Cerrowire ReelRover Training manual

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4
©2020 Cerrowire Rev 07/16/2020
A Marmon/Berkshire Hathaway Company
For use with ReelRover Serial Numbers 36X-20-01-0001-XXX to 36X-2012-0017-XXX

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Contents of the User Manual & Operating Instructions specify the manner in which the
ReelRover™is to be operated as intended by Cerrowire®. The ReelRover is designated for use
only as stipulated within this document. Any deviation from the User Manual & Operating
Instructions is unauthorized and represents improper use of the equipment. This designated
document is used by Cerrowire to conduct training of distribution customers for proper use so that
the ReelRover is safely and correctly operated in both the distribution facility and on the job site.
Cerrowire provides the User Manual & Operating Instructions document to distribution customers
so that subsequent internal training as well as external contractor training may be provided by the
distributor. It is the responsibility of the distributor to ensure that all internal and external users are
properly trained and qualified in accordance with the procedures presented in this manual.

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Contents
Figures ..........................................................................................................................................4
Components ................................................................................................................................. 6
Specifications ............................................................................................................................... 7
Safety Procedures ........................................................................................................................ 8
Symbols and Warnings .................................................................................................................9
Gearbox ..................................................................................................................................... 11
PARK (P) ........................................................................................................................ 12
NEUTRAL (N) ................................................................................................................. 12
DRIVE (D) ....................................................................................................................... 12
Basic Operation ......................................................................................................................... 13
Operating the ReelRover in PARK ................................................................................. 13
Operating the ReelRover in NEUTRAL .......................................................................... 13
Steering in NEUTRAL ..................................................................................................... 13
Operating the ReelRover in DRIVE ................................................................................ 14
Steering in DRIVE ........................................................................................................... 15
Operating the ReelRover in DRIVE on an Incline or Decline Surface ............................ 16
Ground Reel ............................................................................................................................... 17
Free-Spinning Ground Reel: Lock Procedure ..................................................................18
Free-Spinning Ground Reel: Unlock Procedure ...............................................................19
Wire Take-up Process ................................................................................................................ 20
Winding Adaptor – Shaftless Equipment ................................................................................... 20
Inserting Winding Adaptor .............................................................................................. 20
Positioning ReelRover .................................................................................................... 21
Setting the Gearbox ....................................................................................................... 23
Winding Adaptor – Shafted Equipment ...................................................................................... 24
Removal of Shaft and Inserting of Winding Adaptor .......................................................24
Positioning ReelRover in the Take-up Machine ..............................................................25
Setting the Gearbox .................................................................................................... 27
Wire Unloading (Payout) ............................................................................................................ 27
Transportation & Shipping .......................................................................................................... 28
Forklift Locations .............................................................................................................28
Securing ReelRover For Shipping .................................................................................. 28
Using a Liftgate to Load the ReelRover .......................................................................... 29
Using a Liftgate to Unload the ReelRover .......................................................................30
ReelRover Lock-out Procedure .................................................................................................. 31
Troubleshooting ..........................................................................................................................32
Equipment Inspection Prior to Use.............................................................................................. 33
Equipment Inspection Checklist ................................................................................................. 34

