How To Use A Come Along Winch: Step-by-Step Safe Rigging Guide

Learn how to use a come along winch safely by selecting load-rated anchors, extending the cable via the drive pawl release, and systematically tensioning the system using the ratcheting lever. Adhering to ASME B30.21 standards prevents catastrophic rigging failures while maximizing your mechanical leverage. This guide outlines the precise steps needed to rig, tension, and de-tension a hand-operated cable puller under load.

A come along—frequently referred to as a manual lever hoist or hand cable puller—is an invaluable mechanical tool designed to pull, tension, and secure heavy loads. Leveraging a simple ratcheting drum, a steel cable or high-strength strap, and a lever handle, this tool allows a single operator to exert thousands of pounds of pulling force. However, because a come along stores massive amounts of potential energy under tension, understanding proper operation is critical to preventing severe injury or equipment failure.

Pre-Rigging Inspection and Essential Equipment Checklist

Before attempting to move any load, you must assess both your equipment and your environment. A come along is rated by its Working Load Limit (WLL), which is typically stamped on the handle or tool frame. Never exceed this rating. Under ASME B30.21 standards, manual lever hoists must possess a design factor of at least 4:1, but this safety margin is reserved for dynamic shock loads and wear, not for overloading the tool during standard operation.

Required Gear and Site Specifications

Operating a manual winch safely requires more than just the come along itself. Gather the following gear and verify these benchmarks before starting your pull:

• Manual Come Along Winch: Rated for your specific load (commonly 1-ton to 4-ton capacities).
• Heavy-Duty Rigging Gloves: Leather or high-durability synthetic gloves to protect hands from steel cable burrs and pinch points.
• Tree Saver Straps or Tow Straps: Polyester or nylon webbing rated higher than your winch capacity, used to wrap around anchor points without damaging them or the winch line.
• Bow Shackles (D-Rings): Rated steel shackles to connect straps to the winch hooks securely.
• Winch Dampener or Heavy Blanket: Placed over the middle of the cable to absorb kinetic energy and prevent snapback in the event of a cable failure.
• Estimated Duration: 15 to 30 minutes depending on rigging complexity.
• Estimated Budget: $40 to $150 for high-quality, rated rigging components.

Step-by-Step Come Along Operation and Rigging Guide

Successfully pulling a load with a come along requires structured, methodical steps. Hurrying through rigging or skipping pawl verification is the primary cause of manual winching accidents.

Step 1: Inspect the Winch and Cable

Prior to rigging, inspect the steel cable or strap along its entire length. Run your gloved hands down the cable to check for kinks, bird-nesting (fraying of individual strands), flat spots, or rust. Inspect the hook latches to ensure they snap closed automatically and are not bent or warped. Check the ratchet teeth on the drum; they must be sharp, clean, and free of mud or grease.

Warning: Never use a come along if the cable has kinks, broken strands, or if the hooks lack functioning safety latches. A compromised cable can fail catastrophically under tension, snapping back with lethal force.

Step 2: Release the Drive Pawl to Free-Spool

To extend the cable to your load, you must release the tension-holding mechanisms on the winch drum.

1. Locate the drive pawl (the spring-loaded lever that engages the ratchet teeth near the handle) and the stop pawl (the spring-loaded lever mounted to the main frame).
2. Manually compress or lift the drive pawl spring to disengage it from the ratchet wheel.
3. Keep the handle in the fully open position (pushed all the way forward toward the anchor hook) to lock the stop pawl open.
4. Pull the cable smoothly out of the drum by hand. Avoid jerking the cable, as this can cause bird-nesting on the spool. Leave at least three full wraps of cable on the drum to prevent the cable from pulling completely out of its anchor anchor-pocket under load.

Step 3: Establish a Secure Anchor Point

Identify a structurally sound, immobile anchor point. Suitable anchors include mature trees (at least 10 inches in diameter), heavy structural steel beams, or a certified vehicle recovery point.

1. Wrap your polyester tree saver or tow strap around the anchor point.
2. Connect the two looped ends of the strap together using a rated bow shackle.
3. Attach the stationary hook of the come along (the hook connected directly to the winch frame) to the bow shackle. Ensure the safety latch on the hook clicks shut.

Pro-Tip: Never wrap the steel winch cable directly around an anchor object and hook it back onto itself. This creates sharp bends in the cable, severely weakening it, and will cause premature cable failure. Always use a rigging strap and shackle.

Step 4: Hook and Rig the Load

With the winch secured to the anchor, pull the free end of the cable toward the load.

1. Connect a second strap to the load using a bow shackle if there is no built-in tow loop.
2. Attach the pulley hook (the traveling hook at the end of the cable) to the load shackle.
3. Ensure the cable is straight, untwisted, and aligned directly between the anchor and the load. Off-angle pulls can cause the cable to bunch on one side of the drum, damaging the side plates.

