Cerrowire ReelRover Manual

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©2020 Cerrowire Rev C 04/2022
P/N: PU-USEMAN-RR37
A Marmon/Berkshire Hathaway Company

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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 ofdistribution 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.
Do not use ReelRover unless you have read this manual completely along with viewing the
training videos. Using ReelRover without reading this manual and watching the training videos
can be dangerous and could lead to injury or death.
The center of gravity of the ReelRover will vary according to the wire and how it is loaded onto
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.
Revision Date
Description of Changes
Change Owner
March 2020
Initial release
Rich Hawley
April 2022
Add Lull Adaptor, take-up adaptors, warnings
Joshua East

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Table of Contents
Components .................................................................................................................................. 6
Reel Options...................................................................................................................... 6
GPS Unit............................................................................................................................ 7
Specifications................................................................................................................................. 8
Safety Procedures......................................................................................................................... 9
Warnings...................................................................................................................................... 10
Gearbox Operation...................................................................................................................... 12
Driving the ReelRover ................................................................................................................. 14
Operating in PARK ..........................................................................................................14
Operating in NEUTRAL ................................................................................................... 14
Steering in NEUTRAL...................................................................................................... 14
Operating in DRIVE ......................................................................................................... 15
Steering in DRIVE............................................................................................................ 16
Operating in DRIVE on Incline or Decline .......................................................................16
Free-Spinning Ground Reel........................................................................................................18
Lock the Free-Spinning Ground Reel.............................................................................. 19
Unlock the Free-Spinning Ground Reel.......................................................................... 20
WireTake-upProcess..................................................................................................................21
Inspect Left Gearbox Securing Bolt................................................................................. 21
ReelPower STU Shaftless Take-Up Machine.................................................................23
Wemco 2800-series Shafted Take-up Machine..............................................................26
Graham H8T20 Take-up Machine................................................................................... 30
Wemco 2500 Take-up Machine.......................................................................................31
Wire Unloading (Payout).............................................................................................................35
Transportation and Shipping......................................................................................................36
Forklift Locations..............................................................................................................36
Secure ReelRover for Shipping....................................................................................... 38
Load ReelRover Using a Liftgate.....................................................................................38
ReelRover Lock-outProcedure...................................................................................................40
Troubleshooting...........................................................................................................................41
Equipment Inspection Prior to Use.............................................................................................42
Table of Figures
Figure 1 ReelRover 3+1 (model RR-131136)............................................................................................ 6
Figure 2 Reel Options................................................................................................................................. 7
Figure 3 GPS Unit....................................................................................................................................... 7
Figure 4 ReelRover Specifications Side View............................................................................................ 8
Figure 5 ReelRover Specifications Top View............................................................................................. 8
Figure 6 Gearbox Settings........................................................................................................................12
Figure 7 Gearshift in PARK ...................................................................................................................... 13
Figure 8 Gearshift in NEUTRAL...............................................................................................................13
Figure 9 Gearshift in DRIVE..................................................................................................................... 13