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Figures
Figure 1a: ReelRover 3+1 ................................................................................................................... 6
Figure 1b: ReelRover 1+1 ................................................................................................................... 6
Figure 2a: ReelRover Specifications Side View .................................................................................. 7
Figure 2b: ReelRover Specifications Top View ................................................................................ 7
Figure 3: Gearbox Settings ................................................................................................................11
Figure 4: PARK Gearshift Position .................................................................................................... 12
Figure 5: NEUTRAL Gearshift Position ............................................................................................. 12
Figure 6: DRIVE Gearshift Position ................................................................................................... 12
Figure 7a: Sharp Turn in NEUTRAL .................................................................................................. 13
Figure 7b: Gradual Turn in NEUTRAL ...............................................................................................13
Figure 8: Reel and Drive Wheel Rotation .......................................................................................... 14
Figure 9a: Sharp Turn in DRIVE ........................................................................................................15
Figure 9b: Gradual Turn in DRIVE .....................................................................................................15
Figure 10a: Never Stand or Walk Downgrade of ReelRover ............................................................. 16
Figure 10b: Caster Wheels Should Always Be Downgrade ...............................................................16
Figure 11a: Reel Lock ........................................................................................................................17
Figure 11b: Free-Spinning Reel Lock Indicator ................................................................................. 17
Figure 11c: Free-Spinning Reel Unlock Indicator .............................................................................. 17
Figure 12: Free-Spinning Reel Lock Procedure ................................................................................ 18
Figure 13: Free-Spinning Reel Unlock Procedure ............................................................................. 19
Figure 14a: Example of Shaftless Take-up Machine......................................................................... 20
Figure 14b: Winding Adaptor Insertion ............................................................................................. 20
Figure 14c: Opposite-side Adaptor ................................................................................................... 20
Figure 15a: Positioning of the ReelRover into the Shaftless Take-up Machine ................................ 21
Figure 15b: Shaftless Take-up Machine Use with ReelRover Winding Adaptor ............................... 21
Figure 15c: Centerline Alignment of Machine Cone with Outer Bore of Winding Adaptor ................ 22
Figure 15d: Centerline Alignment Between ReelRover and Take-up Machine and Alignment of the
Pin with the Adaptor ...................................................................................................... 22
Figure 15e: ReelRover Adaptors Alignment with Machine’s Cones .................................................. 22
Figure 16: PARK Gearshift Position ................................................................................................ 23
Figure 17a: Shafted Take-up Machine .............................................................................................. 24
Figure 17b: Insertion of Winding Adaptor ......................................................................................... 24
Figure 17c: Positioning of ReelRover into Take-up Machine with Shaft Removed ........................... 25
Figure 17d: ReelRover Gearbox Selections for Positioning into Take-up Machine .......................... 25
Figure 17e: Aligning the Winding Adaptor with the Take-up Machine Spindle Drive ....................... 26
Figure 17f: Aligning the Take-up Machine’s Spindle Drive Pins with the Winding Adaptor Holes ... 26
Figure 17g: Slide the Spindle Drive Pins into the Winding Adaptor Holes ........................................ 26
Figure 18a: PARK Gearshift Position ................................................................................................ 27
Figure 18b: ReelRover in Park for Wire Payout ................................................................................ 27
Figure 19: Forklift Locations .............................................................................................................. 28
Figure 20a: Moving ReelRover onto Liftgate ..................................................................................... 29
Figure 20b: Remove Locking Pin ...................................................................................................... 29

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Figure 20c: Insert Locking Pin ........................................................................................................... 29
Figure 20d: Moving ReelRover into Truck ......................................................................................... 29
Figure 21a: Moving ReelRover off Truck onto Liftgate ...................................................................... 30
Figure 21b: Remove Locking Pin ...................................................................................................... 30
Figure 21c: Insert Locking Pin ........................................................................................................... 30
Figure 21d: Moving ReelRover Off Liftgate ....................................................................................... 30
Figure 22a: Removal of Wire Cable and Lock from Canister ............................................................ 31
Figure 22b: Wire Cable Through Eyebolt .......................................................................................... 31
Figure 22c: Safety Cable Around Both the Outer Hand Rail and Inner Flange Rail .......................... 31
Figure 22d: Lock the Two Ends of the Wire Cable Together with the Lock ...................................... 31
Figure 23: Left-Hand 180° Driven Turn ............................................................................................. 35
Figure 24: Right-Hand 180° Driven Turn ........................................................................................... 36

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Components
Figure 1a: ReelRover 3+1 (model RR-131136)
Figure 1b: ReelRover 1+1 (model RR-111136)

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Specifications
Maximum Height
60 inches
Max Wheel Base Length
65 inches
Wheel Base Width
32 inches
Unloaded Vehicle Weight
700 lbs.
Total Vehicle Capacity (vehicle + wire)
2700 lbs.
Conductor Reel Capacity
1500 lbs.
Ground Reel Capacity
500 lbs.
Figure 2a: ReelRover Specifications Side View
Figure 2b: ReelRover Specifications Top View

