Current tools 99 User manual

CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606

800.230.5421 or 864-721-4230 • FAX 864-721-4232

www.currenttools.com

Operating, Maintenance, Safety

and Parts Manual

06/2019

This manual is free of charge. All personnel who operate this Cable Feeder should have a copy

of this manual and read and understand its contents. To 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

to understand how to safely operate and service

this unit may result in serious injury or death.

Model 99 Cable Feeder

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

Hazards or unsafe

ractices which, if not avoided, COULD result in serious

personal in

or death

ARNIN

Hazards or unsafe

ractices which, if not avoided, COULD result in minor

personal in

or propert

damage

UTI

Immediate hazards which, if not avoided, WILL result in serious

ersonal

or death

DAN

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

Symbol

SAFETY ALERTS

Do not operate in wet or damp locations. Do not expose to rain.

Do not operate in a hazardous location or near combustible materials.

Keep all body parts, hair, loose clothing, etc. away from rotating parts and

pinch points. Also, stay clear of cable during operation as it approaches

and is fed through the Cable Feeder.

An emergency stop is provided on the Cable Feeder for your safety.

Always inspect before each use to ensure proper operation.

The Cable Feeder has no braking system. Do not use the Cable Feeder to

lift or lower any loads or personnel.

Unplug the Cable Feeder when loading cables to avoid accidental starting.

Upper drive clamp MUST be in closed, locked position before attempting

to lift the Cable Feeder. For instructions on lifting the Cable Feeder, see

Page 6.

Always plug the Cable Feeder into a grounded 115 VAC receptable with a

15 amp GFCI protected circuit. Do not modify the plug provided with the

Cable Feeder. Inspect the power cord before each use.

Unplug the Cable Feeder before servicing or maintenance.

Do not remove guards; they are installed for your protection.

The maximum cable diameter is 3.5". The maximum width of all cables in

the Cable Feeder is 6". Exceeding this width may cause the cables to run

off the tire causing cable damage.

Only use the Cable Feeder for its intended purpose to feed cable off of

cable reels as described in this manual. The Cable Feeder is not to be used

as a cable puller to pull cable or rope through conduit or in cable trays.

Only feed electrical cable through the tires 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

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 operate

and service this unit could result in injury or death. This unit should only be

operated and serviced by qualiﬁed personnel.

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

CAUTION

SPECIFICATIONS

• Weight: 345 lbs.

• Dimensions: 26" wide X 42" long X 43" tall

• Power requirements: 115VAC, 15 amps, 60 Hz

• Feeding speed: 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

SPECIFICATIONS

FEATURES

• Hinged upper drive to allow for easy side loading.

• High grip tires can accommodate no lube or regular cable

• Dual drive motors for maximum grip on cables

• Cable separator guides cables to ensure positive grip on tires

• Heavy duty third wheel caster with quick release mechanism

• Adjustable speed control

• May be operated with remote pendant or optional foot 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

LOWER DRIVE

T-BAR

RECEIVER

2" RIGID OR

IMC CONDUIT

(PROVIDED BY END USER)

-ADAPTER

REMOVEABLE

CABLE SEPARATOR

ENTRY SIDE

TRANSPORT

CASTER RELEASE

LEVER

TRANSPORT CASTER

UPPER DRIVE

TENSION

ADJUSTMENT ARMS

ENSION

ADJUSTMENT

HANDLE

EMERGENCY

STOP SWIT

UPPER DRIVE CLAMP

TRANSPORT

HANDLES

EXIT SIDE

ANCHOR BRACKET

ADJUSTABLE

SPEED

CONTROL

(4 PROVIDED)

UPPER DRIVE ARMS

TRANSPORTING THE CABLE FEEDER

TO ROLL ON A SMOOTH SURFACE:

Rotate both transport handles and pin into position with the detent

pins provided. Next, lift the Cable Feeder by the handles and the

transport caster will rotate into place. To retract the caster, lift up on

the transport handles and push the transport caster release 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

UPPER

DRIVE

FRAME

LOWE

DRIVE

FRAME

LOWER

DRIVE

FRAME

UPPER

DRIVE

CLAMP

UPPER

DRIVE

FRAME

SET-UP

The following will help with setting up the Cable Feeder and cable reels:

• Make sure there is enough room for the cable to remain slack after

the cable exits the Cable Feeder.

• The maximum angle that the cable 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

FROM CENTERLINE

AS CABLE

APPR

OACHES FEEDER

PROVIDE SUFFICIENT

DISTANCE HERE FOR

CABLE TO REMAIN SLACK

T-ADAPTER

T-BAR RECEIVER

SET-UP continued . . .