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Figure 10 Sharp Turn in NEUTRAL..........................................................................................................14
Figure 11 Gradual Turn in NEUTRAL ...................................................................................................... 14
Figure 12 Reel and Drive Wheel Rotation................................................................................................15
Figure 13 Sharp Turn in DRIVE................................................................................................................ 16
Figure 14 Gradual Turn in DRIVE ............................................................................................................ 16
Figure 15 Caster Wheels Trail on Incline and Lead on Decline............................................................... 17
Figure 16 Never Stand or Walk Behind ReelRover on an Incline............................................................ 17
Figure 17 Reel Lock.................................................................................................................................. 18
Figure 18 Free-Spinning Reel Locked (left) and Unlocked (right)........................................................... 18
Figure 19 Free-Spinning Reel Lock Procedure........................................................................................ 19
Figure 20 Free-Spinning Reel Unlock Procedure ....................................................................................20
Figure 21 Left Hand Gearbox Securing Bolt ............................................................................................21
Figure 22 Undamaged Securing Bolt Head ............................................................................................. 22
Figure 23 Damaged Bolt Head................................................................................................................. 22
Figure 24 ReelPower STU Shaftless Take-up Machine ..........................................................................23
Figure 25 ReelPower STU Take-up Adaptor ........................................................................................... 23
Figure 26 Take-up Adaptor Insertion (left and right sides) ......................................................................24
Figure 27 Position ReelRover into the Shaftless Take-up Machine........................................................ 24
Figure 28 Centerline Alignment of Machine Cone with Outer Bore of Take-up Adaptor ........................ 25
Figure 29 Align ReelRover and Take-up Machine Centerline and Drive Pin..........................................25
Figure 30 Align ReelRover Adaptors with Take-up Machine Cones ....................................................... 25
Figure 31 Gearshift in PARK .................................................................................................................... 26
Figure 32 Wemco 2800 Shafted Take-up Machine .................................................................................26
Figure 33 Insert Take-up Adaptor............................................................................................................. 27
Figure 34 Use NEUTRAL or DRIVE to Position ReelRover into Take-up Machine................................ 27
Figure 35 Align Take-up Adaptor with Take-up Machine Spindle Drive..................................................28
Figure 36 Align Drive Pins with Take-up Adaptor Holes.......................................................................... 28
Figure 37 Slide Spindle Drive Pins in Take-up Adaptor Holes................................................................ 29
Figure 38 Gearshift in PARK .................................................................................................................... 29
Figure 39 Graham H8T20 Take-up Machine ...........................................................................................30
Figure 40 Take-up Adaptor for Graham H8T20....................................................................................... 30
Figure 41 Wemco 2500 Take-up Machine and Adaptor.......................................................................... 31
Figure 42 Remove Locating Block............................................................................................................ 31
Figure 43 Engage the Motor.....................................................................................................................32
Figure 44 Lock the Output Shaft...............................................................................................................32
Figure 45 Align ReelRover........................................................................................................................ 32
Figure 46 Align Shaft and Hub .................................................................................................................33
Figure 47 Connect Shaft and Hub............................................................................................................33
Figure 48 Engage Reel Lift Lock..............................................................................................................33
Figure 49 Disengage the Adaptor............................................................................................................. 34
Figure 50 Insert Retaining Pin.................................................................................................................. 34
Figure 51 ReelRover in Park for Wire Payout..........................................................................................35
Figure 52 Forklift Tube Locations............................................................................................................. 36
Figure 53 Forks Correctly in Tubes.......................................................................................................... 37
Figure 54 Forks Outside of Tubes............................................................................................................ 37
Figure 55 ReelRover onto Liftgate............................................................................................................ 38
Figure 56 ReelRover into Truck................................................................................................................ 39
Figure 57 Lock-out Connections............................................................................................................... 40
Figure A1 Left-hand 180° Driven Turn ..................................................................................................... 43
Figure A2 Right-hand 180° Driven Turn...................................................................................................43

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Components
Each ReelRover has common components as shown below:
Figure 1: ReelRover 3+1 (model RR-131136)
Reel Options
Three different reel versions are available, as shown in Figure 2:
▪1+1 –ground reel and a single, large conductor reel
▪3+1 –ground reel and conductor reel divided into three sections for three different wires
▪4+1 –ground reel and conductor reel divided into four sections for four different wires

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Figure 2: Reel Options
GPS Unit
A Fleet Complete Model B1-MIOT-GA GPS tracking unit is attached to each ReelRover. The units are
self-sustained and do not require users to complete any tasks to function properly.
Figure 3: GPS Unit
The devices are tied to a ReelRover via the IMEI number listed on the side of the unit. Users can request
tracking for their unit by providing the IMEI number located on the GPS label.

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Specifications
Height
60 inches
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 4: ReelRover Specifications Side View
Figure 5: ReelRover Specifications Top View

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Safety Procedures
The 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.
If you have any questions relative to a particular application, DO NOT use the ReelRover until you have
contacted Cerrowire to determine if that application is appropriate for the ReelRover.
Be aware of these requirements before operating the ReelRover for any purpose:
▪Do not modify the ReelRover in any way.
▪Do not use the ReelRover in any application other than that for which it was designed.
▪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 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.
▪Do not leave ReelRover unattended without being placed in PARK.
▪Always ensure both gearboxes are in PARK when securing ReelRover for loading or 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, or allow any person to stand, sit, or attempt to ride
on 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 by a qualified operator using a properly rated forklift with the
forks positioned in the fork tubes as shown in this manual.
▪Do not lift ReelRover using the take-up adaptors or wire loading equipment.
▪Always use proper safety equipment when using ReelRover, including protective eyewear and
appropriate safety footwear.
▪Do not overload the ReelRover. Do not exceed the rated wire capacity of 2,000 lbs. or gross vehicle
weight of 2,700 lbs.
WARNING: OVERLOADING A REELROVER MAY RESULT IN DEATH OR INJURY.
▪Use only ReelRover take-up adaptors for wire loading.
▪The ReelRover center of gravity will vary according to the wire and how it is loaded. This must be
taken into consideration when the ReelRover is moved, loaded onto or unloaded from a vehicle, and
while being transported.
For technical questions, please contact Cerrowire at
800.367.2906 or [e-mail].

