USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL CableGlider® FO Cable Puller ® CONDUX
Important Safety Notice Read and understand all procedure and safety instructions before using a Condux Fiber Optic Cable Puller. Observe all safety information on this page and note specific safety requirements as explained by procedures called out in this manual. Failure to follow these instructions could result in serious personal injury or death. Advertencia: Favor de leer y comprender todas las instrucciones de operación y seguridad antes de usar la máquina. Si Ud.
Table of Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 4 5 6 7 8 9 10 11 12 13 14 15 a. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 b. Power Requirements . . . . .
1. General Information The Condux Fiber Optic Cable Puller is a hydraulic pulling machine designed for fiber optic cable placement. It offers bi-directional pulling and load-sensing capabilities. The system uses a hydraulic motor and capstan with an electronic tension control system. The tension control system uses an electronic load cell to measure the actual torque at the puller’s motor. Combining this torque value with the capstan’s diameter ensures accurate tension monitoring.
Safe Operating Practices Read and understand all procedure and safety instructions before using the Condux Fiber Optic Cable Puller. Observe all safety information on this page and note specific safety requirements as explained by procedures called out in this manual. Failure to follow these instructions could result in serious personal injury, property damage or death. a. Work Area Safety 1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and leather work gloves. 3. 2.
4. Unpacking the Fiber Optic Cable Puller a. Puller Components 1. Fiber Optic Cable Puller Package 1 Part Number: 08690001 • Hydraulic puller mounted on a 21⁄2 inch (64 mm) square tube • Foot control valve assembly • Hydraulic hoses from puller to foot control valve assembly (10 foot) • Hydraulic hoses from foot control valve assembly to power supply (20 foot) • Owner’s manual • Shipping crate 2.
Set up the Puller This manual contains setup and operating instructions for the Condux Fiber Optic Cable Puller with electronic control box, if equipped. Where operations differ for the other available packages, the instructions specify those differences. a. Mount the Puller 1. The Fiber Optic Cable Puller has a 21⁄2 x 21⁄2 inch (64 x 64 mm) square mounting post. A female receiver, such as the receivers listed in appendix 13.F and 13.G, is recommended.
!WARNING: Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: • Tighten all connections before applying pressure. Relieve pressure before connecting or disconnecting hoses. • Check for leaks with a piece of cardboard. Do not use hands! • Do not exceed working pressure of hydraulic hoses. Visually inspect hoses regularly and replace if damaged. 5.
different load setting. See section 11.B for details. For proper operation, the relief valve must be set at a tension limit greater than the electronic tension limit. d. Attach the Capstan 1. Attach the 30 inch (762 mm) diameter capstan to the puller’s shaft (figure 4) by aligning the capstan’s slots with the shaft’s pins. Push the capstan onto the shaft until it stops, then rotate clockwise until it stops. Pull outward to lock the capstan into position.
b. Connect the Electronics !DANGER: The electronic control box is an electrical device. Electric shock hazards exist that could result in severe personal injury or death. Observe the following precautions: • Do not expose electronic control box to water. • Do not remove cover of electronic control box (no user-serviceable parts inside). Refer servicing to qualified personnel. • The electronic control box power switch should be in the off position before connecting or disconnecting any cords. 1.
3. The 7/8” 2-pin connector on the front panel of the electronic control box supplies electrical power to the electronic control box. (see Figure 10) This power can come from the power pack, a vehicles power point, or a lighter socket. The electronic control box requires 12 Volt DC power for proper operation. Figure 10. ECB Power Connection 4. Connect the power cord to the 2-pin connector labeled “POWER”. Before making these connections, ensure the receptacle is free of dirt and moisture.
scroll through letters and the ◄ and ► buttons to move spaces. (See Figures 11-14). Once the name is set press “MENU” button to go back to Record Mode. From Record Mode, ◄ or ► will return to Menu screen. Pressing ◄ or ►again will return to charting screen. 2. Set to Record Mode: If you are already in the Record Mode screen, use the ▲ and ▼ buttons to scroll to “ON”. If you are starting from the charting screen, press “MENU” and scroll to Record Mode.
E. Data Download Instructions The Running Line Tensiometers come with accessories for downloading your pull data: Navigation software, 256MB Flash Card, card reader and USB cable. Downloading data to your computer via USB Cord 1. Connect Recorder to PC or laptop with supplied USB cord 2. Turn ECB on *and make sure that Record Mode has been turned to OFF. 3. Open Navigator software on PC 4. In Navigator software select “FILE” and “USE RECORDER” 5. Select Open to pull in pulling data from recorder. 6.
7. Finish Puller Setup a. Move the puller into its final position. The pull line will wrap best on the capstan if the capstan is angled about 10° away from the pull line (figure 18). This will allow the line to walk down the side of the capstan and push the previous wraps to the side. 10° b. Place four or more side-by-side wraps of the pull line around the capstan in the direction of rotation. Do not wrap more than one layer of pull line on the capstan. c. Start the hydraulic power source. Figure 18.
Puller Operating Instructions a. Slowly press the foot control pedal. Remove any slack or excess pull line before increasing the puller’s speed. Attend the line coming off the capstan to avoid any tangles, and keep some tension on the line so that the capstan grips the pull line. Never wrap the line around your hand, arm, foot, or leg, and always be prepared to release the line. Stand at least 3 to 4 feet (0.9 to 1.2 m) away and at a 20 degree angle from the capstan.
