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Current Tools 99, Operating, Maintenance, Safety And Parts Manual

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Current Tools 99 Operating, Maintenance, Safety And Parts Manual Download Page 2

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TABLE OF CONTENTS

Safety Alerts ....................................................................................2
Important Safety Information ........................................................3
Specifications .................................................................................. 4
Features ............................................................................................5
Transporting/Lifting the Cable Feeder ..........................................6
Set Up ............................................................................................7,8
Loading Cable into Cable Feeder ............................................. 9-11
Operating Instructions ..................................................................12
Operational Notes .........................................................................13
Exploded View – Lower Drive ................................................ 14-15
Parts List — Lower Drive ........................................................ 16-17
Exploded View — Upper Drive .............................................. 18-20
Parts List – Upper Drive .......................................................... 21-22
Exploded View and Parts List — Final Assembly ......................23
Exploded View – Electrical System .............................................24
Electrical System Diagram ...........................................................25
Exploded View/Parts List – Gear Motor .....................................26

Summary of Contents for 99

Page 1: ... request a copy 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 application of its products Read and understand this material before operating or servicing the Cable Feeder Failure ...

Page 2: ...ing Cable into Cable Feeder 9 11 Operating Instructions 12 Operational Notes 13 Exploded View Lower Drive 14 15 Parts List Lower Drive 16 17 Exploded View Upper Drive 18 20 Parts List Upper Drive 21 22 Exploded View and Parts List Final Assembly 23 Exploded View Electrical System 24 Electrical System Diagram 25 Exploded View Parts List Gear Motor 26 ...

Page 3: ...mmediate 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 death Safety Alert...

Page 4: ...res of the Cable Feeder Do not allow any sharp objects to contact the tires doing so may cause damage to the tires and possibly tire failure Inspect the Cable Feeder for damage or wear before each use RETAIN SAFETY INFORMATION 3 3 IMPORTANT SAFETY INFORMATION This manual should be read and understood by all personnel who operate or service this Cable Feeder Failure to understand how to safely oper...

Page 5: ...ed 0 ft minute to 36 ft minute Cable Capacity 8 X 250 MCM Cable 6 X 500 MCM Cable 5 X 750 MCM Cable Cable size 25 to 3 5 dia max Maximum Width of all cables 6 Maximum Pulling Force Single Cable Approximately 250 lbs All Cables Approximately 1 000 lbs Maximum Reel capacity 25 000 lbs Tire Pressure 50 PSI 4 SPECIFICATIONS ...

Page 6: ...oot switch Low voltage hand control pendant with 8 cable and magnet for easy storage Ratcheting tension adjustment provides tension on cable from 1 4 to 3 1 2 diameter Self lubricating drive chain reduces maintenance LOWERDRIVE T BAR RECEIVER 2 RIGIDOR IMCCONDUIT PROVIDEDBYENDUSER T ADAPTER REMOVEABLE CABLESEPARATOR ENTRYSIDE TRANSPORT CASTERRELEASE LEVER TRANSPORTCASTER UPPERDRIVE TENSION ADJUSTM...

Page 7: ...se lever with your foot This will allow the caster to rotate out of the way Next lower the Cable Feeder LIFTING THE FEEDER When lifting the Cable Feeder attach sling so that it loops around the drive frame as shown below Upper drive clamp MUST be in closed locked position before attempting to lift the Cable Feeder WARNING DANGER WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNI...

Page 8: ...le should approach the Cable Feeder is 25 from the center line Make sure the cable insulation will not be damaged The cable may pay off from either the top or bottom of the reel Place the ground cable in the farthest slot to the left of the cable separator as it enters the cable feeder 25 MAXIMUM FROMCENTERLINE ASCABLE APPROACHESFEEDER PROVIDESUFFICIENT DISTANCEHEREFOR CABLETOREMAINSLACK T ADAPTER...