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Safety Procedures
User must read and completely understand prior to using this product.
The ReelRover is designed for certain industrial / commercial applications only. Cerrowire cannot
be responsible for issues arising from modification. Do not modify the ReelRover in any way. Do
not use the ReelRover in any application other than that for which it was designed. If you have
any questions relative to a particular application, DO NOT use the ReelRover until you have first
contacted Cerrowire to determine if that application is appropriate for the ReelRover.
! Never overload the ReelRover. You must stay within rated capacity.
! Do not operate the ReelRover if damaged or not in proper working order.
! Never put your feet, hands or any other body part under the frame assembly.
! Do not leave ReelRover unattended or in NEUTRAL on a hill or incline.
! Do not leave ReelRover unattended without being placed in park.
! Do not operate ReelRover on a hill or incline with an angle greater than 10°.
! Do not allow the ReelRover to drop from one level to another.
! Always ensure gearbox is in PARK on both sides of the ReelRover when securing
ReelRover for loading/unloading wire from reel.
! When not in use, place both gearboxes in PARK.
! Do not drag, push, or tow ReelRover with another vehicle or device.
! Always keep hands on ReelRover while it is in motion.
! Do not stand or sit on any part of the ReelRover.
! Do not attempt to disassemble or repair the ReelRover unless doing so with
authorization from Cerrowire or by ReelRover maintenance technicians/organizations.
! Do not attempt to lift the ReelRover using a strap or chain. The ReelRover should only
be lifted using a properly rated forklift in the locations shown in this manual.
! Always use proper safety equipment when using ReelRover, including protective
eyewear and appropriate safety footwear.
! Do not overload the ReelRover! Stay within the rated wire capacity of 2,000 lbs. and
gross vehicle weight of 2,700 lbs. Risk of death or injury may result from overloading.
! Use only ReelRover adaptors for wire loading. Do not lift ReelRover using the winding
adaptors or wire loading equipment.
! The center of gravity of the ReelRover will vary according to the wire and how it is
loaded on to the ReelRover. This must be taken into consideration when the ReelRover
is moved, loaded and unloaded on to and off of a vehicle, and while being transported.
For technical questions, please contact Cerrowire
at 800.367.2906 or [email protected].

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Symbols and Warnings

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Gearbox
The gearbox has three settings: PARK, NEUTRAL, and DRIVE. These settings control the
rotation of the drive wheels and reel, as well as their relation to each other. The left and right
gearboxes are independently set using the gearshift as shown in Figure 3.
To change the setting, move the gearshift to the desired position (P, N, or D as labeled), making
sure the spring detent positively locates in the corresponding hole. The positions of the gearshift
for each setting can be seen in Figures 4 through 6. Do not shift with ReelRover in motion.
Figure 3: Gearbox Settings

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Figure 4: PARK Gearshift Position
PARK (P)
- Drive Wheels LOCKED and cannot be rotated
- Reel is FREE to rotate in either direction
- Uses:
! Loading or Unloading wire from reel
! Securing ReelRover for transportation
or shipping, via fork truck or trailer
! Leaving the ReelRover unattended
NEUTRAL (N)
- Drive Wheels FREE to rotate in either direction
- Reel is FREE to rotate in either direction
- Uses:
! Pushing ReelRover across flat ground
! Manually steering and positioning
ReelRover at job site or distribution
center
DRIVE (D)
- Drive Wheel rotation is controlled by the
speed and direction of reel rotation. Three (3)
rotations of the reel is equal to approximately
one (1) rotation of the drive wheels (3:1 gear
ratio)
- Reel rotation drives the motion of the
ReelRover in the same direction of reel
rotation, either forwards or backwards
- Uses:
! Controlling ReelRover down an incline
! Mechanical advantage up an incline
! Going over obstacles, such as job-site
debris not to exceed 1 ½ inches in
height.
Figure 5: NEUTRAL Gearshift Position
Figure 6: DRIVE Gearshift Position

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Basic Operation
Operating the ReelRover in PARK
When both gearboxes are placed in PARK, as shown in Figure 4, neither drive wheel will be able
to rotate, effectively locking the ReelRover in position. The reel is still able to turn freely, allowing
wire to be loaded or unloaded without the ReelRover moving.
Operating the ReelRover in NEUTRAL
When both gearboxes are placed in NEUTRAL, as shown in Figure 5, the reel and drive wheel
rotation are both free and independent. The ReelRover can be pushed manually with no
mechanical advantage in this setting.
Steering in NEUTRAL
The ReelRover can be steered in NEUTRAL by pushing in the direction of the desired turn. The
larger the angle, the sharper the turn.
Figure 7a: Sharp Turn in NEUTRAL
Figure 7b: Gradual Turn in NEUTRAL
NEUTRAL Gearshift
Position

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Operating the ReelRover in DRIVE
When both gearboxes are placed in DRIVE, as shown in Figure 8, the reel rotation is locked to
the drive wheels with a gear reduction. The ReelRover can be driven either straight forward or
back using the reel rotation. The gear reduction allows for driving the ReelRover uphill, controlling
the speed downhill, and going over obstacles.
Figure 8: Reel and Drive Wheel Rotation

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Steering in Drive
When only one gearbox is placed in DRIVE, the ReelRover can be turned in the direction of the
parked wheel. If the other gearbox is placed in PARK, the turn will be sharp (almost 90 degrees).
If the other gearbox is placed in NEUTRAL, the turn will be more gradual, depending on factors
such as ground type and weight of wire on reel.
Figure 9a: Sharp Turn in DRIVE
Figure 9b: Gradual Turn in DRIVE
PARK Gearshift Position
DRIVE Gearshift Position
NEUTRAL Gearshift
Position
DRIVE Gearshift Position