10. Tear Down Procedures a. Remove Hydraulic Power Supply 1. Stop the puller by releasing the foot pedal to its neutral position. 2. Shut off the hydraulic power supply. 3. Push the foot pedal down and lift up at least 3 times to relieve the hydraulic system’s back pressure. !WARNING: Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Release pressure before disconnecting hoses. 4. Disconnect all hydraulic supply hoses.
Puller Calibration When using the electronic control system, the Condux Fiber Optic Cable Puller does not need to be calibrated on a regular basis; however, the calibration should be checked periodically (at least yearly) to ensure that the calibration has not changed. If the calibration procedures specified below are not possible at the operator’s location, we recommend returning the unit to Condux International for calibration by the factory.
!CAUTION: Use the relief valve pressure only as a backup to the electronic tension control system or other load limiting means. Damage to the cable being installed may result. 1. Set up the puller as if cable were to be pulled, including installation of the capstan (figure 21). 2. Place a pull line around the capstan. The pull strength of the pull line must exceed the 2,000 pound maximum capacity of the Fiber Optic Cable Puller. 3.
c. Electronic Tension Control System Calibration The electronic tension control system automatically calibrates itself to the 12”, 30” and 42” Condux capstans simply by turning the Capstan Selection Switch. To verify calibration see section 11.A. !NOTE: If the puller calibration is in question, contact the factory for calibration information at 1-800-533-2077.
12. Troubleshooting Guide a. Puller Problem: Solution: • Reverse the connections on one end of the hose assembly between the foot control valve assembly and the puller (see section 5.B.2). Capstan does not rotate in the required direction when the foot pedal is depressed. Foot control pedal will not depress fully. • The adjustable flow control knob on foot control could be limiting movement. Turn flow control knob counterclockwise until full movement is achieved (see section 5.C.1).
b. Electronic Control Box Problem: Solution: Digital display is not functioning. • Turn electronic control box power switch ON (see section 6.C.1). • Check 12 Volt DC power supply (see section 6.B.3). • Check all electrical connections. Digital display does not display expected values. • Capstan size is different from capstan selected on electronic control box (see section 6.C.2). Numbers on digital display start counting up and do not stop with no load on the capstan.
c. Foot Control Valve Problem: Solution: Foot control pedal is sticking, will not return to neutral. • Remove item numbers 33, 32, 31, 30, knob steel, knob flow adjustment, body spool stop upper & body spool stop lower. • Remove capscrew, spring & washer assembly. • Confirm washer are flat, clean and lubricate the capscrew, spring and washer assembly. • Re-assemble capscrew, spring and washer assembly to the foot control assembly. • Re-assemble body spool lower.
Appendices 13. a. Hydraulic Hose Kits and Parts Lists ITEM PART NO. DESCRIPTION 08675322 10-FT. HOSE ASSY-PULLER SUPPLY (COMPLETE) QTY 1 1 02255801 HOSE ASSEMBLY,2 #8MPT-2 #8MPT 1 2 02260100 COUPLER,QD-MALE FF 1/2IN NPT 4 3 02260200 CAP,DUST(MALE FLAT FACE CPLRS) 4 4 08519300 TIE,CABLE L=14.0 W=.18 50LBS 2 3 2 4 1 4 3 2 3 1 5 2 2 5 ITEM 3 4 PART NO. DESCRIPTION 08675858 20-FT.
b.
c. Parts List for Puller Assembly ITEM PART NO. DESCRIPTION QTY 1 02001600 CAPSRW 0.50-13X1.25 HHSTGR5 CZ 2 2 02004500 LOCKWSHR 0.37 REGULAR ST CZ 4 3 02020701 CAPSRW 0.37-16X1.00 HHSTGR5 CZ 4 4 02021501 LOCKWSHR 0.25 REGULAR ST CZ 2 5 02026200 CAPSRW 0.62-11X2.00 HHSTGR5 CZ 4 6 02027500 NUT 0.62-11 NYLOC ST GR5 CZ 4 7 02114700 FTG,HYD 08 O-RING;08-JIC 45’ 2 8 02190300 O-RING, .103CS- .487ID BUNA-N 2 9 02231400 CAPSRW 0.25-20X0.62 SHSTALY PL 2 10 02253900 CAPSRW 0.
d.
e. Parts List for Foot Control Valve Assembly ITEM PART NO. DESCRIPTION QTY 02272900 FOOT VALVE SEAL KIT 1 1 02021400 CAPSRW 0.25-20X0.75 HHSTGR5 CZ 1 2 02053800 FTG,HYD 08-NPT_M ;08-JIC 8 3 02102000 FLATWSHR 0.25 TYPEA-WIDE ST CZ 2 4 02202100 FTG,HYD 08-NPT_M ;08-NPT_F 90’ 8 5 02234300 CAPSRW 0.25-20X1.00 SHSTALY PL 2 6 02235000 TERMINAL,BUTT CONNCTOR 22-18GA 2 7 02238700 CAPSRW 0.25-20X1.75 SHSTALY PL 3 8 02240800 CAPSRW #10-24X0.
f.
g. Utility Tool and Body Company Mounts Condux Part Number 02260800 Utility Tool and Body Company Floor Socket (No.
14.
Warranty Information a. Factory Assistance Condux International can provide further advise regarding any problems with the installation, service, assembly, or disassembly of the Fiber Optic Cable Puller. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Fiber Optic Cable Puller can be returned to the factory at any time for service or repair; however, obtain a Return Material Authorization (RMA) must be obtained from Condux before shipping.
® Condux International, Inc. P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • E-mail: cndxinfo@condux.com © Copyright 2009, Condux International, Inc. Printed in USA Literature Part Number: 08675881 Revision Number: 2.
