Greenlee 6810-22 User manual

INSTRUCTION MANUAL
6810-22
Ultra Cable Feeder
52045207 REV 2 © 2019 Greenlee Tools, Inc. 10/19
Serial Code AJW
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
Description
The Greenlee Ultra Cable Feeder is intended to pull
cable off of reels to allow feeding the cable into conduit
or cable tray.
The Ultra Cable Feeder is not intended to pull cable or
rope through conduit.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose of this Manual
This instruction manual is intended to familiarize all
personnel with the safe operation and maintenance
procedures for the Greenlee Ultra Cable Feeder Cable
Feeding System.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
Do not discard this product or throw away!
For recycling information, go to www.greenlee.com.
All specications are nominal and may change as design
improvements occur. Greenlee Tools, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
KEEP THIS MANUAL
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information .....................................3–4
Identication.................................................................. 5
Specications................................................................ 5
Features......................................................................... 6
Transportation ............................................................... 6
Setup ........................................................................7–10
Positioning the Cable Feeder and Cable Reels ......... 7
Securing the Cable Feeding System ......................... 8
Loading the Cable Feeder ......................................... 9
Loading Cable.......................................................... 10
Operation..................................................................... 11
Tips for Trouble-free Operation................................ 11
Troubleshooting......................................................12–13
Service....................................................................14–15
Illustrations and Parts Lists ....................................16–25
Wiring Schematic ........................................................ 26

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
IMPORTANT SAFETY INFORMATION
Do not use the cable feeder in a
hazardous environment. Hazards
include ammable liquids, gases,
or other materials. Using the cable
feeder in a hazardous environment
can result in a re or explosion.
Failure to observe these warnings will
result in severe injury or death.
Crushing hazard:
• Keep all parts of the body away
from the tires.
• Do not wear loose clothing when
operating this tool.
Failure to observe this warning could
result in severe injury or death.
This device contains no brake mech-
anism. Do not use as a cable brake
or to raise or lower loads. A runaway
condition could occur resulting in
severe injury or death.
• Disconnect from power when loading cables.
Accidental start-up can result in serious injury.
• Do not attach lifting slings to the upper drive unit.
The drive unit will break loose and the cable feeder
will fall.
Failure to observe this warning could result in severe
injury or death.
Electric shock hazard:
• Inspect the power cord before
connecting to a power source.
Using a damaged cord can result in
electric shock.
• Disconnect tool from power source
before servicing. Electric shock can
result.
Failure to observe these warnings
could result in severe injury or death.
Do not remove guards.
Failure to observe this warning could
result in severe injury or death.
• Do not load with cables totaling more than 150 mm
(6") across. Cables may feed off of the tires, result-
ing in cable damage.
• Do not allow sharp objects to contact the tires.
Failure to observe this precaution may result in
damage to the tire.
• Inspect the tool before using. Replace worn,
damaged or missing parts with Greenlee replace-
ment parts. A damaged or improperly assem-
bled component could break and strike nearby
personnel.
• Use this tool for manufacturer’s intended
purpose only. Use other than that which is
described in this manual can result in injury or
property damage.
Note: Keep all decals clean and legible, and replace
when necessary.

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
Identification
Upper drive
unit
Cable divider
Emergency Stop Switch
(see “Operation” section)
Ground separator
Transport
handle
Stiff-arm
receptacle
Tee
Anchor pads
Specifications
Power Supply .................................................................... 230 VAC, 8 amps, 50/60 Hz
Power Output .........................................................................................1/2 hp (373 W)
Speed ..................................................... 1.3 m/min to 12 m/min (4 ft/min to 36 ft/min)
Cable Capacity ...........................................................................................152 mm (6")
Maximum Tractive Force
Single Cable ...........................................................................approx. 890 N (200 lb)
All Cables .............................................................................approx. 3560 N (800 lb)
Total Reel Capacity......................................................... approx. 11,300 kg (25,000 lb)
Mass/Weight...........................................................................................130 kg (285 lb)
Size.............................................. 1040 mm x 699 mm x 953 mm (41" x 27.5" x 37.5")
Tire Pressure
Carlisle Turf Glide ...............................................................................1.5 bar (22 psi)
Carlisle USA Trail................................................................................3.8 bar (50 psi)
Upper drive unit
attachment pin
Upper drive unit
Lower drive unit
Lower drive
handle
Ratchet