Page 9: ... the T Bar against a stake s in the ground step etc Using Anchors Secure the Cable Feeder by anchoring through the four anchor brackets located on the bottom of the Cable Feeder Use 3 8 or 1 2 anchors provided by end user Always ensure that the structure you are anchoring to will support the forces generated by the pull plus a 4 1 safety factor WARNING DANGER WARNING CABLEREELSTAND T ADAPTER T BAR...

Page 10: ...chet studs Lift up on the handle and place the tension adjustment arms with the resting slots see Figure 1 below on top of the ratchet studs TENSION ADJUSTMENTARM RATCHET STUD TENSION ADJUSTMENTHANDLE TENSION ADJUSTMENTARM Lifting tension adjustment arms to place resting slots on top of ratchet studs Resting slots shown on top of ratchet studs TensionAdjustment ArmRestingSlot Figure 1 ...

Page 11: ...E FEEDER continued THUMBSCREW Cable separator shown installed Cable separator shown in storage slots 3 Place the cables over the lower tire being sure not to cross the cables Note Pull safety lock as shown to release upper drive clamp 10 4 If needed remove the cable separator from the storage slots and install as shown below Be sure to tighten the thumb screw to secure the cable separator ...

Page 12: ...on adjustment handle lower the tension adjustment arms Push down on the handle with enough pressure to engage one set of the ratcheting slots onto the ratchet studs Upper drive arms raised and shown latched into open position 7 Now you are ready to feed cable Note If needed the upper drive can be raised and will latch into open position as shown below ...

Page 13: ...f switch in the continuous on position For intermittent operation With the pendant continuous on off switch in the OFF position depress the pendant jog button If equipped with optional foot switch Plug the foot switch into the foot switch outlet located on the front of the electrical box on the Cable Feeder and depress the foot switch 5 Adjust the speed by rotating the speed control knob as follow...

Page 14: ... back the excess small cable that has built up at the exit end of the Cable Feeder Lower the upper drive arms and push down on the tension adjustment handle until the tension adjustment arms engage the ratchet studs Restart the pull If slippage is a problem more separation may be needed between the ground cable and the larger cables Simply place the ground cable in the farthest slot to the left of...

Page 15: ...refer to PARTS LIST on pages 16 17 14 EXPLODED VIEW LOWER DRIVE WHEELS AND CASTER DRIVE MOTOR LOWER ...

Page 16: ...refer to PARTS LIST on pages 16 17 15 EXPLODED VIEW LOWER DRIVE DRIVE TIRE ASSEMBLY LOWER DRIVE FRAME ...

Page 17: ...N HEAD SLOT 6 32 3 8 6 16 77 063 SWITCH GUARD 1 17 77 508 PRECUT WIRE LEADS NOT SHOWN 1 18 88 47 CIRCUIT BREAKER SWITCH 1 19 99 10 CASTER 1 20 99 100 PROPORTIONAL CONTROLLER 1 21 99 101 BRIDGE RECTIFIER 1 22 99 102 STAND OFF NYLON 4 23 99 117 OUTLET FOOT SWITCH 1 24 99 120 KNOB SPEED CONTROL 1 25 99 18 BEARING FLANGE PLAIN 3 4 2 26 99 2 GEAR MOTOR 1 27 99 21 18 5 x 8 50 TIRE 99 1 28 99 24 KEY 3 16...

Page 18: ...20 SPACER ELEC BOX 3 57 453 16A NUT HEX 8 32 1 58 524 11 3 8 16 x 1 HEX HEAD CAP SCREW 9 59 528 2 SCREW HEX HEAD CAP GR5 ZINC 3 8 16 x 2 1 60 610 25 NUT HEX NYLON INSERT 3 8 16 6 61 9518SR 12 NUT HEX NYLON 1 4 20 3 62 9544 21 WASHER FLAT 5 16 USS ZINC 8 63 99 105 DECAL 1 64 77 050 GUARD PENDANT 1 65 77 451 GASKET 1 66 77 051 SWITCH FORWARD REVERSE 1 67 77 052 SWITCH JOG 1 68 77 048 CONDULET 1 2 1 ...

Page 19: ...refer to PARTS LIST on pages 21 22 18 EXPLODED VIEW UPPER DRIVE DRIVE TIRE ASSEMBLY UPPER DRIVE FRAME ...