To secure the Cable Feeder:

Using T-Bar

• The Cable Feeder may be secured by using the T-Bar method. Slide

a section of 2" Rigid or IMC conduit into the T-Bar receiver located

at the entry side of the Cable Feeder. Next, slide the other end of the

conduit into the T-adapter. Next, slide a second 2" section of Rigid or

IMC conduit through the T-adapter. Now the Cable Feeder and T-bar

set-up are ready to be positioned against cable reel stands.

Note: The second section of conduit should be long enough to

contact both cable reel stands.

Note: Another method of securing the Cable Feeder may be

needed if the cable is not on the reels. Place 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

CABLE REEL STAND

T-ADAPTER

T-BAR

RECEIVER

STEPS

2 INCH RIGID OR IMC CONDUIT

(PROVIDED BY END USER)

T-ADAPTER

2 INCH RIGID

OR IMC CONDUIT

(PROVIDED BY END USER)

T-BAR

RECEIVER

2 INCH RIGID

OR IMC CONDUIT

(PROVIDED BY END USER)

2 INCH RIGID OR IMC CONDUIT

(PROVIDED BY END USER)

CABLE REEL STAND

T-ADAPTER

T-BAR

RECEIVER

STEPS

2 INCH RIGID OR IMC CONDUIT

(PROVIDED BY END USER)

T-ADAPTER

2 INCH RIGID

OR IMC CONDUIT

(PROVIDED BY END USER)

T-BAR

RECEIVER

2 INCH RIGID

OR IMC CONDUIT

(PROVIDED BY END USER)

2 INCH RIGID OR IMC CONDUIT

(PROVIDED BY END USER)

LOADING CABLE INTO THE CABLE FEEDER

1. Standing at the exit end of the Cable Feeder, push down and turn the

tension adjustment handle to release the tension adjustment arms

from the ratchet 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

ADJUSTMENT ARM

RATCHET

STUD

TENSION

ADJUSTMENT HANDLE

TENSION

ADJUSTMENT ARM

Lifting tension adjustment

arms to place resting slots on

top of ratchet studs.

Resting slots shown on

top of ratchet studs.

Tension Adjustment

Arm Resting Slot

Figure 1

2. Next, release the upper drive clamp and raise the upper drive.

Note: The upper drive clamp has a safety lock which must be released

to operate the clamp. See photo below.

LOADING CABLE INTO THE FEEDER continued . . .

THUMB SCRE

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

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.

LOADING CABLE INTO THE FEEDER continued . . .

5. Next, close and reclamp the upper drive

To release latch, lift the lever

on latch as shown.

6. Using the tension 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.

OPERATING INSTRUCTIONS

1. Before operation, be sure the pendant ON/OFF switch is in the OFF

position.

2. Next, plug the Cable Feeder into an 115 VAC, 15 amp, GFCI protected

power source.

3. Adjust the speed control to 12 o'clock position.

4. Turn the circuit break switch located on the side of the Cable Feeder

electrical box to the ON position.

Operate the Cable Feeder by one of the following methods:

• For continuous run: Place the pendant on/off 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 follows:

1. Clockwise – to increase speed

2. Counterclockwise – to decrease speed

Note: The Cable Feeder is equipped with an emergency stop switch

located on the top of the electrical box on the Cable Feeder. To

activate, push down. To reset, turn clockwise.

OPERATIONAL NOTES

• Before feeding begins, make sure the cable on the entry side of the cable feeder

(between the cable reels and the cable feeder) is NOT slack.

• The cable on the exit side of the Cable Feeder should REMAIN SLACK DURING THE

ENTIRE PULL. Do not allow this cable to become taut.

• Keep the speed control at a low setting at the start of the pull.

• Use the speed control to adjust the rate of cable feed to equal that of the cable

puller. Proper use of the speed control should prevent the operator from having to

turn the Cable Feeder off and on during the feeding operation.

• When feeding a cable with a smaller diameter (such as a ground cable) than the

other cables being fed, the smaller cable may tend to feed at a faster rate. To

remedy this:

• Stop the Feeder, then push down and turn the tension adjustment handle to

release the tension adjustment arms from the ratchet studs. Then raise the

upper drive arms. (See photo on the bottom of Page 11).

• Pull 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

the cable separator and skip a slot between the ground cable and the larger cable.

• If necessary, more than one cable may be placed in a single slot of the Cable Separator.

• If the cable feeding off the reels approaches the Cable Feeder at too steep of an angle,

the Cable Feeder may tend to lift. To avoid, move the Cable Feeder further away from

the reel(s) or anchor the Cable Feeder by using the (4) four anchor brackets located on

the bottom of the Cable Feeder or feed the cable from the bottom of the reel.

1) Before use, make sure each tire is inflated to 50 PSI.

2) Chains and bearings are permanently lubricated and should not require any

additional lubrication.

