Condux CableGlider Instruction Manual

CableGlider®FO Cable Puller
USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL

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.
If you have questions on:
SAFETY - OPERATIONS - APPLICATIONS
CALL 1-800-533-2077
ADVERTENCIA:
Favor de leer y comprender todas las instrucciones de operación y seguridad antes de usar la máquina. Si Ud.
no comprende las instrucciones favor de consultarle a su jefe.
READ MANUAL
FIRST
WEAR
HARD HAT
WEAR SAFETY
GLASSES
WEAR SAFETY
SHOES
WEAR SAFETY
GLOVES
Save this user’s guide for future reference.

General Information .............................................4
Technical Specifications ..........................................4
a. Hydraulics ...............................................4
b. Power Requirements ......................................4
c. Digital Chart Recorder .....................................4
d. Factory Presets ..........................................4
e. Maximum Pulling Capacities ................................4
Safe Operating Practices .........................................5
a. Work Area Safety .........................................5
b. Hydraulic Devices .........................................5
c. Electric Devices ..........................................5
Unpacking the Fiber Optic Cable Puller .............................6
a. Puller Components ........................................6
Set up the Puller ...............................................7
a. Mount the Puller ..........................................7
b. Connect the Hydraulic Systems ..............................7
c. Position the Foot Control Valve Assembly ......................8
d. Attach the Capstan ........................................9
Set Up the Electronic Control System ...............................9
a. Switch Configuration .......................................9
b. Connect the Electronics ...................................10
c. Setting Up the Electronic Control Box ........................ 11
d. Digital Chart Recorder Set Up............................... 11
e. Data Download Instructions.................................13
Finish Puller Setup ............................................14
Final Inspection ...............................................14
Puller Operating Instructions .....................................15
Tear Down Procedures .........................................16
a. Remove Hydraulic Power Supply ............................16
b. Disconnect Electronics ....................................16
c. Remove Capstan from Puller ...............................16
Puller Calibration ..............................................17
a. Verify the Puller’s Calibration Settings ........................17
b. Hydraulic Pressure Relief Valve Calibration ....................17
c. Electronic Tension Control System Calibration ..................19
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
a. Puller ..................................................20
b. Electronic Control Box ....................................21
c. Foot control valve ........................................22
Replacement Parts & Accessories ................................23
Warranty Information ...........................................24
a. Factory Assistance .......................................24
b. Puller Calibration ........................................24
c. Limited Warranty .........................................24
Table of Contents
1
2
3
4
5
6
7
8
9
10
11
12
13
14

4
1.
General Information
2.
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 accu-
rate tension monitoring. The system’s design gives the operator complete control over the
equipment. It can be set to a maximum tension limit that will stop the puller and give both
audible and visual alarms if the tension limit is exceeded during the pull.
A digital chart recorder continuously records the pulling tensions during operation. The
power pack or the vehicle’s 12 Volt DC power point energizes the electronic tension
control system.
The puller comes standard with a variable speed foot control and hoses to the puller motor,
an adjustable flow control valve for adjusting maximum pulling speed, and a manually
adjustable pressure relief valve for adjusting the maximum pressure supplied to the
hydraulic motor.
Technical Specifications
A. HYDRAULICS
• Open center system
• Pressure: 2000-2500 psi (137-172 bar)
• Flow: 6-10 gpm (22.7-37.9 lpm)
• Relief valve setting: 2250 psi (155 bar)
• Reservoir capacity: 12 gallons (45.5 l)
• Filtration: 10 micron nominal
• Hydraulic Fluid: Petroleum-based, anti-wear properties, viscosity’s over 140
• Horsepower: Min. 8 hp (5.97 kW)
B. POWER REQUIREMENTS
• 12 volts direct current (DC) for electronic control box
C. DIGITAL CHART RECORDER
• Variable Sample Rate
• 256MB Compact Flash Card
• Download directly to computer via USB connection
D. FACTORY PRESETS
• Relief Valve:
1,783 lbs. (7,930 N) line tension on the 12" (305 mm) diameter capstan
700 lbs. (3,113 N) line tension on the 30" (762 mm) diameter capstan
428 lbs. (1,903 N) line tension on the 42" (1,067 mm) diameter capstan
• Electronic Control Box: 650 lbs. (2,891 N) line tension, any capstan
E. MAXIMUM PULLING CAPACITIES
• 2,000 lbs. (8,896 N) line tension on the 12" (305 mm) diameter capstan
• 1,000 lbs. (4,448 N) line tension on the 30" (762 mm) diameter capstan
• 600 lbs. (2,669 N) line tension on the 42" (1,067 mm) diameter capstan