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Features
• Wide tire grip accommodates:
– 8 x 250 MCM cable
– 6 x 500 MCM cable
– 5 x 750 MCM cable
• Dividers prevent tangling of cables
• Ground Cable Separator ensures traction on smaller
diameter cable
• Variable speed control to match the speed of most
cable pullers
• Quick Squeeze Adjustment accommodates indi-
vidual cables from 6.5 mm to 89 mm (1/4" to 3-1/2")
diameter
• Top loading or side loading
• Hand-held pendant control switch
• Twin drive traction wheels for optimum pulling power
• Low-speed DC motors provide quiet operation
• Efcient permanent-magnet motor design requires
little power
• Maintenance-free chain drive
Transportation
To transport the cable feeder, pull the telescoping
handles out until they stop. If transporting over a
smooth surface, lift up on the handles to extend the
retractable caster. Quickly set the feeder down after the
caster swings out. To retract the caster, lift up on the
handles and quickly set the feeder down after the caster
swings back in.
If hoisting, attach slings only to the main frame. Feed
lifting sling all the way through the frame underneath the
front cable guides as shown.
Do not attach lifting slings to the upper drive unit.
Thedrive unit will break loose and the cable feeder
will fall.
Failure to observe this warning could result in severe
injury or death.
Lifting
sling
Upper Drive Unit
(shaded area)

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Setup
Positioning the Cable Feeder
and Cable Reels
Locate the cable feeder and cable reels so that:
• the cable can be slack between the cable feeder and
the conduit or tray.
• the cables approach the cable feeder at a maximum
angle of 25° from centerline.
• a reel with smaller ground cable is to the left of the
other reels.
• the cable insulation will not be damaged.
Note: The cable can feed from the top or the bottom of
the reel.
25° max.
2" conduit
Provide enough
distance for the
cable to be slack
Smaller ground
cable goes on left
25° maximum
from centerline
when cable feeds
from outside edge
of reel
tee

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Setup (cont’d)
Securing the Cable Feeding System
Select either the Stiff-Arm Boom method or the Anchor
method to secure the cable feeder.
Stiff-Arm Boom Method
Insert one end of a length of 2" rigid or IMC conduit into
the receptacle on the back of the cable feeder. Slip the
tee (supplied with the cable feeder) over the other end
of the conduit. Slide a second length of 2" rigid or IMC
through the tee. Push the cable feeder and stiff-arm
boom up against the reel stands.
Note: If feeding cable has been removed from the reels,
set the stiff-arm boom against a step, curb, door thresh-
old, stake driven into ground, etc.
Anchor Method
Use 3/8" - 1/2" anchors (purchased separately) through
the four anchor pads to stabilize the cable feeder.
Stiff-Arm Boom against Reel Stand
2" Rigid
IMC
Cable
Feeder
2" Rigid
IMC
tee
Stiff-Arm Boom against Step

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Setup (cont’d)
Loading the Cable Feeder
Select either End Loading method or Side Loading
method. Then proceed to the “Loading Cable” section.
End Loading Method
Pinch points: Grasp the middle of the handle.
Failure to observe this precaution may result in injury.
1. Release the ratchet mechanism by pushing down
on the upper drive handle while rotating the top of
the handle toward you.
2. Lift and pivot the upper drive unit back until it
contacts the stops.
3. Rotate the cable divider out and up.
Side Loading Method
1. Release the ratchet mechanism by pushing down
on the upper drive handle while rotating the top of
the handle toward you.
2. Remove the two clevis pins.
3. Unplug the upper drive unit motor.
The upper drive unit is heavy and requires more than
one person to lift.
Failure to observe this precaution may result in injury.
4. Lift the upper drive unit out of the cable feeder.
5. Remove the cable divider.
Cable divider
Push down
on handle
while rotating.
Push down
on handle
while rotating.

6810-22 Ultra Cable Feeder
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Setup (cont’d)
Loading Cable
1. Rotate the ground separator out and down.
3. Lower or remount the upper drive unit by lifting up
on the catch located near the clevis pin on the
control box side of the unit while lowering the upper
drive unit.
4. Push down on the ratchet handle with a moderate
amount of force. Engage the catches.
5. Rotate the ground separator and cable divider into
place, if desired. If pulling more than ve cables,
place two cables in one section of the cable divider.
Make sure the cable divider is fully seated against
the Stiff-arm Shaft.
Note: If pulling cable larger than 600 volt 1000 MCM,
do not use the cable divider.
2. Feed the cables over the lower traction wheel.
• Do not cross the cables.
• If pulling a smaller diameter ground cable, feed it
in at the leftmost side of the cable feeder.