3) Keep all components clean and free of any debris.

MAINTENANCE

KEEP THIS ANGLE

AS SMALL AS POSSIBLE

refer to PARTS LIST on pages 16 & 17

EXPLODED VIEW — LOWER DRIVE

WHEELS AND CASTER

DRIVE MOTOR – LOWER

refer to PARTS LIST on pages 16 & 17

EXPLODED VIEW — LOWER DRIVE

DRIVE TIRE ASSEMBLYLOWER DRIVE FRAME

PARTS LIST — LOWER DRIVE

ITEM # PART # DESCRIPTION QTY.

1 2-1301-4 NUT — HEX NYLON INSERT (5/16"-18) 2

2 2-1501-4 NUT — HEX NYLON INSERT (3/8-16) 8

3 33-53 SCREW — HEX HEAD CAP GR5 ZINC (3/8–16 x 3/4) 4

4 33-706 WELDMENT — WIRE/FOOT SWITCH HOLDER 1

5 66-56 SCREW — SPADE THUMB 18.8SS (5/16–18 X 3/4) 1

6 77-002D1 SCREW — HEX HEAD CAP GR5 ZINC (5/16–18 x 3/4) 4

7 77-004A SCREW — TC (8-32 x 3/8) 12

8 77-004A SCREW — TC (8-32 x 5/8) 1

9 77-016 COTTER PIN — 3/16" x 1-1/4" LONG 2

10 77-017 WASHER — FLAT 3/4"(SAE) 2

11 77-028 STRAIN RELIEF 1

12 77-028A STRAIN RELIEF 3

13 77-033A SCREW — HEX HEAD SELF DRILL ZINC (#10–32 x

1/2) 2

14 77-036A NUT — HEX (#6–32) 4

15 77-061 SCREW – PAN 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 x 3/16 x 1" PLAIN 1

29 99-30 SCREW — HEX HEAD CAP GR5 ZINC (7/16–14 x 1) 4

30 99-31 WASHER — LOCK MEDIUM 7/16" ZINC 4

31 99-32 SCREW — BUTTON HEAD SOCKET (1/2–13 x 3/4) 4

32 99-33 NUT — LUG (1/2"–20) 4

33 99-34 STUD - WHEEL 1/2"–20 4

34 99-38 SCREW — HEX HEAD CAPGR5 ZINC (5/16–18 x 1.5) 5

35 99-5 WHEEL 2

36 99-53 DRIVE CHAIN 1

37 99-85 MASTER LINK 1

38 99-92 E-STOP LEGEND PLATE 1

39 99-93 E-STOP 1

40 99-94 SPEED CONTROL 1

41 99-98 TRANSFORMER 1

PARTS LIST — LOWER DRIVE — CONTINUED

ITEM # PART # DESCRIPTION QTY.

42 99-99 SOLID STATE RELAY 1

43 99-545 AXLE 2

44 99-694 BOTTOM FRAME WELDMENT – 99 FEEDER 1

45 99-696 BOTTOM AXLE WELDMENT 1

46 99-715 SPROCKET – DRIVEN, FEEDER 1

47 99-727 ELECTRICAL PLATE — FEEDER 1

48 99-729 TOP — ELECTRICAL BOX — FEEDER 1

49 99-730 PLATE FAB – CASTER, FEEDER 1

50 99-740 LOWER CHAIN GUARD (TOP) 1

51 99-741 LOWER CHAIN GUARD (BOTTOM) 1

52 99-744 GUIDE PLATE WELDMENT 2

53 99-744A GUIDE PLATE WELDMENT 2

54 99-756 SPROCKET — REDUCER 1

55 99-790 CASTER LOCK WELDMENT 1

56 450-20 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

69 77-065 FISH PAPER 1

70 77-3-1A PLUG - PLASTIC 1

71 99-115 CORD (16/3-8’) - PENDANT 2

72 33-45 FOOT SWITCH 1

73 747-39 LOCKWASHER, EXT. TOOTH - #8 1

74 451-22 SCREW, PAN HEAD PHILLIPS, 10-32 x 3/8" 1

75 747-19 MAGNET - ROUND 1

76 747-34 NUT, HEX - THIN NYLON INSERT #10-32 1

77 747-40 LOCK WASHER, INT. TOOTH – 15/32" 2

78 77-072 SCREW - #8-32 x 1/2" RD. HD. PHILLIPS 2

refer to PARTS LIST on pages 21 & 22

EXPLODED VIEW — UPPER DRIVE

DRIVE TIRE ASSEMBLY UPPER DRIVE FRAME

refer to PARTS LIST on pages 21 & 22

EXPLODED VIEW — UPPER DRIVE

DRIVE MOTOR AND ARMS

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