Step 5: Tension the Line and Pull

Once the rigging is complete, you are ready to engage the mechanical ratcheting system.

1. Release the manual override on the drive pawl so that both the drive pawl and the stop pawl rest firmly against the ratchet wheel teeth.
2. Begin pumping the handle back and forth. You should hear a distinct "clicking" sound as the pawls slip over the teeth and lock into place.
3. As tension begins to build, pause and inspect your rigging connections. Ensure the hooks are seated deeply in the bowls of the shackles and are not loading on their tips.
4. Drape a winch dampener, heavy blanket, or floor mat over the exact center of the extended cable.
5. Stand completely out of the "snap-zone"—the linear path of the cable. Always operate the handle from the side, keeping your body out of alignment with the cable line.
6. Pump the handle through its full range of motion. Each stroke pulls the load closer, wrapping the cable around the drum.

Step 6: Safely De-Tension and Disconnect

Releasing tension from a come along under load is the most dangerous part of the operation. Do not attempt to force the pawls with a screwdriver or fingers.

1. Align the handle so it is pointing toward the load.
2. Manually switch the reversing lever or spring-loaded pawl mechanism into the "down" or "reverse" position.
3. Pull the handle back toward the anchor. This action will transfer the load tension from the stop pawl to the handle itself. You will feel the full weight of the load in your hand.
4. Push the handle forward under control until the stop pawl drops into the next ratchet tooth, safely holding the load.
5. Repeat this controlled, step-by-step lever sweep to release the tension one click at a time until the line is completely slack.
6. Once slack, unhook the connections, clean the cable of any dirt, and neatly spool the cable back onto the drum under light hand tension to prevent tangles.

Technical Comparison of Come Along Materials and Capacities

Choosing the right come along requires matching the tool's structural materials with your specific operational environment.

Common Hand Winch Failures and Field Remedies

Cable Binding or "Bird-Nesting" on the Drum

• Root Cause: Spooling the cable back onto the drum without applying physical tension, causing loose wraps to slide under tight wraps when a load is applied.
• Actionable Fix: Relieve all tension on the line. Pull the free-spool lever and anchor the hook to a stationary object. Walk backward, pulling the cable out forcefully by hand to unravel the buried loop. Rewind the cable while maintaining hand tension with heavy leather gloves.

Ratchet Pawls Slipping Under Load

• Root Cause: Mud, grease, rust, or ice buildup inside the spring mechanism, preventing the pawl from seating deeply into the ratchet teeth.
• Actionable Fix: Safely secure the load with secondary chains or straps. Do not adjust the pawls while under tension. Spray the winch assembly with a fast-evaporating brake cleaner or degreaser to clear debris, then apply a dry graphite lubricant to the pivot points.

Bending the Lever Handle

• Root Cause: Attempting to pull a load that exceeds the winch's capacity, or extending the handle with a "cheater pipe" to gain more leverage.
• Actionable Fix: Immediately cease pulling. The handle is designed to bend as a safety indicator before the cable or frame fails. Back off the tension safely using the step-down procedure. Replace the bent handle and rig a snatch block (pulley) to double your mechanical advantage, halving the load on the winch.

Frequently Asked Questions

Can you use a come along for vertical lifting?

Most standard come alongs are rated exclusively for pulling and dragging horizontally. To lift loads vertically, you must use a hoist certified under ASME B30.16 standards, which features dual automatic braking systems to prevent the load from dropping if you lose control of the handle.

What is the difference between a single-line and double-line rigging setup?

A single-line setup connects the cable hook directly to the load, providing maximum reach but utilizing only the base capacity of the winch. A double-line setup uses a pulley block at the load; the cable passes through the pulley and connects back to the winch frame, doubling the pulling capacity while cutting the line speed and effective pulling distance in half.

How do you maintain a steel cable on a come along?

Keep the steel cable clean and lightly lubricated. After use in wet or muddy conditions, wipe the cable down with a clean rag and apply a thin coat of light machine oil or wd-40 to prevent rust, which weakens the individual wire strands over time. Store the tool in a dry, covered container.

Can a come along be safely used to secure loads on a trailer?

No, a come along should not be used as a permanent transport tie-down. The ratcheting mechanism can vibrationally disengage during transport. Instead, use dedicated load binders, transport chains, or ratcheting tie-down straps specifically designed for transit forces.

Elevate Your Rigging and Pulling Standards

Ensure your team is equipped with high-quality, certified rigging gear before tackling your next heavy lift or recovery operation. Investing in professional-grade manual winches and inspected synthetic recovery straps guarantees both operational efficiency and maximum safety on-site.