to pull, tension, or lift heavy loads by converting physical arm power into massive mechanical advantage via a wire rope or synthetic strap. Mastering this tool requires strict adherence to rated load capacities, proper anchoring techniques, and careful tension release protocols to prevent catastrophic cable snapback or load slip.

Pre-Operation Setup and Rigging Checklist

Before applying any tension with a manual lever puller, you must evaluate the load weight, anchor point integrity, and mechanical condition of the equipment. Using an undersized winch or a compromised anchor point introduces severe safety hazards, including structural failure, snapped cables, and uncontrolled load shifts.

• Essential Gear and Hardware: Industrial-grade come along (typically rated for 1 to 4 tons), heavy-duty rigging straps, screw-pin anchor shackles rated for overhead lifting, work gloves, and a designated anchor chain or strap.
• Prerequisite Technical Standards: Thorough inspection of the winch housing, ratcheting pawl, shear pins, and cable fraying; verify that the operating environment is free of dynamic load shocks or corrosive chemicals.
• Resource Benchmarks: Estimated setup time of 10 to 15 minutes per pull; operational budget ranging from forty to one hundred and fifty dollars for a certified, ASME-compliant tool.

Step-by-Step Rigging and Pulling Procedure

Step 1: Secure the Anchor End

1. Attach the stationary hook of the come along to a stationary, immovable anchor point capable of withstanding the maximum pulling force of the winch plus a safety margin.
2. Use a rated rigging strap or chain to wrap around the anchor structure rather than hooking the cable back onto itself, which damages the line and compromises integrity.
3. Ensure the safety latch on the anchor hook is fully engaged and closed before applying any load tension.

Step 2: Connect to the Load

1. Release the cable spool by shifting or lifting the pawl lever to free-wheel the drum, pulling out enough wire rope or strap to reach your target load.
2. Fasten the pulling hook securely to the designated attachment point on the object you intend to move or tension.
3. Confirm that the hook is seated properly in the attachment eye with no side-loading forces acting on the throat of the hook.

Step 3: Engage the Ratchet Mechanism

1. Flip the control lever or toggle switch into the forward or pulling position to lock the ratcheting pawl against the gear teeth.
2. Pump the operating handle with steady, smooth strokes, keeping your body clear of the direct line of the cable or strap.
3. Observe the initial take-up to ensure the wire rope or strap spools evenly across the drum without overlapping or binding.

Step 4: Execute the Pull and Monitor Tension

1. Continue operating the lever handle while periodically pausing to inspect the anchor points, the load stability, and the cable alignment on the drum.
2. Never lengthen the handle with a pipe cheater bar or extension pole, as this exceeds the design tolerances of the frame and can cause structural fracture.
3. Stop immediately if you hear excessive clicking, popping, or metal deformation, and slowly back off the tension to inspect the rig.

Step 5: Release and Unwind the System

1. Once the load is secured in its final position, switch the control lever to the reversing position to release tension incrementally.
2. Pump the handle carefully to back off the gear teeth, maintaining a firm grip on the handle to prevent kickback from the stored spring energy in the cable.
3. Once fully unloaded, disengage the pawl completely and guide the cable back onto the drum evenly to prevent kinks during storage.

Come Along Specifications and Capacity Standards

Common Operational Failures and Field Fixes

• Root Cause: Cable birdnesting or tangling on the drum during free-wheeling.
  
  
  • Actionable Fix: Release all tension safely, pull the entire length of the cable out manually, and rewind it under slight tension while wearing heavy leather gloves to guide the wraps tightly against the drum.
• Root Cause: The handle bends or snaps during operation.
  
  
  • Actionable Fix: Replace the handle immediately with an OEM-certified replacement part, and verify that you did not exceed the rated load limit or use an unauthorized extension cheater bar.
• Root Cause: The ratcheting gear slips or fails to hold tension.
  
  
  • Actionable Fix: Clean accumulated dirt, rust, or grease out of the pawl teeth using a wire brush and solvent, and check for a sheared internal load-limiting rivet or worn pawl spring.

Frequently Asked Questions

Can I use a come along for overhead lifting?

Most standard come alongs are designed exclusively for pulling and tensioning across a horizontal or inclined plane, not for vertical overhead lifting. Check the manufacturer specifications to ensure the tool is certified for vertical lifting with an automatic load brake before attempting any overhead application.

How do I prevent the cable from kinking?

Never allow the wire rope to develop slack while under load, and avoid pulling at severe lateral angles that force the cable against the side flanges of the drum. Always guide the cable smoothly back onto the spool during retraction.

Can I use a cheater bar to get more pulling power?

Never slide a pipe or extension handle over the original operating lever to increase leverage. Come along handles are engineered to bend or slip as a safety indicator when the tool approaches its maximum rated working load limit.

What is the difference between a cable come along and a strap puller?

Cable come alongs utilize galvanized wire rope and offer longer pull distances, making them ideal for heavy industrial pulls and vehicle recovery. Strap pullers use heavy-duty polyester webbing, which prevents marring on sensitive surfaces and minimizes whip hazard if the line breaks.

Proper rigging discipline ensures safety when managing high-tension loads in industrial, automotive, or construction environments. Always verify your equipment ratings before starting any pull.