5
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.
2. The safe operation of this equipment requires that the operator’s be on stable footing.
3. Stay clear of cables or lines under tension. Do not stand directly behind the puller.
4. Stay clear of rotating equipment.
5. Use the puller only for its intended purpose. Do not hoist people or equipment, and do
not wind up pulling lines with the capstan.
6. Start all pulls slowly and increase speed as the puller stabilizes.
7. Be aware of the location of all underground utilities in your work area.
B. HYDRAULIC DEVICES
Escaping fluids under pressure can penetrate the skin and cause serious personal injury.
Observe the following precautions to avoid hydraulic hazards:
1. Tighten all connections before applying pressure. Relieve pressure when connecting or
disconnecting hoses and when servicing the unit.
2. Check for leaks with a piece of cardboard. Do not use your hands!
3. Do not exceed working pressure of hydraulic hoses.
4. Visually inspect hoses regularly and replace if damaged.
C. ELECTRIC DEVICES
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 to avoid
electrical hazards:
1. Do not operate in or near water. This includes setting the electronic control box on a
wet surface or exposing it to rain.
2. Do not remove cover of electronic control box. There are no user-serviceable parts
inside. Refer servicing to qualified service personnel.
3. The electronic control box power switch should be in the off position before connecting
or disconnecting any cords.
4. Do not connect the electronic control box directly to a vehicle’s battery; use the power
pack, the vehicle’s 12 Volt DC power point, or the vehicle’s lighter socket.
3.

6
Unpacking the Fiber Optic Cable
Puller
A. PULLER COMPONENTS
1. Fiber Optic Cable Puller Package 1
Part Number: 08690001
• Hydraulic puller mounted on a 2
1
⁄ 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. Fiber Optic Cable Puller Package 3
Part Number: 08690055
All Items in Package 1 Plus:
• Electronic load cell mounted on puller
• Electronic control box with digital chart recorder
• Electronic cord from control box to puller
• Electronic cord from control box to foot control valve assembly
• Power cord, vehicle’s power point to control box
!NOTE: If any parts are missing, please contact your Condux representative or call
Condux International at 1-800-533-2077.
4.

7
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 2
1
⁄ 2 x 2
1
⁄ 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. Use grade 5 or grade 8 capscrews to attach these mounts. Materials
used for constructing your own mount should have a minimum wall thickness of
1
⁄ 4 inch (6.25 mm). All welds should be continuous, and gussets should be used
where possible.
!CAUTION: Lift the Fiber Optic Cable Puller only with proper equipment or
sufficient manpower. Improper lifting techniques may result in personal injury
or property damage.
B. CONNECT THE HYDRAULIC SYSTEMS
The Fiber Optic Cable Puller’s hydraulic system uses quick-connect couplings. Keep all
connections clean to avoid contamination and possible system failure. Follow these steps
to connect the hydraulic components:
1. Connect the hydraulic supply hoses to the foot control valve assembly. Ensure the
pressure hose from the power source goes to the inlet of the foot control valve
(labeled PRESSURE on the foot control valve assembly, figure 1).
2. Connect the hoses from the foot control valve assembly to the puller (figure 2). The
supply hose assembly has four identical male couplings and can be attached between
the puller and foot control valve assembly in any orientation.
!NOTE: Switching the quick-connect couplings on one end of hose assembly
between the puller and the foot control valve assembly will reverse the direction of
capstan rotation.
3. Start the hydraulic power source and check all connections for leaks with a piece of
cardboard. Run the puller in both directions to ensure proper operation.
5.
Figure 1. Power Supply Connections Figure 2. Foot Control Connections