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Warnings

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Gearbox Operation
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 6.
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 7, 8, and 9.
CAUTION: Do not shift gears when the ReelRover is in motion. Changing a gearbox setting
while the machine is in motion will damage the gearbox.
Figure 6: Gearbox Settings

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PARK (P)
-Drive Wheels LOCKED and cannot be rotated
-Reel is FREE to rotate in either direction
-Uses:
oLoading or Unloading wire from reel
oSecuring ReelRover for
transportation or shipping, via fork
truck or trailer
oLeaving the ReelRover unattended
Figure 7: Gearshift in PARK
NEUTRAL (N)
-Drive Wheels FREE to rotate in
eitherdirection
-Reel is FREE to rotate in either direction
-Uses:
oPushing ReelRover across flat ground
oManually steering and positioning
ReelRover at job site or distribution
center
Figure 8: Gearshift in NEUTRAL
DRIVE (D)
-Reel rotation drives the motion of the
ReelRover in the same direction of reel
rotation, either forwards or backwards
-Drive Wheel rotation is controlled by the speed
and direction of reel rotation. Three rotations of
the reel equals about one rotation of the drive
wheels (3:1 gear ratio)
-Uses:
oControl ReelRover down an incline
oMechanical advantage up an incline
oGoing over obstacles, such as job site
debris, not to exceed 1.5 inches in
height
Figure 9: Gearshift in DRIVE

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Driving the ReelRover
Operating in PARK
When both gearboxes are placed in PARK, as shown in Figure 7, 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 in NEUTRAL
When both gearboxes are placed in NEUTRAL, as shown in Figure 8, 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 10: Sharp Turn in NEUTRAL
Figure 11: Gradual Turn in NEUTRAL

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Operating in DRIVE
When both gearboxes are placed in DRIVE, as shown in Figure 9, the reel rotation is locked to the drive
wheels with a gear reduction, as shown in Figure 12. 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.
WARNING:Do not stand or sit on any part of the ReelRover, or allow any person to stand, sit, or
attempt to ride on the ReelRover.
Figure 12: 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).
Figure 13: Sharp Turn in DRIVE
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 14: Gradual Turn in DRIVE
Operating in DRIVE on Incline or Decline
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.
▪Allowing free descent on a decline may result in an out-of-control descent, tipping over, or collision
with people or objects.

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Warnings and Recommended Practices:
WARNING: NEVER ALLOW FREE DESCENT ON A DECLINE. ALWAYS PLACE THE
REELROVER IN DRIVE ON FLAT GROUND AND CONTROL THE UNIT DURING DESCENT.
WARNING: THE REELROVER SHOULD NEVER BE OPERATED ON AN INCLINE OR DECLINE
WITH AN ANGLE GREATER THAN 10° AS SHOWN IN FIGURE 15.
Figure 15: Caster Wheels Trail on Incline and Lead on Decline
WARNING: NEVER STAND OR WALK DIRECTLY BEHIND THE REELROVER ON AN INCLINE,
AS SHOWN IN FIGURE 16. OPERATOR SHOULD WALK TO THE SIDE OF THE REELROVER.
Figure 16: Never Stand or Walk Behind ReelRover on an Incline
WARNING: NEVER TURN THE REELROVER ON AN INCLINE OR DECLINE. AIM REELROVER
AND SET THE GEARBOXES TO DRIVE ON A LEVEL SURFACE SO THAT REELROVER MAY
MOVE STRAIGHT UP OR DOWN A RAMP.
▪Always look in the direction of travel.
▪Ensure the caster wheels trail on an incline and lead on a decline as shown in Figure 15.
▪Maintain a safe distance from the edge of an incline or decline.
▪Keep working surfaces clear and clean.

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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 17. This allows for simultaneous loading and unloadingof smaller
gauge ground wire with the conductor wire, without the need for reel disassembly.
Figure 17: Reel Lock
Figure 18: Free-Spinning Reel Locked (left) and Unlocked (right)

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Lock the Free-Spinning Ground Reel
The Free-Spinning Ground Reel should be rotationally locked to the Conductor Reel to load ground
wire with conductor wire, and when operating ReelRover in DRIVE or NEUTRAL.
NOTE: Ensure both gear selectors are placed in the PARK position.
1: Pull plunger knob out so that the Free-Spinning Ground
Lock Handle may slide.
2: Slide the Free-Spinning Ground Lock Handle toward center
of reel until the Position Indicator aligns with the Lock
indicator.
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.
Figure 19: Free-Spinning Reel Lock Procedure

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Unlock the Free-Spinning Ground Reel
Once unlocked, the Free-Spinning Ground Reel is free to spin independently of the Conductor Reel for
even payout of ground wire with conductor wires.
NOTE: Ensure both ReelRover gear selectors are placed in the PARK position.
1: Pull plunger knob out so that Free-Spinning Ground Lock
Handle may slide.
2: Slide the Free-Spinning Ground Lock Handle toward
perimeter of reel until the Position Indicator aligns with the
Unlock indicator.
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.
Figure 20: Free-Spinning Reel Unlock Procedure