Page 20: ...refer to PARTS LIST on pages 21 22 19 EXPLODED VIEW UPPER DRIVE DRIVE MOTOR AND ARMS ...

Page 21: ...refer to PARTS LIST on pages 21 22 20 EXPLODED VIEW UPPER DRIVE DRIVE TIRE TO ARMS ASSEMBLY ...

Page 22: ... SCREW BUTTON HEAD SOCKET 1 2 13 x 3 4 4 20 99 33 NUT LUG 1 2 20 4 21 99 34 STUD WHEEL 1 2 20 4 22 99 37 SCREW BUTTON HEAD SOCKET 5 16 18 x 1 2 23 99 38 SCREW HEX HEAD CAP GR5 ZINC 5 16 18 x 1 5 1 24 99 59 SCREW SOCKET HEAD CAP 3 8 16 x 1 25 4 25 99 60 5 16 18 x 1 00 SHCS 6 26 99 61 SCREW SOCKET SHOULDER 3 4 x 5 8 2 27 99 687 SPREADER TUBE FEEDER 1 28 99 688 ARM DRIVE SIDE 1 29 99 689 ARM OFF SIDE...

Page 23: ...QTY 45 99 777 COVER MOTOR BRACKET BOTTOM 1 46 99 786 LATCH TOP TIRE 1 47 99 787 PIN LATCH 1 48 99 796 STRAP CHAIN GUARD 1 49 99 816 STRAP CHAIN GUARD 1 50 99 80 STEEL CABLE 1 16OD x 8 LG 2 51 670 6 FERRULE DOUBLE 4 52 99 53 DRIVE CHAIN 1 53 99 85 MASTER LINK 1 ...

Page 24: ...9 SCREW SOCKET HEAD CAP 5 16 18 x 1 2 8 6 99 37 SCREW BUTTON HEAD SOCKET 5 16 18 x 1 6 7 99 41 BALL GAS SPRING 2 8 99 64 GAS SPRING 1 9 99 400 99 LOWER DRIVE ASSEMBLY 1 10 99 500 99 UPPER DRIVE ASSEMBLY 1 11 99 714 ROD REAR SUPPORT HOLDER 1 12 99 717 HINGE CAGE 1 13 99 735 T STABILIZER 1 14 99 768 STOP STRAP 1 15 99 823 STABILIZER WELDMENT 1 16 99 827 CABLE SEPARATOR 1 17 406 3 SPRING CLIP 1 18 61...

Page 25: ...refer to PARTS LIST on pages 16 17 24 EXPLODED VIEW ELECTRICAL SYSTEM FOOTSWITCHASSEMBLY optional CONTROLBOX 72 71 12 REMOTEPENDANT 78 12 68 75 74 65 64 66 63 69 67 70 78 73 77 76 71 ...

Page 26: ... Rectifier Speed Control E Stop Blue Brown OFF Circuit Breaker Switch White 115 VAC Plug Continuous Run Off Enable Jog Pendant Jog C NC NO Foot Switch Transformer WIRING DIAGRAM Red Green Black Black Black AC Black Black Ground Green Black Black Black Black Black White Green Ground Ground Black White Green G re e n White Black W h i t e White 25 ...

Page 27: ...CKET HEAD CAP SCREW 99 2L 13 2 MOTOR STUD 99 2M 14 1 ARMATURE BEARING ASSEMBLY 99 2N 15 1 MAGNET HOUSING ASSEMBLY 99 2O 16 1 WAVE WASHER 99 2P 17 1 COMMUTATOR END BELL ASSEMBLY 99 2Q 18 2 BRUSH ASSEMBLY 99 2R 19 2 BRUSH CAP 99 2S 20 2 10 32 K NUT 99 2T 21 1 GEARCASE ASSEMBLY COMPLETE 99 2U PRESS OUTPUT SHAFT ASSEMBLY INTO BEARING PRESS SEAL FLUSH TO TOP OF CASTING TORQUE TO 110 130 IN LBS 1 12 11 ...

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