8
!WARNING: Escaping fluids under pressure can penetrate the skin and cause seri-
ous 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. Run the puller for approximately 1 minute to remove any trapped air and then stop the
hydraulic power source.
!CAUTION: Use a minimum 10 micron nominal filter for proper filtration of the
hydraulic system. Equipment failure could result from improper filtration.
C. POSITION THE FOOT CONTROL VALVE ASSEMBLY
The foot control valve assembly controls the speed and direction of rotation of the cap-
stan. The further the foot pedal is pushed down, the faster the puller turns. To temporarily
reverse the capstan, the foot pedal can be lifted up.
!NOTE: Cable must be pulled only while pushing down on the foot pedal. To pull
cable with the capstan rotating the opposite direction, reverse the quick-connect couplings
of the hydraulic hoses on the puller (see previous section).
1. The foot control valve assembly is fitted with an adjustable speed control stop. The
speed control stop relieves operator foot fatigue by limiting the downward travel of the
foot pedal. Do not force the pedal if it does not move. Adjust the speed control knob
counterclockwise to increase speed, clockwise to decrease speed. The operator should
now feel the pedal move freely.
2. Position the foot control valve at least 3 to 4 feet (0.9 to 1.2 m) from the capstan’s
feed-off side (figure 3). Position the foot control in the best possible location for
safety and proper operation. Multiple operators may be required for safety or
operational requirements.
3. The manually adjustable pressure relief valve allows a secondary method of controlling
the maximum pulling tension. The relief valve is factory set to release the hydraulic
pressure at approximately 700 pounds (3113 N) of pulling tension while using the
Condux 30 inch (762 mm) diameter capstan. If required, adjust the relief valve to a
20°
ECB
OPERATOR
FOOT CONTROL
HAZARD AREA
Figure 3. Foot Control Valve Assembly
Placement
Figure 4. Capstan Assembly

9
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. Make
sure the shaft locking pins are visible through the holes in the capstan hub.
!NOTE: If using a capstan with a diameter other than 30 inches (762 mm), the hydraulic
relief valve must be recalibrated (section 11).
Set Up the Electronic Control
System
If the puller is not equipped with the electronic tension control system, go to section 7.
A. SWITCH CONFIGURATION
Following is a brief explanation of each of the switches for the Condux Fiber Optic Cable
Puller Electronic Control System. Detailed instructions for using the equipment follows
these explanations.
1. Electronic Control Box Panel Switches (Figure 5)
Power: Turns control box ON or OFF.
Set Tension Limit: Sets the limit where the control box will stop the puller. Press
and hold UP or DN button to set the desired value.
Tension Limit Control: Determines if the puller will stop rotating when the preset
tension limit is reached. Switch to ON to activate the
hydraulic bypass valve and stop the puller when the
tension limit is reached. Switch to OFF to disable the
hydraulic bypass valve.
Zero Display: Set the display to zero before beginning. Press “Prog” button
to zero display.
Capstan Selection Switch: Sets the control box to display the proper pulling forces
depending on the size capstan used. Turn switch to set
desired capstan diameter. The meter automatically calibrates
the displayed force to the selected capstan size.
Limit Reset: Resets the control box and puller after the preset tension limit
has been exceeded. Press button to reset hydraulic bypass
valve and audible alarm. This can be done only when the
tension is below the preset limit.
6.
Figure 5

10
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. Connect the male end of the 5-pin sensing cord to the female connector on the
Electronic Control Box labeled “LOAD CELL”. (see Figure 6) Connect the female end
of the cord to the male receptacle located near the load cell. (See Figure 7). Before
making these connections, ensure the receptacles are free of dirt and moisture. Do not
modify this cord’s length.
Tighten the connector collars over the threaded portion of the receptacles. This prevents
the cord from coming loose during operation. This cord is necessary to measure the ten-
sions sensed by the load cell.
2. Connect the male end of the 3-pin footswitch control cord to the female connector on the
Electronic Control Box labeled “FOOTSWITCH” (see Figure 8). Connect the female end of the
control cord to the male receptacle located on the foot control valve assembly (see Figure 9).
NOTE: If the connector on the foot switch is 2-pin, use the patch cord (08675926) included in
the upgrade kit (08675920) to convert to the required connection. Before making these connec-
tions, ensure the receptacles are free of dirt and moisture. Do not modify this cord’s length.
Tighten the connector collars over the threaded portion of the receptacles. This prevents
the cord from coming loose during operation. This cord is necessary to measure the ten-
sions sensed by the load cell.
Figure 6. Load Cell Connection on ECB Figure 7. Load Cell Connection on Puller
Figure 8. Foot Switch Connection on ECB Figure 9. Foot Switch Connection