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Operating the ReelRover in Drive on an Incline or Decline Surface
It is imperative that the following safety precautions be taken when driving ReelRover or
controlling its speed on incline and decline surfaces:
Potential Hazards:
! There is a danger of tip over when traveling on inclines and declines.
! Falling off the edge of an incline or decline.
! Skidding or slipping due to wet or icy conditions.
! Free descent on a decline.
Requirements and Recommended Practices:
! The ReelRover should NEVER be operated on an incline or decline with an angle
greater than 10° as indicated by the ReelRover shown in Figure 10b.
! Always look in the direction of travel.
! The caster wheels should always be trailing on an incline and leading on a decline
as shown in Figure 10b.
! Never turn on an incline or decline. Set the gearboxes and position the ReelRover on a
flat surface prior to using a ramp so that ReelRover may move straight up or down a
ramp.
! Never stand or walk directly behind the
ReelRover on an incline, Figure 10a.
Operator should be to the side of the
ReelRover.
! Maintain a safe distance from the edge
of an incline or decline.
! Keep working surfaces clear and clean.
! NEVER ALLOW FREE DESCENT ON
A DECLINE. ALWAYS PLACE THE
REELROVER IN DRIVE ON FLAT
GROUND AND CONTROL THE UNIT
DURING DESCENT.
Figure 10a: Never Stand or Walk Behind ReelRover on an
Incline
Figure 10b: Caster Wheels Should Be Trailing on an Incline and Leading on a Decline

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Free-Spinning Ground Reel
The ReelRover can be equipped with a free-spinning Ground Reel that can be locked or unlocked
with the reel lock handle as shown in Figure 11a. This allows for simultaneous loading and
unloading of smaller gauge ground wire with the conductor wire, without the need for reel
disassembly.
Figure 11a: Reel Lock
Figure 11b: Free-Spinning Reel Lock Indication
Figure 11c: Free-Spinning Reel Unlock Indication

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Free-Spinning Ground Reel: Lock Procedure
IMPORTANT: Make sure the ReelRover gear selectors
(both sides) are placed in the PARK position.
Step 1:
Pull plunger knob out so that the Free-Spinning Ground
Lock Handle may slide.
Step 2:
Slide the Free-Spinning Ground Lock Handle toward
center of reel until the Position Indicator aligns with the
Lock indicator.
Step 3:
Confirm that the plunger knob has returned to the closed
position (no longer pulled out) and that the Position
Indicator is still aligned with the Lock indicator.
The Free-Spinning Ground Reel is now rotationally
locked to the Conductor Reel.
Uses:
! Loading ground wire with conductor wire.
! DRIVE & NEUTRAL settings.
Figure 12: Free-Spinning Reel Lock Procedure

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Free-Spinning Ground Reel: Unlock Procedure
IMPORTANT: Make sure the ReelRover gear selectors
(both sides) are placed in the PARK position.
Step 1:
Pull plunger knob out so that Free-Spinning Ground
Lock Handle may slide.
Step 2:
Slide the Free-Spinning Ground Lock Handle toward
perimeter of reel until the Position Indicator aligns with
the Unlock indicator.
Step 3:
Confirm that the plunger knob has returned to the
closed position (no longer pulled out) and that the
Position Indicator is still aligned with the Unlock
indicator.
Once unlocked, the Free-Spinning Ground Reel is free
to spin independently of the Conductor Reel.
Uses:
! Even payout of ground wire with conductor
wires.
Figure 13: Free-Spinning Reel Unlock Procedure

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Wire Take-up Process
Winding Adaptor – Shaftless Equipment
In loading wire onto the ReelRover, certain shaftless take-up equipment may be used whereby
right- & left-hand adaptors must be utilized. Use the following procedure for safely operating the
take-up equipment to load the ReelRover. NEVER USE THE TAKE-UP EQUIPMENT AND
ADAPTORS TO LIFT THE REELROVER AS IT MAY RESULT IN SERIOUS INJURIES.
Inserting Winding Adaptor
The winding adaptors can be inserted into either gearbox as shown in Figures 14b and 14c.
The winding adaptor is used as an attachment point for the wire take-up machine.
Figure 14a: Example of Shaftless Take-up Machine
Figure 14b: Winding Adaptor Insertion
Figure 14c: Opposite-side Adaptor